New Holland E45B SR E50B SR E55B Mini Excavators Service Manual (84602422A) - PDF Download by www.heydownloads.com

SERVICE SERVICE MANUAL MANUAL

SERVICE MANUAL E45B WE170B SR / E50B / WE190B SR / E55B Wheeled Mini Excavators Excavators

E45B SR WE170B E50B SR WE190B E55B Wheeled Mini Excavators

Print No.84602422A No.84520338A

TO THE READER This manual has been printed for a skilful engineer to supply the necessary technical information to carry out service operations on this machine. Carefully read this manual to obtain correct information regarding repair procedures.

For any question or remark, or in case of any error in the contents of this manual, please contact: CNH ITALIA S.p.A. Via Plava, 80 10135 TORINO - Italy

REFERENCE Beyond this Service Manual, also refer to the documents listed below: - Operator’s Manual - Parts Catalogue

COMPLETE SERVICE MANUAL The Service Manual consists of one volume: - E45B SR - E50B SR - E55B - Service manual for “Hydraulic Mini Excavators”

The Service Manual for “Hydraulic Mini Excavators” contains the necessary technical information to carry out maintenance and repair operations on the machine, the necessary tools to carry out maintenance operations, the information on service standards, the procedures for removal, installation, disassembly and reassembly. The Service Manual relevant to the excavator models E45B SR - E50B SR - E55B consists in the following volume, which is identified through the relevant print no. as reported below:

VOLUME Service Manual for “Hydraulic Mini Excavators”

MACHINE TYPE

PRINT NUMBER

E45B SR E50B SR E55B

84602422A

AVOID ACCIDENTS Most of the accidents and injuries occurring in the factory, at home or on the road are caused by the failure to follow simple and fundamental safety rules or precautions. For this reason, MOST ACCIDENTS CAN BE PREVENTED by recognizing the real cause and taking the necessary precautions before the accident occurs. With any type of machine, although well designed and constructed, it is not possible to absolutely exclude any possibility of accidents. A careful and cautious operator and/or technician is the best insurance against accidents. The scrupulous observance of this one simple rule would prevent many thousands of serious injuries each year. This precaution is: never attempt to clean, lubricate or service a machine with the engine running.

WARNING Before carrying out any maintenance, adjustment or repair operation on machines equipped with attachments, controlled hydraulically or mechanically, make sure that the attachment is lowered and safely set on the ground. If it is necessary to have the attachment partially or fully raised to gain access to certain items, make sure the attachment is suitably supported by means other than the hydraulic lifting cylinders, the cables and/or the mechanical devices used for controlling the attachment.

SAFETY PRECAUTIONS

0-1

SAFETY PRECAUTIONS

GENERAL SAFETY INFORMATION

2) WARNING- Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury and is represented as follows:

WARNING Do not operate or perform any maintenance on this machine until all instructions found in the OPERATOR’S 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 dealer/distributor for a replacement. If you have any questions, please consult an authorized dealer/distributor.

WARNING 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:

CAUTION (4) It is very difficult to forecast every danger that may occur during operation. However, safety can be guaranteed by fully understanding the operating procedures for this machine according to the methods recommended by the Manufacturer.

(1) Most accidents occurring during operation are due to negligence of precautionary measures and safety instructions. 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 this manual and on the machine should be read and understood by all personnel before starting any work with or on the machine.

(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 this manual until all Safety, Operation and Maintenance procedures are completely understood by all persons working with the machine.

(2) Operation, inspection, and maintenance should be carefully carried out, and first priority must be given to safety. Messages of safety are indicated with marks. The safety information contained in this manual is intended only for supplement of 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 the words “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:

DANGER

0-2

SAFETY PRECAUTIONS

(5)

WARNING 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.

WARNING Do not operate this machine unless you have read and understood all instructions contained in this manual. Improper machine operation is dangerous and could result in injury or death.

The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes a careful use of the systems very important when performing maintenance operations. Sound knowledge of the system and or components is important before the removal or disassembly of any component. Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components. Weight of components table is shown in the section: TECHNICAL SPECIFICATIONS.

(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 under pressure.

(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, blade or other attachment is blocked correctly to prevent it from dropping unexpectedly.

(8)

Use steps and grab handles when mounting or dismounting a machine. Remove any debris or mud from steps, walkways or work platforms before using them. Always face the machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work, platforms to perform safe repair operations.

(9)

To avoid back injury, use a hoist when lifting components which weigh 20 kg or more. Make sure all chains, hooks, slings, etc., are in good condition and are the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.

The following is a list of basic precautions that must always be observed. (1)

(2)

Read and understand all Warning plates and decals on the machine before Operating, Maintaining or Repairing this machine. Always wear protective glasses and protective shoes when working around machines. In particular, wear protective glasses when using hammers, punches or drifts on any part of the machine or attachments. Use welders gloves, hood/goggles, apron and the protective clothing appropriate to the welding job being performed. Do not wear loose fitting or torn clothing. Remove all rings from fingers, loose jewellery, confine long hair and loose clothing before working on this machinery.

(3)

Disconnect the battery and hang a “Maintenance in Progress” tag in the operator’s seat. Remove starter key.

(4)

If possible, make all repairs with the machine parked on a level and firm surface. Block the machine so it does not roll while working on or under the machine. Hang a “Maintenance in Progress” tag in the operator’s seat.

Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or stops for the jack before carrying out any disassembly operation.

(10) To avoid burns, be alert for hot parts and surfaces immediately after stopping the machine such as hot fluids in lines, tubes and compartment covers. (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 the cover loose to relieve any spring or other pressure, before removing the last two capscrews or nuts completely.

0-3

SAFETY PRECAUTIONS (20) Tighten connections to the correct torque. Make sure that all protections against burns, the clamps and the operatorâ&#x20AC;&#x2122;s protective devices are correctly installed in order to prevent excessive heat, vibrations 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.

(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. Danger is even greater if the machine has just been stopped, as liquids might be boiling hot. (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.

(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.

(14) Reinstall all clamps with the same spare part number. Do not use clamps of inferior quality if replacement is necessary. (15) Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and skilled in welding procedures. Determine the type of metal being welded and select the correct welding procedure and electrodes, rods or wires to provide a metal weld strength at least equivalent to that of the parent metal. Make sure to disconnect the battery before any welding operation is performed.

(22) Be careful when servicing or separating the tracks. Chips can fly when removing or installing a track pin. Wear safety glasses and long sleeve protective clothing. Tracks 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.

(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 complete. (18) Performing maintenance and repair operations while the bucket is lifted is dangerous, because there is the possibility of a device falling. Do not fail to lower such device and place the bucket to the ground before starting the operation. (19) Loose or dirty fuel, lubrication and hydraulic systems, pipes and hoses may cause fires. Do not bend or strike high-pressure lines, do not install bent or damaged lines. 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 jet 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.

0-4

DATA

OPT

E/G TROUBLESHOOTING

DISASSEMBLY

SYSTEMS

MAINTENANCE SPECIFICATIONS

SAFETY PRECAUTIONS

TABLE OF CONTENTS

E45B SR E50B SR E55B

Title

Table of Contents No.

DESCRIPTION

SPECIFICATIONS

ATTACHMENT DIMENSIONS

TOOLS

MAINTENANCE STANDARDS AND TEST PROCEDURES

HYDRAULIC SYSTEM

ELECTRICAL SYSTEM

SYSTEMS COMPONENTS

WHOLE DISASSEMBLING AND ASSEMBLING

ATTACHMENT

SLEWING UPPER STRUCTURE

TRAVEL SYSTEM

TROUBLESHOOTING (HYDRAULIC SYSTEM)

TROUBLESHOOTING (ELECTRICAL SYSTEM)

TROUBLESHOOTING (ENGINE)

ENGINE

AIR CONDITIONING SYSTEM

OBJECT HANDLING SYSTEM

SUPPORTING DATA

0-5

SAFETY PRECAUTIONS

[NOTES]

0-6

1. DESCRIPTION TABLE OF CONTENTS 1.1 GENERAL PRECAUTIONS FOR REPAIRS ..................................................... 1-1 1.1.1 PREPARATION BEFORE DISASSEMBLING .............................................. 1-1 1.1.2 SAFETY IN DISASSEMBLING AND ASSEMBLING .................................... 1-1 1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT ............ 1-1 1.1.4 ELECTRICAL EQUIPMENT .......................................................................... 1-2 1.1.5 HYDRAULIC PARTS ..................................................................................... 1-3 1.1.6 WELDING REPAIR ....................................................................................... 1-3 1.1.7 ENVIRONMENTAL MEASURE ..................................................................... 1-3 1.2 INTERNATIONAL UNIT CONVERSION SYSTEM ........................................... 1-4

1. DESCRIPTION

1.1

GENERAL PRECAUTIONS FOR REPAIRS

(2) Suspend warning tag â&#x20AC;&#x153;DO NOT OPERATEâ&#x20AC;? from the doorknob or the operating lever, and have a preliminary meeting before starting work.

1.1.1

PREPARATION BEFORE DISASSEMBLING

(3) Stop the engine before starting inspection and maintenance to prevent the operator being caught in machine. (4) Identify the location of a first-aid kit and a fire extinguisher, and also where to make contact in a state of emergency.

(1) Understanding operating procedure Read OPERATION AND MAINTENANCE MANUAL carefully to understand the operating procedure.

(5) Choose a hard, level and safe place, and place the attachment on the ground securely.

(2) Cleaning machines Remove soil, mud, and dust from the machine before carrying it into the service shop to prevent loss of work efficiency, damage of parts, and difficulty in rust prevention and dust protection while reassembling.

(6) Use a lifter such as a crane to remove heavy parts (20 kg [45 lbs] or more) from the machine. (7) Use proper tools, and replace or repair defective tools. (8) Support the machine and attachment with supports or blocks if the work is performed in the lifted condition.

(3) Inspecting machines Identify the parts to be disassembled before starting work, determine the disassembling procedure by yourself considering the workshop situations etc., and request procurement of necessary parts in advance.

1.1.3

(4) Recording Record the following items for communication and prevention of recurring malfunction.

(1) Removing hydraulic equipment

1) Inspection date and place.

1) Before disconnecting pipes, release the hydraulic pressure of the system, or open the return side cover and take out the filter.

2) Model name, applicable machine number, and hourmeter read.

2) Carefully drain oil of the removed pipes into a containers without spilling on the floor.

3) Trouble condition, place and cause. 4) Visible oil leakage, water leakage and damage.

3) Apply plugs or caps on the pipe ends to avoid oil spillage and dust intrusion.

5) Clogging of filters, oil level, oil quality, oil contamination and loosening of connections.

4) Clean off the external surface of the equipment before disassembling, and drain hydraulic and gear oil before placing it on the workbench.

6) Result of consideration if any problem exists based on the operation rate per month calculated from hourmeter indication after the last inspection date.

(2) Disassembling hydraulic equipment 1) Do not disassemble, reassemble or modify the hydraulic equipment without the permission of the manufacturer, who is not responsible for the performance and function of the product after modification.

(5) Arrangement and cleaning in service shop 1) Tools required for repair work. 2) Prepare space to place the disassembled parts. 3) Prepare oil containers for draining oil etc. 1.1.2

DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT

2) When disassembling and reassembling for unavoidable reason, refer the work to qualified personnel who have the specific knowledge or completed the parts service training.

SAFETY IN DISASSEMBLING AND ASSEMBLING

3) Provide matching marks to facilitate reassembling work.

(1) Wear appropriate clothes with long sleeves, safety shoes, safety helmet and protective glasses.

4) Before starting the work, read the manual of disassembling procedure, if it is provided, and decide whether the work can be performed by yourself.

1-1

1. DESCRIPTION 5) Use the special jig and tools without fail if they are specified.

WARNING

6) If it is hard to remove a part according to the procedure, do not try it by force but investigate the cause.

Operation of the hydraulic equipment without filling hydraulic oil or lubricant or without performing air bleeding will result in damage to the equipment.

7) Place the removed parts in order and attach tags to facilitate the reassembling. 8) Note the location and quantity of parts commonly applied to multiple locations.

3) Bleed air from the hydraulic pump and the rotation motor after loosening the upper drain plug, start the engine and let it run at a low rpm. Complete the air bleeding when seeping of hydraulic oil is recognized, and tightly plug.

(3) Inspecting parts 1) Ensure that the disassembled parts are free from seizure, interference and uneven contact.

4) Bleed air from the travel motor and the hydraulic cylinders by letting the engine run for more than 5 minutes at a low rpm with no load.

2) Measure and record wear condition of parts and clearance. 3) If the problem is found in a part, repair or replace it with a new one.

WARNING

(4) Reassembling hydraulic equipment 1) Turn ON the ventilation fan or open windows to maintain good ventilation prior to starting the cleaning of parts.

Do not allow the hydraulic cylinder to bottom on the stroke end just after the maintenance.

2) Perform rough and finish cleaning before assembling.

5) Perform air bleeding of pilot line by performing a series of digging, slewing and travel.

3) Remove washing oil by air and apply clean hydraulic or gear oil for assembling.

6) Check hydraulic oil level after placing the attachment to the oil check position, and replenish oil if necessary.

4) Always replace the removed O-rings, backup rings and oil seals with new ones by applying grease in advance.

1.1.4

ELECTRICAL EQUIPMENT

5) Remove dirt and moisture from and perform degreasing on the surface where liquid gasket to be applied. 6) Remove rust preventive agent from the new parts before use.

(1) Do not disassemble electrical equipment.

7) Fit bearings, bushings and oil seals using special jigs.

(3) Turn the key OFF prior to connecting and disconnecting work.

8) Assemble the parts utilizing matching marks.

(4) Disconnect the connector by holding it and pressing the lock. Do not pull the wire to apply force to the caulking portion.

(2) Handle it carefully not to drop and give a shock.

9) Ensure all the parts are completely assembled after the work.

(5) Connect the connector and ensure it is completely locked.

(5) Installing hydraulic equipment 1) Ensure hydraulic oil and lubricant are properly supplied.

(6) Turn the key OFF prior to touching the terminal of starter or generator.

2) Perform air bleeding when:

(7) Remove the ground (earth) terminal of battery when handling tools around the battery or its relay.

1. Hydraulic oil changed 2. Parts of suction side piping replaced

(8) Do not splash water on the electrical equipment and connectors during machine washing.

3. Hydraulic pump installed 4. Slewing motor installed

(9) Check for moisture adhesion inside the waterproof connector after pulling it out, since it is hard to remove moisture from the connector.

5. Travel motor installed 6. Hydraulic cylinder installed

1-2

1. DESCRIPTION If moisture adhesion is found, dry it completely before the connection.

1.1.6

WARNING

(2) Disconnect the ground (earth) cable of the battery before starting the repair. Failure to do so will cause damage to the electrical equipment.

(1) Refer repair welding to qualified personnel according to the appropriate procedure.

Battery electrolyte is hazardous. Battery electrolyte is dilute sulfuric acid. Exposure of skin or eyes to this liquid will cause burning or loss of eyesight. If this occurs, take the following measures and get prompt specialised medical attention. • When skin exposed: Wash with water and soap sufficiently. • When eyes exposed: Immediately wash away with city water continuously for more than 10 minutes. • When a large amount of the liquid flows out: Neutralize with sodium bicarbonate or wash away with city water. • When swallowed: Drink a large amount of milk or water. • When clothes exposed: Immediately undress and wash. 1.1.5

(3) Move away the articles in advance that may cause fire if exposed to sparks. (4) Before starting the repair of the attachment, do not fail to cover the plated surface of the piston rod with flameproof sheet to prevent it from being exposed to sparks. 1.1.7

(2) Industrial waste disposal Dispose of the following parts according to the relevant regulations: Waste oil and waste container Battery (3) Precautions for handling hydraulic oil Exposure of eyes to hydraulic oil will cause inflammation. Wear protective glasses before handling to avoid an accident. If an eye is exposed to the oil, take the following emergency measures:

(1) O-ring Ensure O-rings have elasticity and are not damaged before use.

•

Use the appropriate O-rings. O-rings are of different kinds and made of different materials, and they have a different hardness to be applied to a variety of parts, such as moving or fixed parts, subject to high pressure and exposed to corrosive fluids, even if their size is same.

•

Fit the O-rings without distortion and bend.

•

Always handle floating seals as a pair. Use the appropriate parts. Different parts are used depending on the working pressure even the size of fitting and the total length of the hose is same.

•

Tighten the fitting at the specified torque. Ensure no kink, tension, interference nor oil leakage is recognized.

•

When an eye exposed: Immediately wash away with city water sufficiently till stimulative feeling vanishes.

•

When swallowed: Do not let vomit, and receive medical treatment immediately.

•

When skin exposed: Wash with water and soap sufficiently.

(4) Others Use replacement parts and lubricants authorized as the genuine parts.

(2) Flexible hose (F hose) •

ENVIRONMENTAL MEASURE

(1) Run the engine at the place that is sufficiently ventilated.

HYDRAULIC PARTS

•

WELDING REPAIR

1-3

1. DESCRIPTION

1.2

INTERNATIONAL UNIT CONVERSION SYSTEM

(3) Derived Units Table 1-3

Introduction Although this manual includes International System of Unit and Foot-Pound System of Units, if you need SI unit, refer to the following international system of units. Given hereinafter is an except of the units that are related to this manual.

SI units

Derived units of base units

Supplementary units Derived units

MARK

Area

square meter

Volume

cubic meter

Speed

metres per second

m/s

Acceleration

metres per square second

m/s2

Density

kilogram per cubic meter

kg/m3

Table 1-4

2. Construction of SI Unit System

SI unit system

UNIT

(4) Derived units bearing peculiar designations

1. Etymology of SI Unites French: Système International d’Unités English: International System of Units

Base units

QUANTITIES

Derived units bearing peculiar designations

Prefixes of SI (n-th power of 10, where n is an integer)

(1) Base units Table 1-1 QUANTITIES

UNIT

MARK

Length

meter

Mass

Kilogram

Time

second

Electric current

Ampère

Thermodynamic temperature

Kelvin

Amount of substance

mol

Luminous intensity

candela

QUANTITIES

UNIT

MARK

Plane angle

radiant

rad

Solid angle

steradian

(2) Supplementary units Table 1-2

1-4

QUANTITIES

UNIT

MARK

FORMULA

Frequency

Hertz

1/s

Force

Newton

kg • m/s2

Pressure and stress

Pascal

N/m2

Energy, Work and Quantity of heat

Joule

Power

Watt

J/s

Quantity of electricity

Coulomb

°C

A•s

Potential difference, voltage and electromotive force

Volt

W/A

Quantity of static electricity and electric capacitance

farad

C/V

Electric resistance

Ohm



V/A

Celsius temperature

celsius degree or degree

°C

(t+273.15)K

Luminous intensity

lux

lm/m2

1. DESCRIPTION (5) Prefixes of SI Table 1-5 PREFIX

MARK

MULTIPLICATION FACTORS

giga

109

mega

106

kilo

103

hecto

102

deca

deci

10–1

centi

10–2

milli

10–3

micro



10–6

nano

10–9

pico

10–12

(6) Unit Conversion Table 1-6 QUANTITIES Gravitational

SI CONVERSION FACTOR

Mass

Force

kgf

1 kgf = 9.807 N

Torque

kgf•m

kgf•m = 9.807 Nm

Pressure

kgf/cm

Motive Power

1 PS = 0.7355 kW

Revolution

rpm

min-1

rpm

MPa 1 kgf/cm2 = 0.09807 MPa

1-5

1. DESCRIPTION

[NOTES]

1-6

2. SPECIFICATIONS TABLE OF CONTENTS 2.1 COMPONENTS NAME ..................................................................................... 2-1 2.2 MACHINE DIMENSIONS .................................................................................. 2-2 2.3 SPECIFICATIONS AND PERFORMANCE ....................................................... 2-5 2.4 MACHINE AND COMPONENTS WEIGHT (DRY) ............................................ 2-7 2.5 TRANSPORTATION ....................................................................................... 2-10 2.6 CRAWLER TYPE ............................................................................................ 2-13 2.7 TYPE OF BUCKET ......................................................................................... 2-14 2.8 ENGINE SPECIFICATIONS ............................................................................ 2-15 2.8.1 SPECIFICATIONS ...................................................................................... 2-15 2.8.2 ENGINE PERFORMANCE CURVE ............................................................ 2-16 2.9 LUBRICANT, FUEL AND COOLANT SPECIFICATIONS ............................... 2-17

2. SPECIFICATIONS

2.1

COMPONENTS NAME 32 30 36

34 15 16

8 18

35 19

12 3

37 13

29 28 24 27

20 25

7 6

26 21

9 22 10

No.

NAME

No.

NAME

No.

NAME

No.

NAME

1 Engine

2 Oil filter

3 Radiator

4 Expansion tank

5 Air filter

6 Muffler

7 Fuel tank

8 Hydraulic oil tank

9 Hydraulic pump

10 Slewing motor

11 Swing cylinder

12 Control valve

13 Travel lever

14 Safety lock lever

15 Canopy

16 Operating lever

17 Dozer control lever

18 Throttle lever

19 Gauge cluster

20 Battery

21 Rotary control valve

22 Travel motor

23 Slewing bearing

24 Idler adjust

25 Lower roller

26 Upper roller

27 Rubber shoe

28 Dozer

29 Dozer cylinder

30 Boom

31 Boom cylinder

32 Arm cylinder

33 Lights

34 Arm

35 Link rod and idler link

36 Bucket cylinder

37 Bucket

2-1

2. SPECIFICATIONS

2.2

MACHINE DIMENSIONS Unit: mm

115 R980

750 70

1960

725

(1) E45B SR (CANOPY)

5000

1940

2140 1570

635

345

2600

980

1630 1820 2330 2780

400 1560 1960

115 R980

750 70

1960

725

(2) E45B SR (CAB)

5000

1940

2140 1570

635

345

2600

980

1630 400 1560 1960

1820 2330 2780

2-2

2. SPECIFICATIONS Unit: mm

140 R980

750 70

1960

725

(3) E50B SR (CANOPY)

1940

5230 2140 1570

635

345

2600

980

1690 1970 2480 2910

400 1560 1960

140 R980

750 70

1960

725

(4) E50B SR (CAB)

5230

1940

2140 1570

635

345

2600

980

1690 400 1560 1960

1970 2480 2910

2-3

2. SPECIFICATIONS Unit: mm (5) E55B (CAB)

R1080

5340 2240 1670 1080

MX0011

2-4

2. SPECIFICATIONS

2.3

SPECIFICATIONS AND PERFORMANCE

SPEED AND GRADEABILITY Model Crawler type Rotation speed

rpm

Travel speed

km/h

Gradeability

% (degree)

E45B SR E50B SR - E55B Steel crawler Steel crawler Rubber belt Rubber belt (OPT) (OPT) 8.8 8.8 Low High Low High Low High Low High (1st) (2nd) (1st) (2nd) (1st) (2nd) (1st) (2nd) 2.8 4.6 2.5 4.2 2.8 4.6 2.5 4.2 58 (30°)

ENGINE Model (YANMAR) Type Number of cylinders - Bore x stroke Total displacement L Rated output kW / rpm Maximum torque Nm / rpm Starter motor V x kW Generator VxA

4TNV88-XYB Vertical, 4-cycle water-cooled diesel engine 4 - ø88 mm × 90 mm 2.189 31.5 / 2400 139.3 / 1440 12 x 2.3 12 x 55

HYDRAULIC COMPONENTS Hydraulic pump Hydraulic motor Hydraulic Motor w/Reduction gear (Travel) Control valve Cylinder (boom, arm, swing, bucket, dozer) Return filter

Variable displacement axial piston + gear pump Axial piston 2-axial pistons, 2-speed motor 11-spools multiple control valve Double action cylinder Safety valve containing/Filter type (30µ)

SWING AND DOZER Type Boom swing angle Stroke of Dozer (above/below)

Right Left mm

Boom swing by hydraulic cylinder 60° 70° 505 / 325 495 / 375

2-5

2. SPECIFICATIONS WEIGHT Models

Versions

E45B SR E45B SR E50B SR E50B SR E55B

Canopy Cab Canopy Cab Cab

Rubber belt Long arm Standard counterweight Big bucket (117 kg) Fuel (44 kg) Operator (75 kg)

Total weight kg ISO 6016* 4395 4535 4805 4945 5294

* The weight is measured with this configuration

Additional weights kg Models

Versions

E45B SR E45B SR E50B SR E50B SR E55B

Canopy Cab Canopy Cab Cab

Differential of rubber-steel crawler 100 100 110 110 110

2-6

Differential of long-short arm

Additional counterweight

-25 -25 -30 -30 -

2. SPECIFICATIONS

2.4

MACHINE AND COMPONENTS WEIGHT (DRY) Unit: kg E45B SR RUBBER SHOE STEEL SHOE CANOPY CAB CANOPY CAB 4395 4535 4495 4635

MODEL COMPLETE MACHINE

1930 570 85 170 35 5 37 4 110 39 40 35 270 145 47 1670 525 76 65 x 2 5x2 9 x 10 42 x 2 30 x 2 14 x 2 210 x 2 — 22 170 27 505 223 160 42 164 179 105 27 13 4x2 96 95 45 44

UPPER STRUCTURE ASSEMBLY UPPER FRAME CANOPY / CAB ENGINE HYDRAULIC PUMP RADIATOR HYDRAULIC TANK FUEL TANK SWING BRACKET SWING CYLINDER SWING MOTOR CONTROL VALVE COUNTERWEIGHT GUARDS, BONNETS BOOM CYLINDER LOWER STRUCTURE ASSEMBLY LOWER STRUCTURE SLEWING BEARING TRAVEL MOTOR UPPER ROLLER LOWER ROLLER IDLE WHEEL IDLER ADJUSTER SPROCKET RUBBER TRACK STEEL TRACK ROTARY CONTROL VALVE DOZER DOZER CYLINDER ATTACHMENT ASSEMBLY BOOM ASSEMBLY BOOM ARM CYLINDER ARM ASSEMBLY (1.43 m) ARM ASSEMBLY (1.70 m) ARM BUCKET CYLINDER BUCKET LINKS IDLER LINK BUCKET ASSEMBLY (STANDARD) FLUIDS ASSEMBLY HYDRAULIC OIL FUEL

Note: bucket weight is shown with standard bucket weight.

2-7

2070 ← 220 ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← — ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ←

1930 ← 85 ← ← ← ← ← ← ← ← ← ← ← ← 1770 ← ← ← ← ← ← ← ← — 260 x 2 ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ←

2070 ← 220 ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← — ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ←

2. SPECIFICATIONS Unit: kg E50B SR MODEL

RUBBER SHOE CANOPY CAB

STEEL SHOE CANOPY CAB

COMPLETE MACHINE

4805 2280 570 85 170 35 5 37 4 110 39 40 35 580 145 58 1720 545 76 65 x 2 5x2 9 x 10 42 x 2 30 x 2 14 x 2 225 x 2 — 22 180 27 535 273 165 50 175 205 115 27 13 4x2 100 95 45 44 6

4915 2280 ← 85 ← ← ← ← ← ← ← ← ← ← ← ← 1820 ← ← ← ← ← ← ← ← — 275 x 2 ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ←

UPPER STRUCTURE ASSEMBLY UPPER FRAME CANOPY / CAB ENGINE HYDRAULIC PUMP RADIATOR HYDRAULIC TANK FUEL TANK SWING BRACKET SWING CYLINDER SWING MOTOR CONTROL VALVE COUNTERWEIGHT GUARDS, BONNETS BOOM CYLINDER LOWER STRUCTURE ASSEMBLY LOWER STRUCTURE SLEWING BEARING TRAVEL MOTOR UPPER ROLLER LOWER ROLLER IDLE WHEEL IDLER ADJUSTER SPROCKET RUBBER TRACK STEEL TRACK ROTARY CONTROL VALVE DOZER DOZER CYLINDER ATTACHMENT ASSEMBLY BOOM ASSEMBLY BOOM ARM CYLINDER ARM ASSEMBLY (1.56 m) ARM ASSEMBLY (1.87 m) ARM BUCKET CYLINDER BUCKET LINKS IDLER LINK BUCKET ASSEMBLY (STANDARD) FLUIDS ASSEMBLY HYDRAULIC OIL FUEL COOLANT

Note: bucket weight is shown with standard bucket weight.

2-8

4945 2420 ← 220 ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← — ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ←

5055 2420 ← 220 ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← — ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ←

2. SPECIFICATIONS Unit: kg E55B MODEL COMPLETE MACHINE UPPER STRUCTURE ASSEMBLY UPPER FRAME CAB ENGINE HYDRAULIC PUMP RADIATOR HYDRAULIC TANK FUEL TANK SWING BRACKET SWING CYLINDER SWING MOTOR CONTROL VALVE COUNTERWEIGHT GUARDS, BONNETS BOOM CYLINDER LOWER STRUCTURE ASSEMBLY LOWER STRUCTURE SLEWING BEARING TRAVEL MOTOR UPPER ROLLER LOWER ROLLER IDLE WHEEL IDLER ADJUSTER SPROCKET RUBBER TRACK STEEL TRACK ROTARY CONTROL VALVE DOZER DOZER CYLINDER ATTACHMENT ASSEMBLY BOOM ASSEMBLY BOOM ARM CYLINDER ARM ASSEMBLY (1.87 m) ARM BUCKET CYLINDER BUCKET LINKS IDLER LINK BUCKET ASSEMBLY (STANDARD) FLUIDS ASSEMBLY HYDRAULIC OIL FUEL COOLANT

Note: bucket weight is shown with standard bucket weight.

2-9

RUBBER SHOE CAB

STEEL SHOE CAB

5294 2420 570 220 170 35 5 37 4 110 39 40 35 929 145 58 1820 545 76 65 x 2 5x2 9 x 10 42 x 2 30 x 2 14 x 2 225 x 2 — 22 180 27 535 273 165 50 205 115 27 13 4x2 100 95 45 44 6

5404 ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← — 275 x 2 ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ←

2. SPECIFICATIONS

2.5

TRANSPORTATION

(1) LOADING MACHINE ON A TRAILER 1) Keep trailer bed clean. Put chocks against truck wheels. 2) Use a ramp or loading deck. Ramps must be strong enough, have a low angle, and correct height. Load and unload machine on a level surface. 3) Travel machine onto ramps slowly. Centre the machine over the trailer. 4) Lower all attachment. 5) Stop the engine. Remove the key from the starter switch.

WARNING Do not put chains over or against hydraulic lines or hoses. 6) Fasten machine to trailer with chains or cables. During transportation, the bucket or attachments may hit the canopy or the cab. Therefore, set the machine in the transporting position by observing following points: 1. Extend the bucket cylinder fully. 2. Extend the arm cylinder fully. 3. Lower the boom. 4. If machine cannot be transported with dipper cylinder fully extended, remove bucket or attachment and extend dipper cylinder. (2) TRANSPORTATION DIMENSION AND WEIGHT OF ATTACHMENT 1) BOOM WITH ARM CYLINDER Model

E45B SR

E50B SR - E55B

LxHxW mm

2790 x 1070 x 310

2910 x 1040 x 310

Weight w/arm cyl. kg

223

273

2-10

2. SPECIFICATIONS 2) ARM AND STANDARD BUCKET E45B SR Combination LxHxW

Weight

Arm 1.43 m Bucket 0.15 m3

Arm 1.70 m Bucket 0.15 m3

2630 x 510 x 691

2890 x 510 x 691

260

275

Arm 1.56 m Bucket 0.16 m3

Arm 1.87 m Bucket 0.16 m3

2770 x 510 x 741

3080 x 510 x 741

275

300

E50B SR Combination LxHxW

Weight

E55B Combination

Arm 1.87 m Bucket 0.16 m3

LxHxW

Weight

3080 x 510 x 741 300

3) EXCAVATOR ARM E45B SR Type LxHxW

Weight

1.43 m

1.70 m

1870 x 420 x 250

2140 x 420 x 250

164

179

1.56 m

1.87 m

2010 x 420 x 250

2320 x 440 x 250

175

205

E50B SR Type LxHxW

Weight

E55B Type

1.87 m

LxHxW

Weight

2320 x 440 x 250 205

2-11

2. SPECIFICATIONS 4) STANDARD BUCKET E45B SR Capacity

0.15

LxHxW

780 x 690 x 691

Weight

Capacity

0.16

LxHxW

780 x 690 x 741

Weight

E50B SR - E55B

100

5) BLADE w/o cylinder weight Model

E45B SR

E50B SR - E55B

LxHxW mm

1140 x 346 x 1960

1190 x 346 x 1960

Weight kg

170

180

2-12

2. SPECIFICATIONS

2.6

CRAWLER TYPE Type

Rubber belt

Steel track (optional)

Model

Width mm

Total crawler width mm

Number of Link

Ground pressure kPa CANOPY

CAB

E45B SR

400

1960

E50B SR E55B

400

1960

E45B SR

400

1960

E50B SR E55B

400

1960

2-13

2. SPECIFICATIONS

2.7

TYPE OF BUCKET

Nominal

Overall

Width (mm)

Bucket digging

300

339

Bucket digging

450

Bucket digging

Heaped capacity (m3) (ISO 7451)

Weight

Teeth

(kg)

No.

0.060

61.10

491

0.100

80.45

550

591

0.120

88.79

Bucket digging

600

641

0.130

92.43

Bucket digging

650

691

0.150

96.07

Bucket digging

700

741

0.160

100.10

Bucket digging

750

791

0.170

104.86

Bucket digging

800

841

0.190

108.53

Bucket digging

900

941

0.220

117.34

Type

WARNING The buckets with this length, during left arm slewing higher than 1 m from ground, can interfere with the cabin. For your safe use, consult the Dealer and ask for left slewing limiter of the arm support. S: Generic digging: for digging and sand loading operations, gravel, clay, earth in general, etc. The specific weight of the material should not be higher than 1400 kg/m3.

2-14

2. SPECIFICATIONS

2.8

ENGINE SPECIFICATIONS

2.8.1

SPECIFICATIONS Model

E45B SR - E50B SR - E55B

Engine model

4TNV88-XYB

Type

Vertical, 4-cycle water-cooled diesel engine

No. of cylinders - Bore x stroke

4 - 88 mm x 90 mm (3.54 in)

Total displacement

2.189 litre

Compression ratio

19.1

Rated output

31.5 kW at 2400 rpm

Maximum torque

139.3 Nm at 1440 rpm

Low idling

1175 ± 25 rpm

High idling

2600 ± 25 rpm

Fuel consumption rate

Less than 242 g / kWh

Allowable tilting angles

Continuous; 30° for all direction

Rotating direction

Counterclockwise as viewed from flywheel side

Order of ignition

1-3-4-2-1

Injection time (injection time before top dead centre)

15.5 ± 1° +1

Fuel injection pressure Valve action

Valve clearance

19.6 0

MPa (2842 psi)

Open

Intake valve

b.T.D.C. 15 ± 5°

a.B.D.C. 45 ± 5°

Exhaust valve

b.T.D.C. 56 ± 5°

a.B.D.C. 18 ± 5°

Intake valve

0.2 mm (0.007 in) in cold condition

Exhaust valve

0.2 mm (0.007 in) in cold condition

Thermostat action

Start 71 ± 1.5 °C / Fully open 85 °C

Compression pressure

3.4 ± 0.1 MPa at 250 rpm

Lubrication oil pressure

0.44 MPa at 2300 rpm

Dimensions L x H x W

684 x 554 x 662 mm

Dry weight Injection governor

170 kg Mechanical centrifugal governor (All speed type)

Fuel filtration

Cartridge type paper filter

Lubrication system

Forced lubrication with trochoid pump

Cooling system

Coolant / radiator

Starter capacity

12 V x 2.3 kW

Generator capacity

12 V x 55 A

Starting aid

Air heater (12 V - 400 W)

Cooling water capacity: Max / Engine

6.0 / 2.7 liter

Engine oil volume: Max / Effective

7.4 / 4.0 liter

2-15

2. SPECIFICATIONS 2.8.2

ENGINE PERFORMANCE CURVE

E45B SR - E50B SR - E55B Model: 4TNV88A-XYB Rated Output: 31.5 kW / 2400 rpm [Sd] 4

2 0

600

[GT]

500 200 400

[T]

175 300 150

[F]

125

100

50 g/kWh

320

300

280

260

240

10 5

220

kW 1000

1200

1400

F Fuel consumption volume

200

800

[PS]

ρ X 1000 242

0.835 x 1000

1600

1800

2000

2200

2400

2600

2800

XPXα

X 30.4 X α

= 8.81 α F. Fuel consumption rate (g/kWh) P. Shaft output (kW)

Fuel consumption in normal operation; 5.29 ÷ 6.17 l/h (load factor: (0.60 ÷ 0.70))

ρ. Specific gravity α. Standard load factor (0.60 ÷ 0.70)

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

2-16

2. SPECIFICATIONS

2.9

LUBRICANT, FUEL AND COOLANT SPECIFICATIONS

The following table indicates the proper oils, lubricants and fuel to be used with various climates and service conditions. Components

Technical name

Quantity

Hydraulic oil tank

Selenia IDRAULICAR AP31 Selenia IDRAULICAR AP46 Tank: 42.0 l Selenia IDRAULICAR AP51 System: 77 l Ambra HI-TECH 46

Engine oil pan

Ambra Supergold

Fuel tank Cooler

Operating range (ambient temperature °C) Specifications -20° -10° 0° 10° 20° 30° 40°

H level: 7.4 l L level: 3.4 l 53 l

Ambra Agriflu - OT

Travel motor Upper rollers Ambra HYPOIDE 90 Idel wheels Attachment and dozer pin Swing cylinder pin Slewing bearing Ambra GRS PLUS Idler adjuster Operating lever and pedal

2.6 l Total q.ty 6 l 0.9 l X 2 20 cc X 2 70 cc X 2

QKF 583/HD

API CH4 ACEA E5 QFK 583/HD EN590 ASTM D 3306 Type 1 API GL5 NH 520 A

20 - places 1 - place 2 - places

NLGI 2 QFK 586/GR

When required

Rotation gear

MG 2

1 - place

Air conditioner Compressor

R134A Sanden SP-10

700 g 120 cc

NLGI 2 QFK 586/GR

(*) The systems are filled with the products indicated with the asterisk. NOTE: USE OF BIO-DEGRADABLE OILS When you use bio-degradable oil, please refer to following: •

there are two types of bio-degradable oil available: vegetable-based and synthetic-based. We recommend using synthetic oils, because vegetable ones have a maximum operating temperature of 80 °C. For this reason, the degradation of vegetable-based oil occurs more rapidly, and they have a reduced service life;

•

do not mix Bio-oil with original factory-filled mineral oil; in case it is necessary to use Bio-oil, flush the hydraulic system that was filled with bio-oil three times;

•

if you use Bio-oil, the performance of the rotation brake and that of the parking/travel brake will be reduced, because of the lower friction factor of Bio-oil compared to that of mineral oil;

USE OF COOLANT •

There are two types of coolantdepending on the corrosion inhibitors base: ORGANIC-base and INORGANICbase.

•

Mini excavators is ORGANIC-base type factory filled.

•

Both type can be used, BUT THEY CANNOT BE MIXED. Flush the cooling system before change coolant type.

2-17

2. SPECIFICATIONS

[NOTES]

2-18

3. ATTACHMENT DIMENSIONS TABLE OF CONTENTS 3.1 BOOM ............................................................................................................... 3-1 3.1.1 BOOM DIMENSIONAL DRAWINGS ............................................................. 3-1 3.1.2 BOOM MAINTENANCE STANDARDS ......................................................... 3-2 3.2 ARM .................................................................................................................. 3-5 3.2.1 DIPPER DIMENSIONAL DRAWINGS .......................................................... 3-5 3.2.2 ARM MAINTENANCE STANDARDS ............................................................ 3-7 3.3 BUCKET .......................................................................................................... 3-11 3.3.1 DIMENSIONS .............................................................................................. 3-11 3.3.2 DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION .......................... 3-12 3.4 DOZER BLADE ............................................................................................... 3-13 3.4.1 DIMENSIONS .............................................................................................. 3-13 3.4.2 MAINTENANCE STANDARD ..................................................................... 3-14 3.5 SWINGING ...................................................................................................... 3-16 3.5.1 SWING BRACKET DIMENSIONS .............................................................. 3-16 3.5.2 MAINTENANCE STANDARD ..................................................................... 3-17

3. ATTACHMENT DIMENSIONS

3.1

BOOM

3.1.1

BOOM DIMENSIONAL DRAWINGS

Fig. 3-1 Boom dimensional drawings Table 3-1 Unit: mm No.

DIMENSIONS

NAME

E45B SR

E50B SR - E55B

2670

2790

Distance between pins and bushings

R1406

R1434

Distance between pins of bracket

R1475

R1487.5

Height of boom cylinder rod pin

Height of arm cylinder pin (bottom side)

Boom length

470

457.5

941.5

908

Boom width

250

←

Inner width of bracket for boom cylinder (rod side) mounting

←

Boom end inner width

175

←

Boom end outer width

265

←

Inner width of bracket for dipper cylinder (bottom side)

←

Boom pin diameter (Bushing outer diameter)

[ø50] [ø60]

←

Boom cylinder (rod side) pin diameter

[ø50]

←

Dipper end pin diameter

ø60

←

Dipper cylinder (bottom side) pin diameter

ø45

←

3-1

3. ATTACHMENT DIMENSIONS 3.1.2

BOOM MAINTENANCE STANDARDS

(1) Clearance of pin and bushing on boom section

Fig. 3-2 Clearance of pin and bushing on boom section Table 3-2 Unit: mm Standard dimensions Ref.

Piece

Pin diameter

Tolerance on pin diameter

Boom cylinder (Bottom side)

Boom cylinder (Rod side)

Arm cylinder (Bottom side)

Tolerance on bushing bore diameter +0.061 0

A Boom B

Play

ø50

– 0.02 – 0.08

+0.25 +0.05

Standard Serviceability Remedy Standard value value for limit repair 0.02 ÷ 0.141

0.7

1.0

0.07 ÷ 0.33

ø45

NOTE: • The tolerance for bushing inside diameter means the dimension after fitting of it into place. •

The part number for pins may be changed owing to improvement, use them only for reference.

3-2

Replace bushing or pin

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

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

3-3

3. ATTACHMENT DIMENSIONS Table 3-3 Unit: mm Standard dimensions Sec.

Piece No. Dimensions

Swing Bracket

Standard value

Pin length

Remedy Standard Serviceability No. Dimensions value for limit repair

-0.2

Boom A-A Boom

Clearance X adjusted with shim (total of both sides)

Boom Boom cylinder cylinder B-B L2 (Bottom side) Swing Bracket Boom Boom cylinder cylinder L3 C-C (Rod side) Boom Arm Arm cylinder cylinder D-D L4 (Bottom side) Boom

250 -0.3 -0.2 250 -0.3

0.1รท0.5

PL1

377

PL2

264

0.5รท0.9

PL3

213

0.1รท0.5

PL4

200

-0

75 -0.5 -1 77 0 -0 75 -0.5 +1 76 0

0.1รท0.5 1.0

1.5

Adjusted with shim

65 -0.5 +1 66 0

3-4

3. ATTACHMENT DIMENSIONS

3.2

ARM

3.2.1

DIPPER DIMENSIONAL DRAWINGS

Fig. 3-4 Dipper dimensional drawings

3-5

3. ATTACHMENT DIMENSIONS Table 3-4 Unit: mm Dimensions No.

Name

E45B SR (arm 1.43 m)

E45B SR (arm 1.70 m)

E50B SR (arm 1.56 m)

E50B SR (arm 1.87 m)

E55B (arm 1.87 m)

Arm length

1430

1700

1560

1870

←

Distance between pins

R405

R408

R405

R408

←

Distance between pins

R1118

←

R1118

←

Distance between pins

R230,5

←

R230,5

←

Distance between pins

311

←

311

←

Distance between pins

211

220

191,5

199

←

Distance between pins

←

Bosses width

150

←

150

←

Hub width

175

←

175

←

Bracket inner width

←

Bracket inner width

←

Idler link dimension

320

←

320

←

Bucket link dimension

310

←

310

←

D1 O.D. of boss

ø55

←

ø55

←

D2 Hub O.D.

ø55

←

ø55

←

D3 Hub O.D.

ø75

←

ø75

←

Pin diameter

ø45

←

ø45

←

Pin diameter

ø45

←

ø45

←

Pin diameter

ø60

←

ø60

←

Pin diameter

ø45

←

ø45

←

Pin diameter

ø45

←

ø45

←

3-6

3. ATTACHMENT DIMENSIONS 3.2.2

ARM MAINTENANCE STANDARDS

(1) Clearance of pin and bushing

Fig. 3-5 Clearance of pin and bushing on dipper section Unit: mm Standard dimensions Location

Piece

Dipper point (Connected part of bucket)

Bucket connecting rod (Bucket side)

Bucket link (Connected part of arm)

Bucket connecting rod (Idler link side)

Bucket cylinder (Rod side)

Bucket cylinder (Bottom side)

Dipper foot (Connected part of boom)

Arm cylinder (Rod side)

Play

Tolerance on Pin Tolerance on bushing bore Standard value diameter pin diameter diameter

+0.064 +0.005

0.025 ÷ 0.114

+0.076 +0.035

0.055 ÷ 0.126

+0.073 +0.032

0.052 ÷ 0.123

+0.25 +0.05

0.07 ÷ 0.30

ø60

+0.061 0

0.02 ÷ 0.111

ø45

+0.25 +0.05

0.07 ÷ 0.30

ø45 –0.02 –0.05

Standard Serviceability value for limit repair

0.7

1.0

NOTE: • The tolerance for bushing inside diameter means the dimension after fitting of it into place. •

The part number for pins may be changed owing to improvement, use them only for reference.

3-7

Remedy

Replace bushing or pin

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

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

3-8

3. ATTACHMENT DIMENSIONS Table 3-6 E45B SR

Unit: mm Standard dimensions

Sec.

Piece No. Dimensions Arm

A-A Dipper point

Bucket B-B connecting rod Bucket link C-C (Connected part of arm)

D-D

Bucket

PL2 287.5

+0.9 -0.5

—

0.1 ÷ 0.5

—

PL3 210.5

55 -0.5

0.6 ÷ 1.0

1.5

2.0

57±0,4 -0.2 150 -0.3

0.1 ÷ 0.5

Adjusted PL5 210.5 with shim

—

— 0

Bottom side L6 Arm

60 -0.5 +1 61 0

0.5 ÷ 0.9

PL6

183

PL7

265

PL8

183

-0.2

L7 Boom

175 -0.3 +0.3 175 +0.1

Less than 0.5

1.0

1.5

Rod side L8 Arm

See “NOTE”

150

Arm

Arm cylinder G-G (Rod side)

0.7 ÷ 2.2

150 -0.3 151

Arm

F-F Dipper foot

PL1 287.5

+0.9

-0.2

Bucket Bucket connecting rod connecting rod L5 (Idler link side) Bucket link

Bucket cylinder E-E (Bottom side)

Remedy Standard Serviceability value for No. Dimens. limit repair

151 -0.5

Bucket

Bucket Rod side connecting rod Link side (Rod side)

Standard value

Pin length

150 L1

Link side

Clearance X adjusted with shim (total of both sides)

60 -0.5 +1 61 0

0.5÷0.9

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

3-9

3. ATTACHMENT DIMENSIONS Table 3-7 E50B SR

Unit: mm Standard dimensions

Sec.

Piece No. Dimensions Arm

A-A Dipper point Bucket B-B connecting rod Bucket link C-C (Connected part of arm) Bucket connecting rod D-D (Rod side) Bucket connecting rod (Idler link side) Cylinder E-E bottom

Bucket

Arm cylinder G-G (Rod side)

+0.9

-0.2

L2 Arm

PL1

287.5

0.7 ÷ 2.2

PL2

287.5

PL3

210.5

Adjusted PL5 with shim

210.5

See “NOTE”

150 -0.3 +0.9 151 -0.5

150 L3

—

0.1 ÷ 0.5

—

Rod side

55 -0.5 L4

Link side

0.6 ÷ 1.0

1.5

2.0

57±0,4

Bucket connecting rod L5 Bucket link

150

Bottom side

60 -0.5

-0.2 -0.3

0.1 ÷ 0.5

—

— 0

+1 0

Arm

175 -0.3

0.5 ÷ 0.9

PL6

183

Less than 0.5

PL7

265

0.5 ÷ 0.9

PL8

183

-0.2

+0.3 +0.1

Boom

175

Rod side

65 -0.5

1.0

1.5

L8 Arm

Remedy Standard Serviceability No. Dimens. value for limit repair

151 -0.5

Bucket

F-F Dipper foot

Standard value

Pin length

150 L1

Link side

Clearance X adjusted with shim (total of both sides)

+1 0

See “NOTE”

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

3-10

3. ATTACHMENT DIMENSIONS

3.3

BUCKET

3.3.1

DIMENSIONS

Fig. 3-7 Bucket dimensions Table 3-8 Unit: mm Model

No.

Heaped Capacity m

E45B SR

E50B SR - E55B

0.15

0.16

Distance between pin and bracket

228.5

←

Distance between bucket pin and tooth end

R802

←

Inner width of bucket top end

626

676

Inner width of lug

181

←

Bracket inner width

151

←

Outer width of side cutter

691

741

Outer width of bucket bottom plate

568

618

Outer tooth distance

596

646

Pitch between teeth

198.7

215.3

Pitch between teeth

198.7

215.3

Pin diameter

ø45

←

Pin diameter

ø45

←

3-11

3. ATTACHMENT DIMENSIONS 3.3.2

DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION

Fig. 3-8 Dimension of lug section Table 3-9 Unit: mm Part Dimensions

Plate outer diameter øA

Boss thickness B

ø75

3-12

Pin bore diameter Lug plate thickness øC D ø45

+0.15 0

3. ATTACHMENT DIMENSIONS

3.4

DOZER BLADE

3.4.1

DIMENSIONS

Fig. 3-10 Dozer dimensions Table 3-10 Unit: mm No. A

Dimensions

NAME Blade width

E45B SR

E50B SR - E55B

1960

←

346

←

R1092

R1149

Inner width of dozer attaching bracket

531

←

Width of dozer attaching bracket

←

Distance from dozer attaching pin center to attaching pin on dozer cylinder head side

R712

←

Attaching bracket inner width on dozer cylinder head side

←

Horizontal distance from dozer attaching pin center to edge end

1046

1105.3

Vertical distance from dozer attaching pin center to edge end

313

←

Dozer attaching pin dia.

ø40

←

Attaching pin dia. on dozer cylinder head side

ø55

←

Blade height

Distance from dozer attaching pin center to cutting edge end

3-13

3. ATTACHMENT DIMENSIONS 3.4.2

MAINTENANCE STANDARD

Fig. 3-11 Maintenance standards A-B-C = Pin (1) Clearance of pin and bushing Table 3-11 Unit: mm Standard dimension Ref.

Piece

Dozer cylinder (Bottom side)

Dozer cylinder (Rod side)

Dozer foot

Pin diameter

ø55

ø40

Tolerance on pin diameter

Play

Tolerance on bushing bore Standard value diameter

–0.15 –0.21

+0.25 +0.05

0.20÷0.46

–0.06 –0.09

+0.215 +0.115

0.175÷0.305

Standard value for repair

Serviceability limit

1.5

2.0

NOTE: • The tolerance for bushing inside diameter means the dimension after fitting of it into place. •

The part number for pins may be changed owing to improvement, use them only for reference.

3-14

3. ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on the dozer and cylinder installation section Table 3-12 Unit: mm Standard dimensions Ref.

Piece

Dozer cylinder (Bottom side)

No.

Dozer foot

+1 62- 0

Rod side

0 60--0.5

Lower frame

Remedy

60--0.5

Dozer

Dozer cylinder Lower (Rod side) frame

Pin length No. Dimensions

Bottom side

Dozer C

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

PL1

141

PL2

141

PL3

137

2.0÷3.5 Adjusted with shim

+1 62- 0

69±0,5 L3

2.5÷4.5

+1 0

72-

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

3-15

3. ATTACHMENT DIMENSIONS

3.5

SWINGING

3.5.1

SWING BRACKET DIMENSIONS

C F1

F J

F2 d4

d1 Fig. 3-12 Swing bracket dimensional Table 3-13

Unit: mm No.

NAME

DIMENSION

A Distance between swing centre pin and boom foot pin

B Distance between boom foot pin and boom cylinder pin

207.6

C Distance between boom foot pin and boom cylinder pin

320.7

D Distance between swing centre pin and swing cylinder pin E Distance between swing centre pin and swing cylinder pin

R307.5 290

F Inside width of swing centre

326.7

F1 Inside width of swing centre (Upper side)

76.2

F2 Inside width of swing centre (Lower side)

G Inside width of boom foot

250

H Inside width for installing boom cylinder

Inside width for installing swing cylinder

d1 Pin diameter of swing center

ø80

d2 Pin diameter of boom foot pin

ø50

d3 Pin diameter of boom cylinder

ø50

d4 Pin diameter of swing cylinder

ø50

3-16

3. ATTACHMENT DIMENSIONS 3.5.2

MAINTENANCE STANDARD

(1) Clearance of pin and bushing

D Fig. 3-13 Clearance of pin and bushing on swing portion Table 3-14 Unit: mm Standard dimension Ref.

Piece

Swing cylinder (Rod side)

Swing cylinder B (Bottom side) C

Swing center (Upper side)

Swing center D (Lower side)

Pin diameter

Tolerance on pin diameter

Play

Tolerance on bushing bore diameter +0.150 0

ø50

Standard value

Standard Serviceability value for limit repair

0.02÷0.20

-0.02 -0.05

1.5 +0.061 +0.009

ø80

NOTE: the tolerance for bushing inside diameter means the dimension after fitting of it into place. The part number for pins may be changed owing to improvement, use them only for reference.

3-17

0.029÷0.111

2.0

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

PL1 X

PL2

B-B

A-A

C-C, D-D Fig. 3-14 Clearance in thrust direction on swing portion 1. Washer - to be installed by directing the groove to the lower side (shim = 2.3)

3-18

3. ATTACHMENT DIMENSIONS Table 3-15 Unit: mm Standard value Dimension Sec.

Piece No. Dimensions

Swing cylinder A-A (Rod side)

L1 Bracket

Upper Swing center frame C-C (Upper side) Bracket Upper Swing center frame D-D (Lower side) Bracket

Standard value

Pin length

Remedy Standard Serviceability value for No. Dimensions limit repair

Cylinder

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

Clearance X adjusted with shim (total of both sides)

70--0.5 +2 73 0

0.5÷0.9

1.5

—

PL1

146.5

PL2

151

—

Replace PL3 washer

155

1.5

Adjusted with PL4 shim

142

Adjusted with shim

70--0.5 +1 72 0

0.5÷0.9

1.0

—

+0.5 0

+0.5 78,5 0 +0.5 0

Less than 0.5

+0.5 78,5 0

3-19

—

3. ATTACHMENT DIMENSIONS

[NOTES]

3-20

11. TOOLS TABLE OF CONTENTS 11.1 TORQUE SPECIFICATIONS FOR CAPSCREWS AND NUTS ...................... 11-1 11.2 SCREW AND TOOL SIZES ............................................................................ 11-3 11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES ............................. 11-3 11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS ............ 11-4 11.5 SPECIAL SPANNERS FOR TUBES ............................................................... 11-5 11.6 SPECIAL TOOLS ............................................................................................ 11-5 11.7 APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS ......... 11-5 11.8 COUNTERWEIGHT LIFTING JIG ................................................................... 11-6 11.9 UPPER FRAME LIFTING JIG ......................................................................... 11-7

11. TOOLS

11.1

TORQUE SPECIFICATIONS FOR CAPSCREWS AND NUTS

The following torque specifications are indicated in case the actual torque value of a fastener is unknown. Check the capscrews and nuts for their looseness and dropping off before the start of daily work and at the periodical maintenance. Retighten the loosened ones, and install new ones for the dropped off. For the new machine, the check and retightening of them must be carried out at first 50 hours operation. For the replacement of them, make sure to use the same size of manufacturer’s genuine parts. Refer to the table below for the tightening and retightening of capscrews. • The table below is not applicable for the capscrews to fix the cover, etc., made of plastic. For the tightening torque for such capscrews, consult with an authorized Distributor. Over-tightening may cause damages on the parts to be fixed. • If the operator’s manual specifies a different torque, use such value regardless of the tables below. • Numerical indication on the capscrew head shows the classification for strength (e.g., 7 = 7 T). No indication is provided for smaller size of capscrews, M5 or less.

11.1.1

Metric coarse thread standard tightening torque values. Be certain to tighten all capscrews and nuts to proper torque values. Unit: Nm

Classification 4.8T 7T 10.9T Nominal dimension No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication M6 P=1 4.4±0.5 3.7±0.4 9.6±1.0 8.1±0.8 17.4±1.8 14.7±1.5 M8 P=1.25 10.7±1.1 9.0±0.9 23.5±2.0 19.6±2.0 42.2±3.9 35.3±3.9 M10 P=1.5 21.6±2.0 17.9±1.8 46.1±4.9 39.2±3.9 83.4±8.8 70.6±6.9 M12 P=1.75 36.3±3.9 31.4±2.9 79.4±7.8 66.7±6.9 143±15 121±12 M14 P=2 57.9±5.9 49.0±4.9 126±13 106±10 226±20 191±19 M16 P=2 88.3±8.8 74.5±6.9 191±20 161±16 343±39 284±29 M18 P=2.5 122±12 103±10 265±29 226±20 481±49 402±39 M20 P=2.5 172±17 144±14 373±39 314±29 667±69 559±59 M22 P=2.5 226±20 192±20 500±49 422±39 902±88 755±78 M24 P=3 294±29 235±29 637±69 520±49 1160±118 941±98 M27 P=3 431±39 353±39 941±98 765±78 1700±167 1370±137 M30 P=3.5 588±59 490±49 1285±127 1079±108 2300±235 1940±196 M33 P=3.5 794±78 667±69 1726±177 1451±147 3110±314 2610±265 M36 P=4 1030±98 863±88 2226±226 1863±186 4010±402 3360±333

11-1

11. TOOLS 11.1.2

Metric coarse thread standard tightening torque values. Be certain to tighten all capscrews and nuts to proper torque values. Torque value Unit: Nm

Classification

4.8T

10.9T

Nominal dimension No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication M8

P=1.0

11.3±1.1

9.5±1.0

24.5±2.0

20.6±2.0

44.1±3.9

37.3±3.9

M10

P=1.25

22.6±2.0

18.7±1.9

48.1±4.9

41.2±3.9

87.3±8.8

73.5±6.9

M12

P=1.25

39.2±3.9

33.3±2.9

85.3±8.8

71.6±6.9

154±16

129±13

M16

P=1.5

92.2±8.8

77.5±7.8

196±20

169±17

363±39

304±29

M20

P=1.5

186±19

155±16

402±39

333±29

726±69

608±59

M24

P=2

314±29

265±29

686±69

569±59

1240±118

1030±98

M30

P=2

637±59

530±49

1390±137

1157±118

2500±255

2080±206

M33

P=2

853±88

706±70

1860±186

1550±155

3350±334

2790±275

M36

P=3

1070±108

892±88

2330±226

1940±196

4200±422

3500±353

11-2

11. TOOLS

11.2

SCREW AND TOOL SIZES

11.2.1

Edge bolt

Nominal screw size (d) M6 M8 M10 M12 M16 M20 11.2.2

B mm Tool size 10 13 17 19 24

Nominal screw size (d) M24 M30 M36 M42 M48

B mm

Tool size 36 46 55 65 75

30 Capscrew (Socket bolt)

Nominal screw size (d) M6 M8 M10 M12 M14 M16 M18

B mm Tool size 5 6 8 10 12 14

Nominal screw size (d) M20 M24 M30 M36 M42 M48

B mm

Tool size 17 19 22 27 32 36

11.3

TORQUE SPECIFICATIONS FOR JOINTS AND HOSES

11.3.1

JOINTS FOR PIPING (WITH O-RING)

Nominal screw size (PF) 1/8 1/4 3/8 1/2 3/4

Wrench size mm 14 19 22 27 36

11.3.2

Tightening torque 17±2 36±2 74±5 108±9.8 162±9.8 255±9.8

HYDRAULIC HOSE (30° FLARE TYPE)

Nominal screw size (PF) 1/8 1/4 3/8 1/2 3/4

Wrench size mm 17 19 22 27 36

Tightening torque Nm 15±2.0 29±4.9 49±4.9 78±4.9 118±9.8

137±15

NOTE: The application of the tightening torque is subject to a dry condition.

11-3

11. TOOLS

11.4

TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS

11.4.1

SLEEVE TYPE TUBE FITTINGS

Tube size Outside diameter x thickness mm

Wrench size mm

Tightening torque Nm

10 x 1.5

44±4.9

15 x 2.0

147±20

18 x 2.5

177±20

22 x 3.0

216±20

28 x 4.0

275±29

35 x 5.0

441±44

11-4

11. TOOLS

11.5

SPECIAL SPANNERS FOR TUBES

Applicable tube diameter mm

HEX mm

11.6

Dimensions of a special spanner mm

SPECIAL TOOLS Unit: mm

No.

Name

Torx driver (with tamper proof) T25 (for M5)

11.7

Tools no.

Shape

Use

4.4

For instrument right cover

â&#x20AC;&#x201D;

APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS Service Screw locking compound Sealing compound

Loctite

Features

#242

Low strength

#262

Middle strength

#271

High strength

#515

Sealing

11-5

11. TOOLS

11.8

COUNTERWEIGHT LIFTING JIG

Q.ty: 2 set Material: mild steel UNIT: mm

170 49

112

C 4-

310

100 20(4)-90

R15

477

527

(539)

100

R50

300

135

160

Fig. 11-1 Counterweight lifting jig

11-6

11. TOOLS

11.9

UPPER FRAME LIFTING JIG

Q.ty: 2 set Material: mild steel UNIT: mm 170 49

112

C 4-

310

100 20(4)-90

R15

477

527

(539)

100

R50

10 C

300

135

160

Fig. 11-2 Upper frame lifting jig

11-7

11. TOOLS

[NOTES]

11-8

13. MAINTENANCE STANDARDS AND TEST PROCEDURES TABLE OF CONTENTS 13.1 HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS ............ 13-1 13.2 PERFORMANCE INSPECTION STANDARD TABLE ..................................... 13-3 13.2.1

STANDARD VALUE TABLE ................................................................... 13-3

13.3 MEASURING ENGINE SPEED........................................................................ 13-5 13.3.1

MEASURING ENGINE SPEED .............................................................. 13-5

13.4 MEASURING HYDRAULIC OIL PRESSURE .................................................. 13-7 13.4.1

STANDARD FOR HYDRAULIC OIL PRESSURE MEASUREMENT...... 13-7

13.4.2

PRESSURE MEASUREMENT AND ADJUSTMENT.............................. 13-7

13.5 MEASURING TRAVEL PERFORMANCES ................................................... 13-10 13.5.1

TRAVEL ................................................................................................ 13-10

13.5.2

TRAVEL DEVIATION ............................................................................ 13-10

13.5.3

MOVEMENT DRIFT DUE TO GRAVITY .............................................. 13-11

13.5.4

DRAIN RATE ON TRAVEL MOTOR..................................................... 13-11

13.6 MEASURING SLEW PERFORMANCES ....................................................... 13-12 13.6.1

SLEW TIME .......................................................................................... 13-12

13.6.2

OVERRUN WHEN SLEWING STOPS ................................................. 13-12

13.6.3

SLEW DRIFT DUE TO GRAVITY ......................................................... 13-12

13.6.4

DRAIN RATE OF TRAVEL MOTOR ..................................................... 13-13

13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES................... 13-14 13.7.1

CYLINDER SPEED ............................................................................... 13-14

13.7.2

GRAVITY DRIFT OF CYLINDERS ....................................................... 13-15

13.8 MEASURING SLEW BEARING PERFORMANCES ...................................... 13-16 13.8.1

SLEW BEARING-BUCKET TIP PLAY .................................................. 13-16

13.8.2

SLEW BEARING PLAY......................................................................... 13-16

13.9 MEASURING CRAWLER TENSION.............................................................. 13-17 13.9.1

CRAWLER TENSION ........................................................................... 13-17

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13.1

HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS

(1) Application 1) For new machine This manual is to be used to check the actual performance and functions of the machine compared with the PERFORMANCE STANDARDS. 2) At Specific Self-Inspection (as per LOCAL RULES) The maintenance standards are used to make them as the criteria to determine the time for reconditioning, adjustment and replacement. 3) At Deterioration of Performance This manual is of the criteria of safe and economical judgment whether the deterioration of performance on the machine would be caused by any faults or normal deterioration due to machine operation for a long period. 4) For Replacement of major components This manual is of the standard to determine the time for replacement to recover the performance of major components such as pump, etc. (2) Terminology 1) Standard values These are of the standard values to assemble and regulate a new machine. Where special notes are not given, these values are based on the machine with standard structure (the machine with standard attachments and shoes). 2) Standard values for repair These are of the values at which the reconditioning is required. In order to ensure the performance and safety, it is strictly prohibited to use the machine with the parts and components being over the standard values. 3) Serviceability limit This is of the service limit for each part and component at which the reconditioning is impossible and they must be replaced to new ones. All the parts and components which are estimated to exceed the serviceability limit up to the next periodical inspection and maintenance, should be also replaced to new ones. The machine operation with the parts and components which have exceeded the serviceability limit, causes increase of troubles and down time of the machine, and also causes safety problems. (3) Precautions for Judgment 1) Evaluation for measured data It is inevitable some variation on the measured data due to differences between measuring conditions, peculiar variability on a new machine, old and new versions of the machine and measuring characteristics. The judgment for the measured data should be comprehensively conducted based on the extent of level of the measured data, instead of mere comparison with the standard values. 2) Determination for reconditioning, adjustment or replacement There are two kinds of deterioration of machine performance; one is due to normal wear with time elapsing of operation, and the other is recoverable to the standard values with the adjustment for pressure, etc. Therefore, the determination for reconditioning, adjustment or replacement should be conducted taking various factors into consideration such as operating hours, working conditions and maintenance conditions of the machine, so that the machine is able to be operated at the optimum performance level. (4) Other precautions 1) Parts with aging effect The rubber products such as hydraulic hoses, O-rings, oil seals, etc. are deteriorated with the aging effect. It is necessary to replace them to new ones at periodical intervals or at every overhaul. 2) Parts required periodical replacement It is recommendable to designate the important hoses critical to secure the safety as Very Important Parts (V.I.P.), and periodically replace with new ones.

13-1

13. MAINTENANCE STANDARDS AND TEST PROCEDURES 3) Inspection and replacement of lubricants It is necessary for the user of the machine to fully familiarize himself with the procedures and precautions to handle the machine in safe and carry out the maintenance, as well as the procedures for inspection and lubrication. Refer to the OPERATION AND MAINTENANCE MANUAL as well.

13-2

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13.2

PERFORMANCE INSPECTION STANDARD TABLE

13.2.1

STANDARD VALUE TABLE Table 13-1(1/2) Model

Div.

Piece

Unit

Hydraulic oil cleanliness Hydraulic oil temperature Measurement (Tank surface) of condition Coolant temperature (Radiator surface) Low idling Engine speed High idling Deceleration Boom • Bucket • Travel P1 (LH) Main pressure Arm • Swing • Travel (RH) P2 relief valve • Attachment Dozer Pilot pressure relief valve

*2 Pressure (overload) relief valve port

[TEMPORARY] E50B SR - E55B Standard Repair limit value 8±1 —

50 ÷ 60

—

50 ÷ 60

—

60 ÷ 90

—

60 ÷ 90

—

1150 ± 50 2550 ± 50 1150 ± 50

— — —

1150 ± 50 2550 ± 50 1150 ± 50

— — —

°C

rpm

+0.5 0

—

23.0

+0.5 0

—

23.0

+0.5

—

23.0 0 3.5 ± 0.4

23.0 MPa

23.0

23.0 0 3.5 ± 0,4

—

+0.5 0

—

+0.5 0

—

+0.5

— —

Boom

Head

27.5

0 -4.9

Arm

Head

25.5

0 -2.9

—

25.5

0 -2.9

—

Bucket

Head

25.5

0 -2.9

—

25.5

0 -2.9

—

Dozer

Head

25.5

0 -5.9

—

25.5

0 -5.9

—

*1st slew

LH/RH

+1.0

—

+1.0

—

Low speed High speed Low speed Steel crawler High speed Low speed Rubber belt High speed Travel time Low speed Steel (10 m) crawler High speed

Crawler time (5 rev.)

Travel

Pilot line

Class

E45B SR Standard Repair limit value 8±1 —

MPa

Rubber belt

Travel deviation Drift due to gravity

w / P.B. (5 min)

sec

21.0 0 37.5 ± 2.1 21.9 ± 1.1 35.1 ± 2.0 20.5 ± 1.0 13.7 ± 0.7 8.1 ± 0.4 15.0 ± 0.7 8.8 ± 0.4 0

—

27.5

0 -4.9

—

48 28 45 26 18 10 19 11

21.0 0 40.2 ± 2.3 23.5 ± 1.2 37.5 ± 2.1 21.9 ± 1.1 13.7 ± 0.7 8.1 ± 0.4 15.0 ± 0.7 8.8 ± 0.4 0

51 30 48 28 18 10 19 11

140 -140

280

140 -140

280

*1. The pressure for slew is controlled by the relief valve attached to the slew motor. *2nd Reference value for checking of pressure (tightening the adjusting nut of the main pressure relief valve). Refer to item 13.4.2.1

13-3

13. MAINTENANCE STANDARDS AND TEST PROCEDURES Table 13-1(2/2)

[TEMPORARY]

Model Unit

Standard value

Repair limit

Standard value

Repair limit

Slew time per 2–revolution

sec

13.9 ± 0.7

—

Ext.

2.3 ± 0.4

2.9

3.0 ± 0.4

3.8

Ret.

2.1 ± 0.4

2.7

2.6 ± 0.4

3.3

Ext.

2.2 ± 0.4

2.8

2.9 ± 0.4

3.7

Ret.

2.0 ± 0.4

2.6

2.5 ± 0.4

3.2

Ext.

2.8 ± 0.4

3.6

3.3 ± 0.4

4.2

2.1 ± 0.4

2.7

2.5 ± 0.4

3.2

2.8 ± 0.4

3.6

2.8 ± 0.4

3.6

Ret.

1.8 ± 0.4

2.3

1.8 ± 0.4

2.3

Ext.

5.5 ± 0.8

7.0

5.5 ± 0.8

7.0

Ret.

4.0 ± 0.6

5.1

4.0 ± 0.6

5.1

Ext.

2.7 ± 0.4

3.5

2.7 ± 0.4

3.5

Ret.

1.9 ± 0.4

2.4

1.9 ± 0.4

2.4

Overrun when slewing stops

Drift due to gravity Canopy Boom Cab Arm

Cylinder speed

Ret. Ext.

Bucket Swing

Cylinders

Dozer

Cylinder gravity move

Slewing bearing Crawler

E50B SR - E55B

Piece

Div.

Slewing

E45B SR

Boom

Arm

Dozer

Bucket tip

150

(10 min)

Bucket tip play Crawler tension

sec

Rubber

0 -12

0 -6

0 -150

260

150

0 -150

260

+20 -10

85 ÷ 95

—

85 ÷ 95

—

130 ÷ 150

—

130 ÷ 150

—

Steel

13-4

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13.3

MEASURING ENGINE SPEED

13.3.1

MEASURING ENGINE SPEED

(1) Measuring instruments

1) Diesel Speedometer (1) (Measuring engine speed by means of applying a pick-up (2) to one of injection pipes)

2) Surface thermometer (measures the surface temperature generated by the probe when coming in contact with the surface of the hydraulic oil in the tank and in the radiator). (2) Engine warming up operation Start the engine and take the coolant temperature within the range of 60 to 90 째C (140 to 194 째F). Check the coolant temperature with the coolant thermometer on the control panel. The white colour zone shows approximately 67 to 105 째C (152 to 221 째F) of temperature range. Therefore, when the indicator is located at around centre of the white zone, it is suitable for the engine operation.

Fig. 13-1 Engine speed measurement (The above figure shows concept)

(3) Engine speed measurement 1) Apply the pick up of speedometer to one of convenient injection pipes. (Refer to Fig. 13-1)

WATER TEMPERATURE

2) Measure the engine speed at idling with no load, and compare it to the figure in the STANDARD VALUE TABLE.

13-5

13. MAINTENANCE STANDARDS AND TEST PROCEDURES (4) Speed adjustment

1) Low (3) / high (4) idling speed is low; The proper engine speed is obtained with the length of accelerator wire as shown in the right sketch. When the engine speed is lower than the standard speed, adjust the length of wire with loosening the capscrew (9) of throttle lever side.

(5.28") 134

CAUTION

However, if the proper high idling speed is not obtainable, consult it with the engine manufacturer.

30 15

Z [WATER TEMPERATURE (OPT)] 5. Decel cable 6. Throttle cable

A Fig. 13-2 Accelerator wire adjustment

13-6

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13.4

MEASURING HYDRAULIC OIL PRESSURE

13.4.1

STANDARD FOR HYDRAULIC OIL PRESSURE MEASUREMENT

(1) Hydraulic instruments • 6.86 MPa (995 psi) pressure gauge: 1 set • 49 MPa (7104 psi) pressure gauge: 3 set • Surface thermometer: 1 set • Pressure measuring kit and oil analyzing • Equipment: 1 set

P3 (G3)

(2) Measuring cleanliness of hydraulic oil

P2 (G2)

CAUTION 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 exceeds the standard value, replace the return filter and/or change the hydraulic oil. 13.4.2 13.4.2.1

P1 (G1)

PRESSURE MEASUREMENT AND ADJUSTMENT Main circuit pressure

(1) Measuring conditions Engine speed: High idling Hydraulic oil temperature:50 ÷ 60 °C (122 ÷ 140 °F)

OR9

OR8 OR3

Coolant temperature (on radiator surface): 60 ÷ 90 °C (140 ÷ 194 °F)

OR1

(2) Pressure measuring procedures 1) After releasing pressure in the hydraulic oil tank, and setting a 49 MPa (7104 psi) pressure gauge to either of pressure detecting ports (G1, G2 or G3, PF1/4 with plug), operate the circuit to be measured to measure the relief pressure. 2) When the main relief pressure is being within the standard range, the measurement for the overload relief pressure may be omitted.

OR7

OR4

Fig. 13-3 Main hydraulic oil pressure measurement

3) If the main pressure relief valve detects a pressure which is lower than the standard limit, tighten the valve by half a turn [pressure increases by 12.2 MPa (1770 psi)], then measure pressure at overload relief valve. 4) After adjusting pressure at the overload relief valve, take pressure back within the standard limit of the main relief valve.

13-7

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

Operating circuit

Pressure detecting Pressure port relief Port Dimensi valve location ons

Boom, bucket and travel (left)

Arm, travel (right), swing and attachment

Dozer and slewing

MR1 PF1/4

MR2 Main relief valve (MRV2) MR3 2

Overpressure relief valve attaching position OR1

BUCKET DIGGING

OR3

RAISED BOOM

OR4

LOWER BOOM

OR9

DOZER DOWN

OR7 OPERATING ARM OR8

Fig. 13-4 Main relief valve (MRV1)

FREE ARM

(3) Set pressure 1) Control valve: main pressure relief valve and overpressure relief valve a. Loosen the locknut (2) and adjust pressure by turning the setscrew (1). Roughly with one full turn: Main relief valve and overpressure relief valve: approximately 12.2 MPa Clockwise turning: increasing setting pressure Counterclockwise turning: decreasing setting pressure b.. After the adjustment, tighten the locknut and hold the setscrew so that it does not turn. c. Again activate the relief valve to check the stable setting pressure. Tightening torque for nut (2): 19.6 Nm 2) Slewing motor: pressure relief valve a.. The pressure adjuster for relief valve and slewing motor is not available. If the adjustment is required by fatigue of spring and so on, replace with the new relief valve in an assembly. b. Therefore the port of detecting pressure is not equipped on the slewing motor.

13-8

Fig. 13-5 Pressure relief valve (slewing motor)

13. MAINTENANCE STANDARDS AND TEST PROCEDURES 13.4.2.2

Pilot circuit pressure

(1) Measuring conditions Engine: high idling Hydraulic oil temperature: 50 ÷ 60 °C Coolant temperature: 60 ÷ 90 °C at radiator surface (2) Measurement Releasing pressure in the hydraulic oil tank of hydraulic system, and setting a 6.86 MPa pressure gauge to the pressure detecting port (G4, PF 1/4 with plug) (4), measure the pilot relief pressure. Pressure detecting port Port location

Dimensions

Pressure relief valve

PF1/4

PR1

Fig. 13-6 Pilot oil pressure measurement Unplug PF1/4, and set a 6.86 MPa pressure gauge (3) Set pressure Adjust it with the relief valve attached to the solenoid valve (5).

1) Loosen the locknut (2), then turn the setscrew (1) to adjust pressure. Clockwise turning: pressure increases. Counterclockwise turning: pressure decreases.

2 3

PR1

2) After the adjustment, lock the setscrew with the lock nut holding the setscrew not to allow its turning. 3) Again actuate the relief valve, and verify that the set pressure is being stable. Tightening torque: Lock nut (2): 7.8 Nm Pressure relief valve (PR1): 44 Nm Capscrew (3): 7.8 Nm

Fig. 13-7 Pressure relief valve

13-9

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13.5

MEASURING TRAVEL PERFORMANCES

•TEST PROCEDURES Measure 3-time each. Apply average data of the above for judgement. 13.5.1

Travel

(1) Travel speed (5 revolutions) • Engine: high idling • Hydraulic oil temperature: 50 ÷ 60 °C • Measurement position: machine body is raised using both hoe attachment and dozer blade. • Set crawler shoes in motion. Starting after one full revolution, measure the time required for 5 revolutions. (To measure speed after it has stabilized). (2) Travel speed (10 m) • Engine: rated rpm • Hydraulic oil temperature: 50 ÷ 60 °C • Measurement position: travel position • Set machine in motion. Starting after a running of 5 metres, measure the time required to travel 10 metres. Do this on level and hard ground.

10m

• Travel position: Fully extend the arm and bucket cylinders and place the hoe attachment so that its lowest part is even with the machine’s minimum ground clearance level. The hoe attachment must be in a no-load and the dozer blade must not touch the ground.

13.5.2

Travel deviation

•

Engine: rated rpm

•

Hydraulic oil temperature: 50 ÷ 60 °C

•

Measurement position: Travel position

•

Measure the deviation “X” at the point of half of 10 m travel after 5 m preliminary running. Do this on level and hard ground.

13-10

13. MAINTENANCE STANDARDS AND TEST PROCEDURES 13.5.3

Movement drift due to gravity

Measure the movement distance of machine on a slope due to machine’s own weight, holding the machine for 5 minutes on the slope. Measuring conditions: •

Engine: stopped

•

Hydraulic oil temperature: 50 ÷ 60 °C

•

Gradient: 15° (Approx. 1/3.73)

•

Machine position: fully extending the boom, arm and bucket cylinders, and fully contracting the dozer cylinder.

13.5.4

DRAIN RATE ON TRAVEL MOTOR

(1) Preparation 1) Apply stopper pins (1) for both travel sprockets of left and right. 2) Stop the engine, and release air in the hydraulic oil tank. 3) Connect a hose to the drain port of travel motor, and receive the drained oil in a container. 4) Apply a plug to the drain piping at tank side.

WARNING Make sure of the rotating direction of travel motor referring to the right sketch. Otherwise, the rib (A) may be broken by the stopper pin (1).

(2) Measurement: • Engine: at rated speed • Hydraulic oil temperature: 50 ÷ 60 °C • Machine position: locking the travelling, and allowing relief on the travel motor • Measure the drained volume of oil for 30 seconds of relief. Unit: l/30 sec DRAIN RATE OF TRAVEL MOTOR MOVING SPEED 1a

Standard value

Standard value for repair

Serviceability limit

1.5 or less

3 or more

13-11

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13.6

MEASURING SLEW PERFORMANCES

•TEST PROCEDURES Measure 3-time each. Apply average data of the above for judgement. 13.6.1

Slew time

•

Engine: high idling

•

Hydraulic oil temperature: 50 ÷ 60 °C

•

Measurement position: completely retract the arm cylinder, fully extend the bucket cylinder and place so that boom foot pin (B) and bucket pin (A) are at matching height. Place the dozer blade on the ground.

•

With the hoe attachment in a no-load, drive 1 rotation, then measure the time required for the next 2 rotations.

13.6.2

Overrun when slewing stops

•

Engine: high idling

•

Hydraulic oil temperature: 50 ÷ 60 °C

•

Measurement position: the same used to measure the slewing time.

•

Prior to measuring, draw matching marks on the outer race of the slew bearing and lower frame at exactly 180 degrees slew from the starting point. Then with the hoe attachment in a no-load, slew 180 degrees from starting point (A). At which point return the operating lever to neutral (B). Measure the distance between the position marks and the point the hoe attachment stops (C).

13.6.3

Slew drift due to gravity

•

Engine: stopped

•

Hydraulic oil temperature: 50 ÷ 60 °C

•

Gradient: 15° (Approx. 1/3.73)

•

Measurement position: the same used to measure the slewing time.

•

Slew the upper slewing structure and stop at right angle to the slope, then draw matching marks on the slew bearing’s outer race and the lower frame. Then measure the distance (A) that develops between the marks after 5 minutes. Measure in both directions: right and left.

13-12

13. MAINTENANCE STANDARDS AND TEST PROCEDURES 13.6.4

Drain rate of travel motor

(1) Preparation 1) Stop the engine, and release air in the hydraulic oil tank. 2) Disconnect the slew motor drain hose at the return side to the hydraulic oil tank. Then receive the drain oil to a container. Install plug on bore of tank after removing drain hose. (2) Measurement: • Engine: at rated speed • Hydraulic oil temperature: 50 ÷ 60 °C • Machine position: pushing a fixture with the side of bucket, operating the engine. • Measure the drained volume of oil for 30 seconds relieving at full stroke of the slewing operation. Unit: litres/30sec DRAIN RATE OF SLEW MOTOR Standard value

Standard value for repair

Use

3.0 or less

13-13

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13.7

MEASURING ATTACHMENT OPERATING PERFORMANCES

•TEST PROCEDURES Measure 3-time each. Apply average data of the above for judgement. 13.7.1

Cylinder speed

(1) Boom cylinder speed • Engine: high idling • Hydraulic oil temperature: 50 ÷ 60 °C • Measurement position: completely retract the arm cylinder, fully extend the bucket cylinder and place the dozer blade on the ground. • Then measure the time required for the bucket to reach its highest point (lowest point) from its lowest point (highest point) placing on the ground. (Do not include the cushioning time). (2) Arm cylinder speedEngine: high idling • Hydraulic oil temperature: 50 ÷ 60 °C • Measurement position: completely retract the arm cylinder, fully extend the bucket cylinder, position the arm horizontally and place the dozer blade on the ground. • Then measure the time required for the arm cylinder to completely retract (extend) from a fully extended state (retracted state). (3) Bucket cylinder speed • Engine: high idling • Hydraulic oil temperature: 50 ÷ 60 °C • Measurement position: completely retract the arm cylinder, position the arm horizontally and place the dozer blade on the ground. • Then measure the time required for the bucket cylinder to completely retract (extend) from a fully extended state (retracted state). (4) Swing cylinder speed • Engine: high idling • Hydraulic oil temperature: 50 ÷ 60 °C • Measurement position: the same used to measure the slewing time. • While swinging the boom left (right) to right (left), measure the time required for a full stroke each way.

13-14

13. MAINTENANCE STANDARDS AND TEST PROCEDURES (5) Dozer cylinder speed • Engine: high idling • Hydraulic oil temperature: 50 ÷ 60 °C • Measurement position: using the hoe attachment lift up the dozer blade side. • Then, up and down the dozer blade with full stroke, measure the time required per stroke in each direction. 13.7.2

Gravity drift of cylinders

(1) Boom, arm, bucket, dozer, bucket tip • Engine: stopped • Hydraulic oil temperature: 50 ÷ 60 °C • Measurement position: completely retract the dozer and arm cylinders, fully extend the bucket cylinder and position the bucket pin to the same height as the boom foot pin. • Maintain the position for 10 minutes then measure the change of rod length and distance of the bucket tip. (2) Swing cylinder • Engine: stopped • Hydraulic oil temperature: 50 ÷ 60 °C • Gradient: 15° (Approx. 1/3.73) • Measurement position: the same used to measure the slewing time. • Slew the upper slewing structure and stop at right angle to the slope, then measure the change in rod length after 5 minutes.

13-15

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13.8

MEASURING SLEW BEARING PERFORMANCES

•TEST PROCEDURES Measure 3-time each. Apply average data of the above for judgement. 13.8.1

Slew bearing-bucket tip play

•

Measurement position: completely retract the arm cylinder and fully extend the bucket cylinder.

•

Move the tips of the bucket teeth from side to side (left and right) and measure the play.

13.8.2

Slew bearing play

(1) Attach a dial gauge to the bottom face of the slew bearing’s outer-race located in front of the upper slewing structure.

(2) Raise the crawler on one side off the ground and set the dial gauge to zero.

(3) Then raise the opposite crawler and read the dial gauge.

13-16

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13.9

MEASURING CRAWLER TENSION

13.9.1

Crawler tension

•

Raise the machine completely off the ground using the hoe attachment and dozer blade. Then measure the distance (A) (of sag) between the centre point on the crawler frame and top of the crawler shoe.

B A

CAUTION

In the case of rubber crawlers, measurements should be taken with setting the joint (“M” or “∝” mark) in the top centre position.

A. Distance B. Rubber C. Steel

13-17

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

[NOTES]

13-18

22. HYDRAULIC SYSTEM TABLE OF CONTENTS 22.1 SUMMARY ...................................................................................................... 22-1 22.1.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT ....................... 22-1 22.2 HYDRAULIC CIRCUITS AND COMPONENT MODELS ................................ 22-2 22.3 HYDRAULIC CIRCUIT OPERATION .............................................................. 22-4 22.3.1 COLOR CODING STANDARD FOR HYDRAULIC .................................. 22-4 22.3.2 NEUTRAL CIRCUIT .................................................................................. 22-4 22.3.3 TRAVEL OPERATING CIRCUIT............................................................... 22-5 22.3.4 SLEW OPERATING CIRCUIT .................................................................. 22-6 22.3.5 BUCKET OPERATING CIRCUIT .............................................................. 22-6 22.3.6 BOOM OPERATING CIRCUIT.................................................................. 22-7 22.3.7 ARM OPERATING CIRCUIT..................................................................... 22-7 22.3.8 SWING OPERATING CIRCUIT ................................................................ 22-8 22.3.9 DOZER OPERATING CIRCUIT ................................................................ 22-8 22.3.10TRAVEL / DOZER COMBINED OPERATING CIRCUIT........................... 22-9 22.3.11TRAVEL / BOOM COMBINED OPERATING CIRCUIT ............................ 22-9 22.3.12HYDRAULIC NIBBLER AND BREAKER OPERATING CIRCUIT .......... 22-10

22. HYDRAULIC SYSTEM

22.1

SUMMARY

22.1.1

FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT

The hydraulic circuits are built up with the following functions and features in order to achieve easy operation, safety and high working efficiency. Device

Slewing

Travel

Performance

Easy operation and safety Tool Miscellaneous Travel Pump Electricity

Low fuel consumption

Features • Straight travelling secured by balanced operation travel function in combined operations

• Preventing overrunning of travel motor

• Preventing overrunning on a slope

• Parking brake • Slewing (with dozer) independent circuit

• Automatic braking at parking

• Auto slewing parking brake

• Protecting against slewing drift on a slope

• Slewing shockless function

• Graduality feeling when stopping slewing operation • Gradual operation control

• Hydraulic pilot control system

Tool

High working performance

Operation • Straight travelling

• Constant slewing speed when operating in simultaneous operation condition starting

and

• Dozer (with slewing) independent circuit. • Closed pressurized hydraulic oil tank

• Secure the travel straight when travelling and working with dozer. • Preventing contamination of hydraulic oil and improvement of the pump self-suction efficiency

• Suction strainer

• Removing dirt of suction side

• Pilot valve filter

• Preventing malfunction in pilot operating circuit

• Return filter • Power control

• Preventing contamination of hydraulic oil • Effective use of engine power with variable pump (Power shifting by P3 pump)

• 2 speeds travelling

• Improving working efficiency with 2 travel speeds shifting

• P3 pump oil flow conflux in arm or • Speed increased by conflux P3 pump oil attachment operation piping (when no dozer or slewing used) • Push button deceleration • While waiting for the truck to dump, the engine speed changes continuously and the fuel consumption and the noise are reduced.

22-1

22. HYDRAULIC SYSTEM

22.2 •

HYDRAULIC CIRCUITS AND COMPONENT MODELS

For the Hydraulic circuit diagram, refer to Fig. 71-1 of Supporting Data that is provided at the and of this manual. No.

NAME

E45B SR

PUMP ASSY

AP2D25LV1RS7

CONTROL VALVE

BCV65

SLEWING GEARBOX

PLC-120-18B-1FS2-8284A

TRAVEL MOTOR

GM06VA

BOOM CYLINDER

ARM CYLINDER

ø80-ø50-717

BUCKET CYLINDER

ø75-ø45-546

SWING CYLINDER

ø90-ø50-567

DOZER BLADE CYLINDER

ø95-ø55-200

ROTARY CONTROL VALVE

ATTACHMENT CONTROL VALVE

PV48M2042

TRAVEL CONTROL VALVE

PVD6P4001

SOLENOID VALVE

2KWE5G-30/G12WS-249A

DOZER CONTROL VALVE

PV6P

SHUTTLE VALVE

AUXILIARY CONTROL VALVE

RETURN FILTER

SUCTION STRAINER

PILOT VALVE FILTER

Y-457400

CHECK VALVE

Y-2389

STOP VALVE

SELECTOR VALVE

OIL COOLER

HYDRAULIC OIL TANK

SOLENOID VALVE (ONLY A/C VERSION)

CANOPY

ø90-ø50-704

CAB

ø90-ø50-680

NOTE: this is for reference only, because the model number might be changed due to improvement.

NOTE: the version with air conditioned has a modified pump assy (with the same P/N).

22-2

22. HYDRAULIC SYSTEM •

For the Hydraulic circuit diagram, refer to Fig. 71-1 of Supporting Data that is provided at the and of this manual. No.

NAME

E50B SR - E55B

PUMP ASSY

AP2D25LV1RS7

CONTROL VALVE

BCV65

SLEWING GEARBOX

PLC-120-18B-1FS2-8284A

TRAVEL MOTOR

GM06VA

BOOM CYLINDER

ARM CYLINDER

ø90-ø50-716

BUCKET CYLINDER

ø75-ø45-546

SWING CYLINDER

ø90-ø50-567

DOZER BLADE CYLINDER

ø95-ø55-200

ROTARY CONTROL VALVE

ATTACHMENT CONTROL VALVE

PV48M2042

TRAVEL CONTROL VALVE

PVD6P4001

SOLENOID VALVE

2KWE5G-30/G12WS-249A

DOZER CONTROL VALVE

PV6P

SHUTTLE VALVE

AUXILIARY CONTROL VALVE

RETURN FILTER

SUCTION STRAINER

PILOT VALVE FILTER

Y-457400

CHECK VALVE

Y-2389

STOP VALVE

SELECTOR VALVE

OIL COOLER

HYDRAULIC OIL TANK

SOLENOID VALVE (ONLY A/C VERSION)

CANOPY

ø100-ø55-699

CAB

ø100-ø55-666

NOTE: this is for reference only, because the model number might be changed due to improvement.

NOTE: the version with air conditioned has a modified pump assy (with the same P/N).

22-3

22. HYDRAULIC SYSTEM

22.3

HYDRAULIC CIRCUIT OPERATION

22.3.1

COLOR CODING STANDARD FOR HYDRAULIC

Blue:

Feed, drain circuit,

less than 0.34 MPa

Green:

Return, make-up circuit,

0.34รท 0.59 MPa

Violet:

Secondary pilot pressure,

0.59รท3.5 MPa

Red:

Primary pilot pressure,

3.5รท3.9 MPa

Orange:

Main pump drive pressure,

4.9รท23 MPa

Blue:

At valve selection

Red valve:

When proportional valve is operating

Red solenoid:

Active and operating

Displaying the flow circuit and stand-by circuit when operating. Regarding the electrical symbols in this manual, refer to the electric circuit diagram. NOTE: for the hydraulic circuit operation, refer to Fig. 71-2 to 71-13 of supporting data that is provided at the end of this manual. 22.3.2

2) Pilot secondary pressure circuit While the pilot valves (11), (12) and (14) are being in neutral, the pilot secondary pressure is not generated. By means of operating the operating lever, the secondary pressure is generated in accordance with its motion and led to the control valve (2) from the pilot valve to shift each spool of shifting valve.

NEUTRAL CIRCUIT (Refer to fig. 71-2)

(1) Pilot circuit 1) Pilot primary pressure circuit The oil delivered from the A4 port on pump assy (1) enters into the solenoid valve (13) through the line filter (19). The pressurized oil from the port A2 of the solenoid valve (13) with the safety lock lever released (in the operating condition) is supplied to the P ports of the pilot valves for attachment (11), travel (12) and dozer (14). Since the operating circuit is fully closed in the neutral position, the oil delivered by the pump other than the oil supplied to the Pp1 port of the control valve loses its flowing passage, and returns to the hydraulic tank (24) through the relief valve (set pressure: 3.5 MPa built in the solenoid valve (13). The oil supplied to the Pp1 port is led to the tank passage through the pilot passages provided to the service spool and through the pilot passages provided to the right and left travel spools.

(2) Main circuit

22-4

1) Variable pump circuit The delivered oil from A1 and A2 ports on variable pump enters into P1 and P2 ports on control valve (2) respectively. All the discharged oil from these two ports finally returns to the hydraulic oil tank (24), through each valve of travel left, boom and bucket for the P1 oil, and through each valve of travel right, swing, service and arm for the P2 oil. 2) Third pump circuit The oil delivered from A3 port on 3rd pump enters into P3 port on control valve (2). The whole amount of oil discharged through the port P3 returns to the hydraulic oil tank (24) through the selector valves for the dozer and slewing and the independent travel and flow conflux valves.

22. HYDRAULIC SYSTEM 22.3.3

TRAVEL OPERATING CIRCUIT (Refer to fig. 71-3)

Hydraulic pilot system allows to operate, through the control levers, the 2-speed travel. 22.3.3.1

2nd speed operating circuit (Independent-forward travel)

(1) Pilot circuit 1) Shifting signal for 2nd speed travel. When the â&#x20AC;&#x153;Rabbit and Turtleâ&#x20AC;? mark (at the power cut-off, it automatically takes back for 1st speed) on the knob of travel right lever is pushed down, it actuates the 1st and 2nd speed travel shifting valve of solenoid valve (13). The pressurized oil signal for 2nd speed is generated from the A1 port of solenoid valve (13), and led to the P port on travel motor (4) through swivel joint (10), and shifts the 2-speed shifting valve (404). 2) Changing travel valve spool The pilot secondary pressure is generated from pilot valve (12) by the operation for travel forward. The pressurized oil is led to the Pb7 and Pb6 ports on control valve (2) to shift the travel valve spool. (2) Main circuit 1) Circuit up to travel motor (4) The delivered oil from A1 and A2 ports on variable pump enters into the P1 and P2 ports of control valve (2), and led to the B7 and B6 ports through the travel valve. Then it is led to the A and B ports on left and right travel motors respectively through the swivel joint (10). 2) Travel motor a. The pressurized oil supplied to the travel motor shifts the spool of the counterbalance valve (brake valve) (408), releases the parking brake (403), opens the hydraulic circuit having closed by the check valve (407) and rotates the travel motor. It actuates the speed shifting valve (404) when the 2nd speed signal is sent.

22-5

The high-pressure oil pumped through the shuttle valve (406) passes through the speed change valve (404), actuates the speed shifting piston (401) so that the engine rotates at high speed but with a low torque. b. When the motor reaches near to a self-running condition (over-running) at going down a slope and so on, the oil pressure of supply side gets down to lower pressure, and the counter balance valve [brake valve] (408) spool moves to the neutral position with the spring force. As the results, the passage in return oil side is throttled, and the motor speed is suppressed by a back-pressure, then the motor is controlled to the speed corresponding to the supplied oil volume of the pump. c. The counterbalance valve spool is so designed that it is gradually shifted by a throttle effect to stop or start the motor absorbing shock at the start and stop of the machine. d. When load increases during high speed travel, the speed automatically shifts to the 1st speed, resulting in low speed and high torque.

22. HYDRAULIC SYSTEM 22.3.4

22.3.5

SLEW OPERATING CIRCUIT (Refer to fig. 71-4)

BUCKET OPERATING CIRCUIT (Refer to fig. 71-5)

Hydraulic pilot system allows to operate, through the left control lever, the slewing.

Hydraulic pilot system allows to operate, through the right control lever, the bucket.

22.3.4.1

22.3.5.1

Slew (left) operating circuit

(1) Pilot circuit

Bucket digging operation circuit

(1) Pilot circuit 1) Bucket spool shifting When the operating lever is put at bucket digging position, the pilot secondary pressure oil is generated from the pilot valve (11). The pressurized oil entered into the Pb9 port on control valve (2) shifts the bucket valve spool.

1) Slew valve spool shifting With operation for slew (left), the pilot secondary pressure oil is generated from the pilot valve (11), and led to the Pb2 port of control valve (2) to shift the slew valve spool. 2) Releasing parking brake The pilot primary pressure is always led to PB port on the timer valve (303). With the slew operation, the operating pilot secondary pressure is led to PP port on the timer valve (303) through the shuttle valve (15) to shift the spool. It leads the pilot primary pressure 3.5 MPa to the parking brake to release it. (Similarly, the arm in operation releases the slewing brake). 3) Activating parking brake When the slew operating lever is returned to neutral position to stop slewing, the pilot secondary pressure disappears causing to shift the timer valve (303), then the pressurized oil is shut down. The oil in the brake cylinder is discharged due to spring force, and drained through the throttle in the timer valve (303). Thus the braking is activated with some time interval for 2.5 to 5.0 seconds to smoothly absorb the slewing inertia at its stop of motion.

(2) Main circuit 1) Supply circuit for cylinder (7) The oil delivered from A1 port on variable pump of pump assy (1) enters into P1 port on control valve (2). The pressurized oil from B9 port through bucket valve is supplied to the head side of bucket cylinder (7) to activate the digging work. The return oil from the rod side of cylinder (7) enters into A9 port on control valve (2) and returns into the tank through bucket valve. 22.3.5.2

Bucket dumping operating circuit

(1) Pilot circuit 1) Bucket spool shifting When the operating lever is moved to bucket dumping position, the pilot secondary pressure oil is supplied from pilot valve (11), and enters into Pa9 port on control valve (2) to shift the bucket valve spool. (2) Main circuit

(2) Main circuit 1) Supply circuit for slewing motor (3) The oil delivered from the A3 port on hydraulic oil pump (1) is supplied to the B port on slewing motor (3) through the P3 port on control valve (2) and slew valve to drive the slewing motor. 2) Slewing motor (3) a. The relief valve (304) relieves rapidly increased pressure at start and stop of the machine to ease shock. b. The make-up valve (check valve) (305) has a function to replenish oil from the return oil circuit that is led to the tank [T2 port on control valve (2)] to the slewing motor, to prevent the slewing motor from the cavitation due to negative pressure generated in it because of inertia on the slewing mass.

22-6

1) Supply circuit for cylinder (7) Similar to the case for bucket digging, the pressurized oil delivered from A1 port on variable pump enters into P1 port on control valve (2). The oil supplied from A9 port through bucket valve is entered into the rod side of bucket cylinder (7) to activate the bucket dumping.

22. HYDRAULIC SYSTEM 22.3.6

22.3.7

BOOM OPERATING CIRCUIT (Refer to fig. 71-6)

Hydraulic pilot system allows to operate, through the right control lever, the boom. 22.3.6.1

Boom UP operating circuit

Hydraulic pilot system allows to operate, through the left control lever, the arm, with a return oil recirculation during performing of light load digging works. 22.3.7.1

(1) Pilot circuit 1) Boom spool shifting When the operating lever is put at boom up position, the pilot secondary pressure oil is generated from pilot valve (11). The pressurized oil entered into Pa8 port on control valve (2) shifts the boom valve spool.

1) Shift for arm spool At the arm in operation, the pilot secondary pressure generated from the pilot valve (11) is led to the Pa3 port on control valve (2) to shift the arm valve spool. Furthermore, the pilot secondary pressure acts to the PP port on timer valve (303) through the shuttle valve (15) to release the parking brake. Since the spool of the arm valve shifts to close the pilot passage, the pressure of pilot oil through the Pp1 port equals to the supply pressure. Thus the pressure overcomes the spring forces of the independent travel and flow conflux valves to shift the valve spool.

1) Supply circuit for cylinder (5) The oil delivered from A1 port on variable pump of pump assy (1) enters into P1 port on control valve (2). The oil supplied from B8 port through boom valve and lock valve is entered into the head side of boom cylinder (5) to up the boom. Boom down operating circuit

Arm in operating circuit

(1) Pilot circuit

(2) Main circuit

22.3.6.2

ARM OPERATING CIRCUIT (Refer to fig. 71-7)

(2) Main circuit

(1) Pilot circuit

1) Supply circuit for cylinder (6) Delivery oil from A2 port on the variable displacement pump enters into P2 port on control valve (2). The pressurized oil from the P3 port joins with the oil from the P2 port through the independent travel and flow conflux valves. The joined oil flows out from the A3 port through the arm valve and is supplied to the head side of the arm cylinder (6) to perform arm in work.

1) Boom spool shifting When the operating lever is put at boom down position, the pilot secondary pressure oil is generated from pilot valve (11), and enters into Pa8 port on control valve (2) to shift the boom valve spool. At the same time, the pilot secondary pressure is led to the boom lock valve (206) to push up the check valve and open the oil path from closed condition.

2) Return line from cylinder (6) The return oil from the rod side of arm cylinder enters into the B3 port on control valve (2), and is led to the return line from the T1 port through arm valve, then return to the tank.

(2) Main circuit 1) Supply circuit for cylinder (5) and return oil circuit The pressurized oil delivered from A1 port on variable pump is led to boom valve provided on control valve (2), and supplied to the rod side of boom cylinder (5) to down the boom. The oil returned from the head side of cylinder (5) enters into B8 port on control valve (2), and returns to the tank through the boom lock valve (206) and boom valve. Its flow rate is restricted by the throttle effect in boom valve, accordingly the boom is lowered at a stable speed.

22.3.7.2

Operating circuit for arm out

(1) Pilot circuit At the operation for arm out, the pilot secondary pressure is generated from the pilot valve (11), and led to the Pb3 port on control valve (2) to shift the arm valve spool. The independent travel and flow conflux valves are actuated as in the excavating operation. (2) Main circuit

a. Boom lock valve (206) This is of a check valve mechanism to prevent the boom from lowering due to its own weight while the boom valve is being at neutral position.

22-7

As in the case of excavating operation, the oil having flown into the control valve (2) joins with the pressurized oil from P2 and P3, flows out from the B3 port and is supplied to the rod side of the arm cylinder to perform arm out work.

22. HYDRAULIC SYSTEM 22.3.8

22.3.9

SWING OPERATING CIRCUIT (Refer to fig. 71-8)

DOZER OPERATING CIRCUIT (Refer to fig. 71-9)

This function is activated by means of control pedal, which controls the valve activation cable. This function is activated regardless to the safety lock lever position.

Hydraulic pilot system allows to operate, through the dozer control lever, the dozer.

22.3.8.1

(1) Dozer operation

Swing (left) operating circuit

22.3.9.1

(1) Swing operation When depress the left side of swing pedal, the swing valve spool in control valve (2) is shifted by the cabling mechanism. Since the pilot oil pressure is not utilized for it is activated regardless to the safety lock lever.

Dozer down operating circuit

When the operating lever is pushed forward, the pilot secondary pressure is generated from the pilot valve (14) to shift the dozer valve spool through the Pb1 port of the control valve (2). (2) Main circuit

(2) Main circuit 1) Supply circuit for cylinder (8) The delivered oil from A2 port on variable pump enters into P2 port on control valve (2), and comes out from A5 port through cylinder valve, and is supplied to the head side of cylinder (8) to activate the swing (left). a. At activation of the swing valve spool for both left and right swing motions, a part of appropriate volume of oil is returned to the tank through the P2 bypass circuit due to the throttle effect on the spool. Then supplying volume of oil to the cylinder is restricted to ensure the slow and stable swing motions for both leftward and rightward.

22-8

1) Supply circuit for cylinder (9) The oil delivered from A3 port of the hydraulic pump (1) enters into P3 port on control valve (2), and is led to B1 port through dozer valve. The pressurized oil passed through swivel joint (10) is supplied to the head side of dozer cylinder (9) to activate dozer down motion.

22. HYDRAULIC SYSTEM 22.3.10

22.3.11

TRAVEL / DOZER COMBINED OPERATING CIRCUIT (Refer to fig. 71-10)

TRAVEL / BOOM COMBINED OPERATING CIRCUIT (Refer to fig. 71-11)

At the combined operation of travel and dozer at the same time, the straight travelling is secured with this function.

At the combined operation of travel and boom at the same time, the straight travelling is secured with this function.

22.3.10.1

22.3.11.1

Travel (1st speed forwarding) / dozer down operating circuit

(1) Pilot circuit Both the travel and dozer are operated by the lever using the pilot oil system. The operation of each lever directly shifts the travel valve spool and dozer valve spool in the control valve (2) respectively. (2) Main circuit The oil delivered from A1 and A2 ports on the variable pump (1) enters into P1 and P2 ports on control valve (2), and each flow of left and right is led to swivel joint (10) and travel motor (4) respectively through each travel valve of left and right. The oil delivered from A3 port on the third pump enters into P3 port on control valve (2), then it is led to the dozer cylinder (9) through dozer valve and swivel joint (10). 1) The dozer is operated by the pressurized oil supplied by the third pump which has no relation with travel circuit. Then there is no variation on the supply volume of pressurized oil for both travel motors of left and right even though the dozer is operated during travelling. Thus the straight travelling is secured. (The slewing is operated in the same way as the dozer). 2) As the above mentioned, the travelling speed is not changed from the single operation for travelling securing the straight travelling.

Travel (1st speed forward) / boom up operating circuit

(1) Pilot circuit The travelling/boom up is of the pilot oil hydraulic system with lever operation. By means of pushing forward of travel operating lever and pulling this side of boom up operating lever, the pilot secondary pressure shifts the travel valve spool and/or boom spool in the control valve (2). Thus the pilot passage of the boom valve is closed to make the pressure of the oil from the Pp1 port equal to the supply pressure. Therefore the hydraulic pressure overcomes the spring force of the independent travel and flow conflux valves to shift the valve spool. (2) Main circuit The delivered oil from A1 and A2 ports on variable pump enters into P1 and P2 ports on control valve (2) respectively. The whole amount of oil from the P1 and P2 ports is supplied to the travel motor in the same way as operating the independent travel. The oil flows from the travel valve through the B7 and B6 ports and the swivel joint (10) to the right and left travel motor (4). The oil delivered from the port A3 of the hydraulic pump (1) is supplied to the boom cylinder. The oil through the P3 port of the control valve (2) flows through the dozer and slewing valves and through the shifted independent travel and flow conflux valves to the boom valve. The oil from the B8 port through the boom and block valves is supplied to the head side of the boom cylinder (5).

22-9

1) When the travel and other attachments (boom, arm, bucket, swing and additional equipment) are operated in combination, the independent travel and conflux valves are actuated. Thus the attachments are actuated only by oil supplied from the P3 port. Therefore the oil of the P1 and P2 ports is utilized only by the travel to secure stable travel in the combined operation.

22. HYDRAULIC SYSTEM 22.3.12

HYDRAULIC NIBBLER AND BREAKER OPERATING CIRCUIT (Refer to fig. 71-12)

Hydraulic pilot system allows to operate, through the slider and the pushbutton located on the right control lever, the hydraulic nibbler and the breaker. 22.3.12.1

22.3.12.3

Change the valve position of selector valve (22) to the position for breaker. (1) Pilot circuit 1) Press the button on the grip of right control lever, and secondary pilot pressure flows out from A1 port of solenoid valve (16). The pressurized oil which entered into Pa4 port of control valve (2) switches the attachment spool.

Nibbler closing circuit

(1) Pilot circuit 1) Shift for attachment spool Sliding movement of slider located on right control lever allows the pilot secondary oil to flow from A1 port of solenoid valve (16). The sliding movement of slider controls hydraulic flow rate to the attachment. Pressurized oil enters into Pa4 port of control valve (2) and shifts the attachment spool.

(2) Main circuit

(1) Main circuit 1) Supply circuit for cylinder The oil delivered from A2 port of variable displacement pump of pump assy (1) enters into P2 port of control valve (2) and, through the A4 port, supplies bottom side of nibbler cylinder (nibbler closing). 2) Return circuit Return flow coming from nibbler cylinder enters into B4 port of control valve (2) and reaches the discharge circuit through the T1 port, then reaches the hydraulic tank. 22.3.12.2

Hydraulic breaker blow circuit

Nibbler opening circuit

(1) Pilot circuit 1) Shift for attachment spool Sliding movement of slider located on right control lever allows the pilot secondary oil to flow from A2 port of solenoid valve (16). The sliding movement of slider controls hydraulic flow rate to the attachment. Pressurized oil enters into Pb4 port of control valve (2) and shifts the attachment spool. (1) Main circuit 1) Supply circuit for cylinder The oil delivered from A2 port of variable displacement pump of pump assy (1) enters into P2 port of control valve (2) and, through the B4 port, supplies rod side of nibbler cylinder (nibbler opening). 2) Return circuit Return flow coming from nibbler cylinder enters into A4 port of control valve (2) and reaches the discharge circuit through the T1 port, then reaches the hydraulic tank.

22-10

1) Supply circuit for breaker The oil delivered from A2 port of variable displacement pump of pump assy (1) flows in the P2 port of control valve (2): flow is led to the A4 port of the control valve through the attachment spool, thus feeding the breaker inlet. 2) Return line from breaker The return oil of breaker flows through the selector valve (22), and the oil returns directly to hydraulic tank (24).

23. ELECTRICAL SYSTEM TABLE OF CONTENTS 23.1 HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION ......... 23-1 23.1.1 ELECTRIC CIRCUIT DIAGRAM .............................................................. 23-1 23.1.2 HARNESS CONNECTION ....................................................................... 23-1 23.2 ELECTRICAL EQUIPMENT AND HARNESS ................................................. 23-2 23.2.1 ELECTRICAL EQUIPMENT LIST ............................................................ 23-2 23.2.2 HARNESS AND CABLE LIST .................................................................. 23-4 23.2.3 ARRANGEMENT DRAWING FOR COMPONENTS AND HARNESS ..... 23-6

23. ELECTRICAL SYSTEM

23.1

HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION

23.1.1

ELECTRIC CIRCUIT DIAGRAM

NOTE: for the electric circuit diagram, refer to Fig. 71–14 of Supporting Data that is provided at the end of this service manual. (1) In the diagram, the number, size and colour of wires are shown on the wiring line. The size of the wire is to be 0.75 sq (square mm = mm2) unless otherwise specified. Symbol B G L

Colour BLACK GREEN BLUE

Symbol O Br Lg

Colour ORANGE BROWN LIGHT GREEN

RED

GRAY

W Y

WHITE YELLOW

Sb V

SKY BLUE VIOLET

PINK

23.1.2

Example: 6 2 R 1 2 3

1. Red wire 2. Wire size 2 mm2 3. Wire no. 6

HARNESS CONNECTION

(1) Indication for connector 1

4 2

1) The figure for the connector pin arrangement is shown by putting the lock (1) (nail) to upper portion, and looking from the fitting face. 2) The numbers in the connector show the wire no. (3), and alphabetical letters show the wire color (2). 3) On the side face of connector, the connector name (4) and serial number of the connector No. (5) are indicated. 4) At the place indicated as “DOUBLE SPLICE”, two wires are connected to one place. (2) The connector is to be connected with engaging the male (M) and female (F) connectors of the same number. Example: CN-101M and CN-101F Where: M means for male, and F for female. (3)

mark means the connector with diode. The direction for diode is shown by the arrow.

(4) The AVSS wires must be used for sizes between 0.75 and 2 sq, the AVS wires for sizes between 3 and 5 mm2 and AV wires in all other cases, unless otherwise specified. (5) The wire size is 0.75 sq unless otherwise specified. (6) The treatment for the harness end is to be as follows: 1)

: after roughly applying some tape, wires are installed in a corrugated tube.

: wind the wires with two layers of tape.

: cables are not arranged for connection.

(7) The length for the above (6)-3) is to be 30 ± 10 mm, and the length includes in the total length of wire shown in the diagram.

23-1

23. ELECTRICAL SYSTEM

23.2

ELECTRICAL EQUIPMENT AND HARNESS

23.2.1

ELECTRICAL EQUIPMENT LIST

Refer to figure 71-14 Group

Diode

Electrical system Fittings

Lights

Engine

Relay

Sensors

Solenoid

Code D-1 D-2 D-3 D-4 D-12 D-13 D-14 D-18 E-1 E-2 E-3 E-4 E-6 E-7 E-8 E-10 E-11 E-12 E-13 E-14 E-15 E-16 E-17 E-18 E-23 E-26 L-1 L-2 L-5 M-1 M-2 M-3 M-4 M-6 R-1 R-2 R-3 R-6 R-7 R-8 R-9 R-14 SE-1 SE-2 SV-1 SV-2 SV-3 SV-5

Part Name DIODE DIODE DIODE DIODE DIODE DIODE DIODE DIODE FUSE BOX GENERATOR (ALTERNATOR) HORN FUSIBLE LINK (45A) GAUGE CLUSTER POWER SOCKET AIR HEATER RADIO (OPT) OVERLOAD BUZZER HEATER (OPT) BATTERY SEQUENCE BOX FUSE BOX FOR COOLER (OPT) RADIATOR ENGINE CONDENSER COMPRESSOR ANTENNA HOUR COUNTER ROOM LAMP BOOM WORKING LIGHT CAB / CANOPY WORKING LIGHT STARTER MOTOR WIPER MOTOR (CAB) WASHER MOTOR (CAB) DECELERATION MOTOR FUEL PUMP BATTERY RELAY SAFETY RELAY DECELERATION RELAY TIMER UNIT ENGINE STOP RELAY CHARGE INDICATOR RELAY CAB / CANOPY WORKING LIGHT RELAY SLEW / SWING SELECT RELAY FUEL SENSOR ENGINE THERMO SENSOR LEVER LOCK SOLENOID 2-SPEED SELECT SOLENOID ENGINE STOP SOLENOID POWER SHIFTING SOLENOID (Radiator specifications)

23-2

23. ELECTRICAL SYSTEM Group Solenoid

Switch

Code PSV-D PSV-E SW-1 SW-2 SW-3 SW-4 SW-5 SW-6 SW-7 SW-9 SW-10 SW-11 SW-15 SW-16 SW-35 SW-39 SW-40

Part Name NIBBLER OPEN PROPORTIONAL SOLENOID (RIGHT SLIDE) NIBBLER CLOSE PROPORTIONAL SOLENOID (LEFT SLIDE) (KEY) STARTER SWITCH WORKING LIGHTS SWITCH 2nd SPEED SELECTOR SWITCH WIPER WASHER SWITCH ENGINE COOLANT TEMPERATURE SWITCH ENGINE OIL PRESSURE SWITCH HORN SWITCH LEVER LOCK SWITCH HEATER SWITCH (OPT) DECELERATION SWITCH HIGH AND LOW PRESSURE SWITCH CONDENSER SPEED SHIFT SWITCH HYDRAULIC NIBBLER ACTIVATION SLIDER OVERLOAD PRESSURE SWITCH OVERLOAD SWITCH

NOTE: the part number may be changed owing to modification, use them only for reference.

23-3

23. ELECTRICAL SYSTEM 23.2.2 Code H-1 H-3 H-4 H-5 H-6 H-7 H-8 H-9 H-10 H-11

HARNESS AND CABLE LIST Name Inst Main Harness Engine wiring harness Starter cable (+) Battery ground cable (-) Engine ground cable Boom harness Key switch harness Canopy work light harness Boom work light extension harness Connection harness with cab

Observations

(OPT)

NOTE: the part number may be changed owing to modification, use them only for reference.

23-4

23. ELECTRICAL SYSTEM

This page is blank because of editing convenience.

23-5

23. ELECTRICAL SYSTEM 23.2.3

ARRANGEMENT DRAWING FOR COMPONENTS AND HARNESS

23.2.3.1

Upper frame wiring harness

Fig. 23-1 Upper frame (1/7) 1. Fairlead 2. Clamp

8. Tightening torque 46.1 ± 4.9 Nm (Tighten after checking no paint)

3. Canopy light

9. Battery ground cable

4. Tightening torque 10.7 ± 1.1 Nm (Tighten after checking no paint)

10. Connect with 2-speed select switch

5. To boom

12. Relay box assy

6. Starter cable

13. Tightening torque 23.5 ± 1.96 Nm

7. Tightening torque 12 ± 1 Nm

14. Connect with main harness

11. Connect with fuel sensor

15. Main harness and engine harness are connected by the machine center side so that a tube may not hit a bared part.

NOTE: Tightening torque of battery terminal must be 4.4 ± 0.5 Nm.

23-6

23. ELECTRICAL SYSTEM

1. Tightening torque 46.1 ± 4.9 Nm

Fig. 23-2 Upper frame (2/7) 6. Fixed so that branch may be come downward

2. Tightening torque 7.4 ÷ 9.8 Nm

7. Hole of grommet suitable in front

3. Tightening torque 9.6 ± 1 Nm

8. To boom

4. Clip fusiblelink to connector 5. Attachment of slit downward

23-7

23. ELECTRICAL SYSTEM

Fig. 23-3 Upper frame (3/7) 1. Instrument panel 2. Connect with lever lock switch 3. Slit of grommet suitable in front

23-8

23. ELECTRICAL SYSTEM

Fig. 23-4 Upper frame (4/7) A. B. 1. 2. 3. 4.

Version without heater Detail of heater Air filter Tightening torque 3.4 ÷ 4.9 Nm Engine harness Tightening torque 46.1 ± 4.9 N (Tighten after checking no paint) 5. Engine ground cable

6. 7. 8. 9. 10. 11. 12. 13.

23-9

Tightening torque 10.7 ± 1.1 Nm To canopy light WG (+) P (-) Fix the connector to the plate Install under piloting hoses Fix harness to joint of solenoid valve “T” port Fix to the upper frame

23. ELECTRICAL SYSTEM

Fig. 23-5 Upper frame (5/7) A. Detail of fusible link installation B. Detail of relay box

7. Fix so that harness is not swell to the tank air breather side

1. Engine harness

8. Fix harness so that it is not straddled by plate

2. Connection to main wiring harness

9. Fix harness into the dozer pilot cover hole

3. Breather tank

10. Fix to the seat stand ring

4. Connect main harness to cab harness 5. Tightening torque 23.5 Âą 1.96 Nm 6. Connection to heater wiring harness

23-10

23. ELECTRICAL SYSTEM

Fig. 23-5 Upper frame (6/7) A. Version with heater B. Version without heater 1. Fix harness to hose above engine hanger hole. Leave a gap of 20 mm or more. 2. Air heater 3. Fastening clamp 4. Fix to the ring 5. Fasten the air hose so it may not be hit.

23-11

23. ELECTRICAL SYSTEM

Fig. 23-5 Upper frame (7/7) A. Detail of hoses bracket position

8. Nibbler and breaker - return

B. Detail of hoses rubber protection

9. Harness

1. Connect with boom light harness

10. Nibbler and breaker - supply

2. Main harness

11. Bucket cylinder - return

3. Fix towards right inclination

12. Boom cylinder - return

4. Fix the clip to 230 mm from boom hose end

13. Arm cylinder - return

5. Fix boom light harness to boom hose

14. Arm cylinder - supply

6. Fix in 100 mm pitch

15. Boom cylinder - supply

7. Fix cylinder hoses with adhesive tape

16. Bucket cylinder - supply

23-12

23. ELECTRICAL SYSTEM 23.2.3.2

Engine harness

Fig. 23-6 Engine (1/2) 1. Tightening torque 1.7 รท 2.4 Nm 2. Connect with main harness 3. Fix with adhesive tape

23-13

23. ELECTRICAL SYSTEM

Fig. 23-7 Engine (2/2) 1. Connect with main harness 2. Tightening torque 5.9 รท 9.8 Nm 3. Fix with adhesive tape

23-14

23. ELECTRICAL SYSTEM

Fig. 23-8 Harness assy (1/2) 1. Fix to the main harness

4. Horn relay

2. Fix harness and connector PSV-F and PSV-G to bracket with a clip

5. Put white tape positioned on plate

3. Tightening torque 5.0 รท 0.5 Nm

23-15

23. ELECTRICAL SYSTEM

A. Detail of left control lever stand

Fig. 23-8 Harness assy (2/2) 5. Horn switch

B. Detail of right control lever stand

6. For main harness of horn connector

1. Connection for nibbler and breaker connector. Switch for nibbler opening/closing

7. Horn push-button

2. Fuse

9. Pass along the right-hand side of the valve

3. Put white tape positioned on gasket

10.Fix harness to the hole of plate

8. Breaker activation push-button

4. Fixed on main harness

23-16

23. ELECTRICAL SYSTEM 23.2.3.3

Relay box assy

Fig. 23-9 Relay box 1. To decelerator and air heater 2. To horn switch and safety lock lever switch 3. To cab harness 4. To engine wiring harness 5. To frame

23-17

23. ELECTRICAL SYSTEM 23.2.3.4

Fuel tank

Fig. 23-10 Fuel tank (1/2) 1. Tightening torque 11.0 ± 1 Nm

2. Tightening torque 2.94 ± 0.2 Nm

23-18

Fuel tank

23. ELECTRICAL SYSTEM

Fig. 23-10 Fuel tank (2/2) 1. Fuel filter

A. Return

2. Water separator

B. Inlet

23-19

23. ELECTRICAL SYSTEM 23.2.3.5

Work lights

(1) Boom work light

Fig. 23-11 Boom work light 1. Connect with main harness

5. Fix harness with white tape to one of bracket hole

2. To working light

6. Fix with clip the terminal and the harness

3. Fix harness along hydraulic tubes

7. Fix eyebolt to the bolt

4. Fix harness to plate using a hole

23-20

23. ELECTRICAL SYSTEM (2) Canopy work light

1. Tightening torque 7.0 ÷ 8.0 Nm 2. Tightening torque 16.7 ÷ 21.6 Nm

Fig. 23-12 Canopy work light 3. Work light (install light 40° lower from ground level) 4. To connect harness of upp frame side.

23-21

23. ELECTRICAL SYSTEM (3) Cab work light

Fig. 23-13 Cab work light 1. Tightening torque 7 ÷ 8 Nm 2. Tightening torque 16.7 ÷ 21.6 Nm 3. Work light (install light 40° lower from ground level) 4. Connect to the cable terminal of the cab wiring harness assy

23-22

23. ELECTRICAL SYSTEM 23.2.3.6

Cab

Fig. 23-14 Cabin harness 1. Connect to cabin side harness

6. Connect main harness with wiper harness

2. Clip cab side harness

7. Label attachment

3. Tightening torque 23,5 Âą 2 Nm. Fix ground terminal 8. Clip 4. Connect to the cabin work light harness

9. Washer motor

5. Connect to the installation main harness

23-23

23. ELECTRICAL SYSTEM

[NOTES]

23-24

24. SYSTEMS COMPONENTS TABLE OF CONTENTS 24.1 HYDRAULIC COMPONENTS ......................................................................... 24-1 24.1.1 HYDRAULIC PUMP .................................................................................. 24-1 24.1.2 ATTACHMENT CONTROL VALVE......................................................... 24-11 24.1.3 TRAVEL CONTROL VALVE ................................................................... 24-14 24.1.4 CONTROL VALVE .................................................................................. 24-19 24.1.5 SWING MOTOR...................................................................................... 24-36 24.1.6 TRANSLATION MOTOR......................................................................... 24-43 24.1.7 CONTROL VALVE .................................................................................. 24-54 24.1.8 CYLINDERS............................................................................................ 24-56 24.2 ELECTRICAL EQUIPMENT .......................................................................... 24-64 24.2.1 ELECTRICAL EQUIPMENT LIST ........................................................... 24-64 24.2.2 ELECTRICAL EQUIPMENT SPECIFICATIONS..................................... 24-66

24. SYSTEMS COMPONENTS

24.1

HYDRAULIC COMPONENTS

24.1.1

HYDRAULIC PUMP

24.1.1.1 TECHNICAL FEATURES

No. S1 A1, A2 A3 A4 R1

Ports name

Dimensions SAE 1 1/2 PF 1/2 PF 1/2 PF 3/8 M10 x 1.0

Suction port Delivery port Delivery port Pilot delivery port Air bleed port (with breather valve) Fig. 24-1 Technical features Model (type)

AP2D25LV1RS7 Piston pump P1 + P2

Pump Working pressure

MPa

Gear pump P3

Trochoid pump P4

23.0

3.5

Displacement

cc/rev

23.8 × 2

14.1

5.1

Delivery flow

l/min

57.1 × 2

33.8

12.2

Control system Rating speed Weight

Total power shift control by tilting angle (power shift) rpm

2400

35.0

24-1

24. SYSTEMS COMPONENTS 24.1.1.2 CONSTRUCTION • FUNCTION

No.

NAME

No.

NAME

Shaft assy

Piston assy

Swash plate assy

Gear pump assy

Rotary group

Housing assy

Cover assy

Trochoid pump assy

Spring assy Fig. 24-2

1. Piston pump • This pump is a variable displacement double piston pump which delivers two equal flows with one cylinder block, and has only one inlet port, but the flow is separated into two flows by the control plate on the cover and is led to two delivery ports provided on the cover. • The hydraulic pressure produced by delivery oil resists against the spring force and tilts the plate. Delivery changes, because the piston stroke changes according to the plate’s tilting angle. • The 3rd pump or pilot pump is installed on the same shaft with a coupling.

24-2

24. SYSTEMS COMPONENTS 2. Operation • Pump operation Displacement q (cm3) q=ΠXd2/4XtanαXDXZ/2X10-3 s (Stroke) (Number of piston)

1 12

2 3

4 5

13 11

9 10

8 7 6

1. 2. 3. 4. 5. 6. 7.

Piston Bottom dead point Cylinder block Control plate Suction port P2 side output P1 side output

8. 9. 10. 11. 12. 13.

Delivery port Suction stroke Delivery stroke Top dead point Plate (sliding surface) Plate bearing

a. The cylinder block is fitted on the spline and rotates with the drive shaft. b. The piston fitted in the cylinder block follows the movements of the sliding surface of the plate. c. The piston moves to increase the capacity from the bottom dead point to the top dead point, the pressure oil flows from the inlet port into cylinder block through the control plate. (Suction stroke 9) d. But as the piston moves to decrease the capacity from the top dead point to the bottom dead point, the pressure oil is sent out to the delivery port. (Delivery stroke 10) e. By changing the tilting angle of the plate (sliding surface), delivery varies. f. The oil sucked from the inside port of the cylinder block is delivered from the delivery port inside of the control valve. g. The oil sucked from the outside port of the cylinder block is delivered from the delivery port outside of the control plate.

24-3

24. SYSTEMS COMPONENTS • Control

15 S

13. 14. 15. 16. 17.

Spring A Plate Piston Piston for P3 shift Spring B

∑PI.Total pressure ∑P

Q. Flow rate S. Shift control line

a. The delivery pressure P1 and P2 is directed to the piston which slides on the plate and acts on it. b. The spring is provided to act against the delivery pressure. c. When the oil pressure, through the piston acting on the plate, exceeds the adjustment load of the spring, the plate is fixed to the maximum tilting position. d. When the oil pressure, through the piston acting on the plate, exceeds the adjustment load of the spring, the plate is tilted and kept tilted in a position where the oil pressure is balanced by the spring force. (Region A in above figure) e. When the oil pressure acting on the piston rises further to reduce the tilting angle, the spring B which has been inactive up to now becomes active. f. To overcome the spring force of two springs, the oil pressure must be higher and the shifting line becomes more steep. (Regions A + B in the middle of the figure above) g. When the P3 oil pressure acts on the shift piston, the control shifting line is shifted.

24-4

24. SYSTEMS COMPONENTS • Adjusting procedure of set torque 18

24 22

23 22

17. 18. 19. 20. 21.

Spring seat Cover Set screw Spring guide Tighten

22. Loosen 23. Hexagon nut 24. Starting pressure of tilting ∑P. Total pressure Q. Flow rate

a. Setting procedure 1. Loosen the hexagon nut 2. Set the power line by tightening or loosening the adjusting screw.

24-5

24. SYSTEMS COMPONENTS 24.1.1.3 INNER CONSTRUCTION Refer to Fig. 24-2 regarding the whole pump Drive shaft

No.

2 8 10 9 6

NAME

Q.TY

No.

NAME

Q.TY

Shaft

Seal ring

Seal case

O-ring

Bearing

Snap ring

Snap ring (for shaft)

Key

Snap ring (for shaft)

Swash plate (Plate)

1 2 5 6 3 4

No.

NAME

Q.TY

No.

NAME

Q.TY

Plate

Bearing

Plate

Edge bolt

Spacer

O-ring

24-6

24. SYSTEMS COMPONENTS Rotary group

No.

NAME

Q.TY

No.

NAME

Q.TY

Piston

Spring

Cylinder block

Parallel pin

Cup

Spring seat

Plate

Snap ring (for hole)

Guiding

Control spring

No.

NAME

34, 44, 54, 64 2 7 9 4

Q.TY

No.

NAME

Q.TY

Spring seat

Edge bolt

Spring seat

Nut

Cover

Spring

Set screw

Shim

Spring

Shim

Spring

Shim

O-ring

Shim

24-7

24. SYSTEMS COMPONENTS Cover

3 10

2 Z Z 7

X-X

6 7

9 7 Z-Z

16 Y

9 11

Y-Y

No.

NAME

Q.TY

No.

NAME

Q.TY

Cover

Orifice

Control plate

Bearing

Parallel pin

Cap

Edge bolt

O-ring

Plug M8

O-ring

Plug M5

Plug M6

24-8

24. SYSTEMS COMPONENTS Gear pump

No.

NAME

Q.TY

No.

NAME

Q.TY

No.

NAME

Q.TY

Housing

Plate

16 Square ring

Cover

Guiding

17 Square ring

Gear

Coupling

18 O-ring

Gear

O-ring

19 Screw M12 x 25

Side plate assy

O-ring

24-9

24. SYSTEMS COMPONENTS Housing

5 X

4 No.

NAME

9 Q.TY

No.

NAME

Q.TY

No.

NAME

Q.TY

Cylinder

Parallel pin

Disk spring

Piston

Spring seat

O-ring

Piston

Edge bolt

O-ring

Trochoid pump

No.

NAME

Q.TY

No.

NAME

Q.TY

Gear

Edge bolt

Housing

Side plate (B)

Side plate (A)

Spring pin

O-ring

Plate

Spring pin

24-10

24. SYSTEMS COMPONENTS 24.1.2

ATTACHMENT CONTROL VALVE

24.1.2.1 TECHNICAL FEATURES

The adjust nut (opposing flats: 22): Fix adjust nut by means of spanner (opposing flats: 22) when the lever is installed. Then tighten the mating lock nut to

41 ± 0.3 Nm (30 ± 2.2 lbf•ft) OA.Operation angle (degree) OT. Operation torque (Nm) PR.Push rod stroke (mm) SP. Secondary pressure (MPa) T. Tightening torque: 6-PF1/4 T= 29.4 ± 2.0 Nm (21.7 ± 1.47 lbf•ft) Maximum primary pressure

6.9 MPa (1000 psi)

Delivery

15 l/min (3.90 gal/min)

Weight

1.6 kg (4 lb)

24-11

24. SYSTEMS COMPONENTS 24.1.2.2 CONSTRUCTION COMPONENTS 1

2 2

2 (4)

1 (3)

Fig. 24-3 Pilot valve-sectional view 3. Secondary pressure adjusting shims 1. Apply Loctite #277 (part of slant line) 2. Apply grease on top No.

NAME

Q.TY

No.

NAME

Q.TY

No.

NAME

Q.TY

101 Housing

213

Seal

241–1 Spring

151 Plate

214

O-ring

241–2 Spring

201 Spool

216–1 Spring seat

301

Joint M14 (1)

211 Cap

216–2 Spring seat

302

Disk

212–1 Push rod (2)

217

Washer 2 (3)

312

Adjusting nut M14

212–2 Push rod (2)

221

Spring

501

Boot

RIGHT PILOT VALVE Port no.

OPERATION

BUCKET DIGGING

LOWER BOOM

BUCKET DUMP

RAISED BOOM 1

LEFT PILOT VALVE Port no.

SLEWING LEFT

FREE ARM

SLEWING RIGHT

OPERATING ARM

4 F25782

OPERATION

3 2

24-12

24. SYSTEMS COMPONENTS 24.1.2.3 OPERATION â&#x20AC;˘ Lever in neutral position (See Fig. 24-4) In this case, the force of the secondary pressure setting spring (241) that determines the output pressure of the pilot valve is not transmitted to the spool (201). Accordingly, the spool (201) is pushed up by the return spring (221) and spring seat (216) permitting the output port 2, 4 to connect with the tank port T. This makes the output pressure equal to the tank pressure.

Fig. 24-4 Lever in neutral position â&#x20AC;˘ When the Lever is tilted (See Fig. 24-5) When the lever is tilted, the push rod (212) strokes. The spool (201) and 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 flow out to the port 2, 4, to produce a pressure.

Fig. 24-5 When Lever is tilted â&#x20AC;˘ The lever being held (See Fig. 24-6) When the lever is tilted till the pressure of the port 2, 4 rises to an oil pressure corresponding to the set spring force, the hydraulic pressure is balanced with the spring (241) force. And when the pressure of the port 2, 4 rises above a set pressure, the port P are closed and the port T are opened. When the pressure of the port 2, 4 falls below a set pressure, the port P are caused to open and the port T are caused to close, thus holding the second pressure constant.

Fig. 24-6 Lever being held

24-13

24. SYSTEMS COMPONENTS 24.1.3

TRAVEL CONTROL VALVE

24.1.3.1 TECHNICAL FEATURES 472 501

1 1

471

413

214 210 202 271 201 212 224

402

414

203

213

336

102

218

225

311

211 252

324 335

217 313 251 261 301 101

1. 4-M8 x P1.25 Tightening torque = 16.7 ± 1.5 Nm 2. 2-PF1/4 Tightening torque = 29.4 ± 2.0 Nm

3. 4-PF1/4 Tightening torque = 29.4 ± 2.0 Nm

Model (type)

PVD6P4001

Maximum primary pressure

6.9 MPa

Delivery

10 l/min

Weight

3.9 kg

3. Performance Characteristics • Required operating torque (damper) 12.9 ± 1.9 Nm. Push rod speed 0.0275 m/s (the actual required torque is found by adding the operating torque of the damper in the valve operating torque in the left operating lines)

MPa

SP. Secondary pressure (MPa) OT. Operation torque (Nm) PR.Push rod stroke (mm) OA.Operation angle (degree)

SR SP

PR OA

24-14

24. SYSTEMS COMPONENTS 24.1.3.2 CONSTRUCTION COMPONENTS 472 501

1 1

471

413

214 210 202 271 201 212 224

402

414

203

213

336

102

218

225

311

211 252

324 335

217 313 251 261 301 101

Fig. 24-7 Pilot valve-sectional view 1. Apply grease Torque Nm

29.4

Q.TY

Torque Nm

101 Housing

6.9

102 Casing (damper)

201 Cover

202 Plug (1)

No.

NAME

No.

NAME

Q.TY

252 Cap

261 O-ring

271 Edge bolt

301 Spool

203 Grease cup

311 Spring seat

210 Seal

313 Washer

211 O-ring

324 Spring

212 O-ring

335 Spring

213 O-ring

336 Spring

214 Push rod (1)

413 Cam shaft

217 Shim

414 Bushing (1)

218 Spring seat

420 Cam

224 Piston

471 Steel ball

225 Steel ball

472 Set screw

251 Cap

501 Boots (bellows)

8.8

24-15

6.9

24. SYSTEMS COMPONENTS 24.1.3.3 OPERATION 1. Reducing valve â&#x20AC;˘ When the lever is at neutral position, (See Fig. 24-8) the spool is pushed up by the return spring (335) through spring seat (311), and is positioned at the neutral position in the right figure. Therefore, the pressure at delivery ports 1 and 2 is equivalent to that of port T because the delivery port is connected to only port T following the switched spool condition. 311

335

301

2,4

1,3

Fig. 24-8 â&#x20AC;˘ In case where the lever is tilted, (See Fig. 24-9) By rotating cam (420) in clockwise, push rod (214) on the port 1 side is pushed down, and the spool moves down by way of spring seat (311), spring (324) for setting the secondary pressure, shim (217) and washer (313) and consequently the port P is connected to the port 1 and the supplied oil from the pilot pump flows into port 1 and generates pressure. When the pressure at port 1 rises to the pressure equivalent to the spring pressure for the secondary pressure setting set by tilting the control section, the hydraulic pressure applied to the spool balances the spring force, and maintains port 1 at a constant delivery pressure. The spool on the port 2 side is held at neutral position, and the return oil from the control valve is discharged through port T.

420 214

311 324 217 313

2 (4) A 24-9 B Fig.

A. B.

24-16

Neutral position Full stroke

1 (3)

24. SYSTEMS COMPONENTS 2. Dumping mechanism â&#x20AC;˘ In case of neutral position, push rod (214) is pushed up by dumping spring (336) through piston (224), and holds at the position shown in Fig. 24-7. â&#x20AC;˘ Where the control section is inclined from the neutral position, by rotating the cam clockwise, the push rod on the port 1 side is pushed down, and the piston also moves down. Then, the oil in the dumping piston chamber is discharged through the orifice, and the simultaneously generated pressure produces dumping force. On the other hand, the push rod on the port 2 side moves up by the dumping spring through the piston. Then, oil is sucked from the tank into the dumping piston chamber through three ball check valves. The oil outside of the piston chamber flows out through the passage leading to port T on the casing top end.

3 2

4 A

2 (4)

1 (3)

Fig. 24-10 Operation when the lever is stroked from the neutral position 1. 2. 3. 4. 5.

Cam Orifice Push rod Piston Steel ball

When stroking from the neutral position towards the mark â&#x2021;&#x2019;, the oil in the piston chamber on the right (left) side is discharged through the orifice, and the simultaneously generated pressure produces damping force.

24-17

24. SYSTEMS COMPONENTS • Where the control section is inclined in the opposite direction from the full tilting After tilting the cam clockwise fully, if it is rotated counterclockwise, the push rod on the port 2 side is pushed down and the piston moves down. Then, the same as above, the oil in the damping piston chamber is discharged through restriction of piston, and the simultaneously generated pressure produces damping force. On the other hand, the push rod on the port 1 side is moved up by the force of the return spring and damping spring. Similarly oil is sucked from the tank into the damping piston chamber through three ball check valves. And the oil in the piston chamber flows out through the passage leading from the casing top end to the tank port. That is, either tilting operation from the neutral position to the full tilting position or the full tilting position to the neutral position is designed to produce the damping force. 7

1 3

C E

9 F

2 (4)

1 (3)

Fig. 24-11 Operation when the lever is stroked or operated in reverse 1. 3. 4. 6. 7. 8. 9. B.

Cam Push rod Piston Damping spring Neutral position Full stroke Return spring The oil outside of the piston flows through the passage leading to port T on the casing top end. (In operation in ⇒ direction) C. The oil in the piston chamber is discharged through the restriction, and the simultaneously generated pressure produces the damping force. (In operation in ⇒ direction)

D. When tilting in reverse direction from the neutral position, the push rod is pushed up by the force of the damping spring. (In operation in ⇒ direction) E. Oil in T lines is sucked in the damper chamber through three ball check valves. (In operation in ⇒ direction) F. When shifting the lever in revese from ⇒ direction to ( ) condition, the piston on the left side immediately performs the roles of the damper piston. The damping force is produced on both sides constantly.

24-18

24. SYSTEMS COMPONENTS 24.1.4

CONTROL VALVE

24.1.4.1 GENERAL VIEW B G

Pb1

Pb2

Pb3

Pb4

H 3

Pb8 Pb6

Pb7

Pb9 Pb8’

Pa1

Pa2

Pa4

Pa6

F 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Pa9

Pa7 Pa8

Pa3

Dozer Slewing Supply and independent travel Digging Service Swing Travel right Feed Travel left Boom

C 12 Bucket 13. Manual operation A. Pilot port 16-PF1/4 (Pa1÷Pa4 - Pa6 - Pa9 Pb1÷Pb4 - Pb6 - Pb9) B. Drain port Dr1 PF1/4 C. Tank port T2 PF1/2 D. Pump port P1, P3-P2 3-PF1/2 F. Actuator port 18-PF3/8 (A1÷A9 / B1÷B9) G. Tank port T1 PF1/2 H. Pp1 PF1/4

24.1.4.2 TECHNICAL FEATURES Model (type) Valve operation

BCV65

Manual

Swing

Pilot

Travel left, travel right, boom, arm, bucket slewing, dozer, attachment Straight travel and conflux

Delivery

P1, P2 – 57.1 L/min, P3 → 33.8 L/min

Setting pressure at main pressure relief valve P1, P2, P3

P1, P2: 23.0 0 MPa at 57.1 L/min (MR1, MR2)

Setting pressure at over load relief valve

+0.5

P3:23.0

+0.5 0

MPa at 33.8 L/min (MR3)

B1, A3, B3, B10 port (OR6, OR4, OR5, OR1) 25.5 B8, B9 port (OR3, OR2)

24-19

+0.5 27.5 0

+0.5 0

MPa at 5 L/min

24. SYSTEMS COMPONENTS 24.1.4.3 CONSTRUCTION COMPONENTS 15

19 18

20 12

No.

NAME

Q.TY

No.

NAME

Q.TY

No.

NAME

Q.TY

Dozer section

P1, P2 inlet straight

15 Pressure relief valve

Slewing section

Travel (left) section

16 Pressure relief valve

P3 inlet, independent travel and conflux section

10 Boom section

17 Anticavitation valve

Arm section

11 Boom lock section

18 Edge bolt

Attachment section

12 Bucket section

19 Edge bolt

Main pressure relief 13 valve P1, P2

20 Nut

Swing section

supply 7

Travel (right) section

14 Main relief valve P3

24-20

24. SYSTEMS COMPONENTS The control valve is roughly classified into the following four sections. • Manual operation section: swing • Pilot operation section: travel right and left, boom, arm, bucket, slewing, independent travel and conflux, dozer blade, service (nibbler and breaker) • Accessory section: P1 and P2 inlets, and P3 inlet (common with independent travel and conflux) • Accessory section (valve): P1, P2, P3 main relief, overload relief, anti cavitation, boom lock * For respective operation section, only typical example is described. - Manual swing operation (No. 6) No.

Name

Q.TY

Body

Spool

O-ring

Dust wiper

Oil seat retainer

Spring seat

Spring

Spool end

O-ring

Dust wiper

Oil seat retainer

Screw M16 x 12

Screw M16 x 22

Cover

Load check valve

Spring (for check valve)

Plug (for check valve)

O-ring

Cap

O-ring

Anticavitation valve

12 11

9 10

14 13

2g 6

24-21

2b 2c 2d 2e 2f

24. SYSTEMS COMPONENTS - Pilot operation: slew (no. 2) No.

Name

Q.TY

Body

Spool

Spring seat

Spring

Spool end

Spring seat

O-ring

Pilot cover “A”

Pilot cover “B”

Screw M16 x 45

Load check valve

Spring (for check valve)

Cap

O-ring

Cap

O-ring

10 9

7 8

12 11

4 6

- Main relief valve (P1, P2, P3) and overpressure relief valve No.

Name

Q.TY

Socket

Pressure regulating valve

Piston

Body

Poppet

Set screw

Lock nut M14

Spring (adjust valve)

Spring (pressure regulating)

O-ring

Back-up ring

Seat (adjust section)

O-ring

Back-up ring

24-22

24. SYSTEMS COMPONENTS - Anticavitation valve No.

Name

Q.TY

Anticavitation valve

Body

Cap

Spring

Back-up ring

O-ring

- Main relief valve (P3) No.

Name

Q.TY

Socket

Pressure regulating valve

Piston

Cap

Body

Poppet

Set screw

Lock nut M14

Spring (adjust valve)

Spring (pressure regulating)

O-ring

Back-up ring

O-ring

24-23

24. SYSTEMS COMPONENTS - Pressure relief valve No.

Name

Q.TY

Socket

Pressure regulating valve

Piston

Cap

Body

Poppet

Set screw

Lock nut M14

Spring (adjust valve)

Spring (pressure regulating)

O-ring

Back-up ring

Spring guide

Dozer spool Swinging spool Travel independent and conflux spool Arm spool Service spool Boom swing spool Travel right spool Travel independent and conflux spool Travel left spool Boom spool Bucket spool P1 (MRV) relief valve P3 (MRV3) relief valve B1 Over load relief valve A3 Over load relief valve B3 Over load relief valve

24.1.4.4 HYDRAULIC DIAGRAM 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.

24-24

A8 Over load relief valve B8 Over load relief valve B9 Over load relief valve Boom lock valve Anticavitation valve Over load relief valve P1 by-pass passage P2 by-pass passage P3 by-pass passage P1 parallel passage P2 parallel passage P3 parallel passage Pp1 Pilot passage Tank passage

24. SYSTEMS COMPONENTS

24-25

24. SYSTEMS COMPONENTS 24.1.4.5 FUNCTIONAL EXPLANATION 1. Neutral position P1: The oil delivered from the hydraulic pump flows from the P1 port of the control valve (hereafter called a C/V) into the left travel spool section through the passage of the supply section. At the spool neutral position, the entered oil passes through the by-pass of the spool leading from the left travel to the boom because the spool does not cut off the by-pass and flows out to the tank circuit through the by-pass of the spool for the bucket and the by-pass leading to the tank. P2: The oil delivered from the hydraulic pump flows from the P2 port of C/V into the right travel spool section through the passage of the supply section. At the spool neutral position, the entered oil passes through the by-pass of the spools for the right travel, boom swing and service, and flows out to the tank circuit through the by-pass circuit leading from the by-pass of the spool for service. P3: The delivery from the hydraulic pump flows from the (C/V) P3 port into the parallel circuit of swing and dozer operation. Since the spool does not shut off the by-pass passage in the neutral spool condition, the oil having flown into the parallel passage flows out to the tank passage through the by-pass passages of the spools for the dozer and slewing and through the by-pass passage of the P3 supply section. WARNING As the flow from the pump is fed into each line (P1, P2, P3), the switching sections of respective line shown below are in operable condition. Therefore, donâ&#x20AC;&#x2122;t operate them except when working. P1 line: left travel, boom, bucket P2 line: right travel, boom swing, service and arm P3 line: dozer, slewing [service and arm] Pp1: The delivery oil from the gear pump flows from the (C/V) Pp1 port into the pilot circuit through the orifice provided on P3 supply section. (Two systems for shifting independent travel and for shifting arm and service flow conflux) In the neutral spool condition, the oil of the independent travel shifting side flows out to the tank passage through the passages provided to the right and left travel spool and the swing spool. Therefore the pilot circuit pressure becomes equal to the tank pressure, the received pressure of the independent travel valve is equal to the tank pressure, and consequently the independent travel spool does not switch. Moreover, the oil of the flow conflux shifting side flows out to the tank passage through the passage provided to the service spool. Since the pilot passage pressure equals to the tank pressure and the receiving pressure of the flow conflux piston equals to the tank pressure, the flow conflux spool is not shifted. WARNING When the engine is stopped (when each hydraulic pump is stopped), the actuator does not function even when being loaded by the self weight, because the pilot pressure does not act on the pilot control spool (except for the condition where the accumulator, etc. is attached and the pressure remains due to the pipe volume). On the spool of boom swing which directly actuates the spool, the port on the loaded side is led to the tank circuit with the operating direction making it unable to hold the load, consequently the actuator may be actuated causing danger. Therefore, even if the engine is stopped, when there are people around the machine or it may be in contact with implements, donâ&#x20AC;&#x2122;t use the control lever.

24-26

24. SYSTEMS COMPONENTS

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 12. B. C.

Fig. 24-12 Operation at neutral position D. Tank passage Dozer E. P3 side by-pass passage Slewing F. Independent travel - flow conflux spool Supply and independent travel G. From P3 port Digging H. P2 side by-pass passage Service I. From P2 port Swing L. Pilot passage for independent travel Travel (right) M. Orifice Feed N. Piston for conflux Travel (left) O. Pilot passage for conflux Boom P1. From P1 port Bucket Q. P1 side by-pass passage P3 side parallel passage From by-pass passage of tank to tank passage

24-27

24. SYSTEMS COMPONENTS 2. Pilot operating section â&#x20AC;˘ Boom lifting operation While lifting, the pressure of the secondary pilot circuit enters through port Pa8 and moves the spool for the operation of the boom. And with the movement of the spool, as the by-pass circuit is cut at the boom switching section, the oil received through the P1 port flows from the parallel circuit through the check valve installed on the upper part of the spool by-pass circuit for the travel operation into the parallel circuit on the boom switching section. With the movement of the spool, as the circuit from the passage leading to the boom lock section to the bridge passage is opened, the oil entered in the parallel circuit passes through the load check valve on the boom switching section and flows into the boom lock section through the bridge passage. The oil entered in boom section opens the lock valve and is fed into the boom cylinder head side. On the other hand, the return oil from the boom cylinder rod side flows into the B8 port, and with the movement of the spool the oil flows out into the tank circuit that is connected by the notch of the spool. Consequently, the boom cylinder extends and raises the boom. The oil from the Pp1 port passes through the orifice provided on the P3 supply section and flows into the pilot circuit. The oil entered into the pilot circuit flows from the travel switching section to the tank circuit, and the pilot circuit pressure becomes equal to the tank pressure, consequently the independent travel spool is not switched. 14

R T

11 11 P 9 10

Fig. 24-13 Operation at boom raising 9. 10. 11. 14. P. R.

Travel (left) Boom P1, P2 supplied port Boom cylinder From P1 pump Parallel passage

S. T. U. W.

24-28

Pilot passage Bridge passage By-pass passage The oil entered in through the Pp1 port flows out from the travel switching section into the tank circuit.

24. SYSTEMS COMPONENTS 3. Manual operation section â&#x20AC;˘ Left swing operation With the left swing operation, the swing spool moves to the pushâ&#x20AC;&#x201C;in direction. With the movement of the spool, as the by-pass circuit is cut off at the swing switching section, (a portion of the oil flows out to the by-pass (tank) circuit through the notch provided on the swing spool.), the oil entered through the P2 port flows into the parallel circuit through the check valve provided on the upper part of the travel spool by-pass circuit. With the movement of the spool, as the circuit from the A5 port to the bridge passage is open, the oil entered in the parallel circuit passes though the load check valve, flows into the A5 port through the bridge passage, and is fed into the swing cylinder head side. On the other hand, the return oil from the swing cylinder rod side flows into through the B5 port, and with the movement of the spool the return oil flows out to the tank circuit that is connected by the notch of the spool. Consequently, the swing cylinder extends, and the boom swings leftward. The oil from the Pp1 port passes through the orifice provided on the P3 supply section and flows into the pilot circuit. As the oil entered in the pilot circuit flows out from the travel switching section into the tank circuit, the pilot circuit pressure becomes equal to the tank pressure, and consequently the independent travel spool is not switched. 15

T R S

7 I

Fig. 24-14 Operation of swing 6. 7. 15. I. R. S.

Swing Travel (right) Swing cylinder From P2 pump Parallel passage Pilot passage

T. Bridge passage U. By-pass passage W. The oil entered in through the Pp1 port flows out from the travel switching section into the tank circuit. Z. Some oil flows into the by-pass passage.

24-29

24. SYSTEMS COMPONENTS 4. Digging capacity conflux function This valve actuates the arm and additional attachments by using the combined flows of P2 and P3. The conflux circuit is used only for actuating the arm and additional equipment, as explained below. The operation for the service shifts the spool for the arm by the secondary pressure from the remote control valve. Since the spool shifting results in shut-off of the pilot and tank passages for flow conflux, the pressure in the flow conflux pilot passage equals to the Pp1 port supply pressure, which acts on the flow conflux piston to move it to the position where the piston collar contacts with the inner shoulder the valve. At the same time, the flow conflux piston moves the flow conflux and independent travel spools. Once the spool is shifted, the pressurized oil supplied from P3 flows into the second by-pass passage of P2 side through the parallel and by-pass passages of the slewing and dozer shifting and through the check valve provided to the P3 supply section, which is connected to the by-pass passage of the P2 side at the upstream (between boom swing and service) of the service shifting section, and also connected to the by-pass passage of the P2 side through the check valve at the P3 supply section. Therefore the flow of oil supplied from P3 joins in the parallel passage of the P2 side in proportion to an operating amount of the arm or the service. (The drawing below shows service operation).

Fig. 24-15 Actuation of flow conflux circuit in service operation `

3. 4. 5. G. H. I. N.

Supply and independent travel Digging Service From P3 port P2 side by-pass passage From P2 pump Piston for conflux

K. The parallel passage of P2 side through the check valve P. From P1 pump R. Parallel passage S. Pilot passage V. From P3 pump W. By-pass passage W1.Bridge passage

24-30

24. SYSTEMS COMPONENTS 5. Independent travel function When both right and left travels is shifted, and one of boom, bucket and boom swing is shifted, the oil flows from the Pp1 port through the throttle into the pilot passage, in which pressure equals to the Pp1 port supply pressure because the pilot passage is shut off from the tank passage. Then the Pp1 port supply pressure acts on the travel straight spool, and the spool moves until it contacts with the pilot cap overcoming the spring force. Once the spool is shifted, the pressurized oil supplied from P3 passes through the parallel and by-pass passages of the slewing and dozer shifting sections, and passes through the spool of the P3 supply section and the land of main unit to flow into the second parallel passage of the P1 side and the parallel passage of the P2 side. In addition, if the pressure of pilot passage is equal to the pressure of Pp1 port, the spools in the P1/P2 supply section are shifted too. Thereby P2 parallel passage is connected with P1 parallel passage. After these shifting, the pressurized oil supplied to P1 and P2 actuates the right and left travel, and the pressurized oil supplied to P3 actuates the other attachments. Therefore even if the travel and other attachment are simultaneously operated, the travel is correctly performed without deviating. The arm or service operated in the flow conflux position without relating to the independent travel function can be simultaneously performed with the travel in the same operability as the independent travel function. K

2 G

G P2 K

P3 P1, P2 P1 Q

Fig. 24-16 Independent travel actuation 1. 2. 3. 4. G. K. Q.

Dozer Slewing Supply and independent travel Digging From P3 pump The parallel passage of P2 side To the parallel passage of P1 side

S. Pilot passage P1. Pp1 pressure P2. The oil from pump P3 is cut off by the operation of travel and attachment P3. Travel straight spool and P1/P2 supply spool are shifted simultaneously, and P1 parallel passage connects with P2 parallel passage.

24-31

24. SYSTEMS COMPONENTS 6. Function of lock valve â&#x20AC;˘ Piston holding When the boom spool is at neutral position, the pilot piston chamber (a) is connected to the drain passage through the pilot port (Pb8â&#x20AC;&#x2122;) for releasing lock valve. And the piston chamber (b) is also connected to the drain passage through the drain port (Dr1). Therefore the piston (C) is held at the position shown in the figure. And the hydraulic pressure to hold the boom cylinder is applied to the lock valve chamber as shown in the figure, pressing the needle valve and lock valve to their seats respectively. Then it prevents leakage on the head side of boom cylinder, and also prevents the arm cylinder from its movement due to leakage.

16 17

Fig. 24-17 Function of lock valve (piston holding) 14. Boom cylinder 16. Lock valve chamber 17. Needle valve seat

18. Needle valve 19. Lock valve 20. Body seat

24-32

24. SYSTEMS COMPONENTS • Release When the pilot pressure is applied to the pilot port (Pb8’) for releasing lock valve, the piston (C) is moved to the right side opening the needle valve through piston (A). At that time, the return oil from boom cylinder passes through the throttle on lock valve, then lock valve chamber • → pilot piston chamber → drilled hole in turn, and flows into the tank path through the throttle hole (drilled hole) on boom spool pushing up the steel ball. The opening of the needle valve results in the pressure drop in the lock valve chamber. The return oil from the boom cylinder opens the lock valve, and flows into the tank passage through the notch (groove) of the boom spool and the throttle (drilled hole).

Fig. 24-18 Function of lock valve (release) 14. 16. 17. 18.

Boom cylinder Lock valve chamber Needle valve seat Needle valve

19. 20. 22. 23.

24-33

Lock valve Body seat Pilot piston chamber Drilled hole

16 17

23 A

24. SYSTEMS COMPONENTS 7. Operation of relief valve • Operation at relief condition - The pressure oil passes through the inside of the piston placed in the pressure regulating valve (main valve) and fills in “A” chamber inside of the piston through the orifice “B” to securely seat the pressure regulating valve and the socket, and the socket and the body seat. 25

"B"

27 28

"A"

Fig. 24-19 24. 25. 26. 27.

28. Shutter 29. Pressure regulating valve 30. Adjusting valve

Tank passage Piston Adjust valve spring Body seat

- When the pressure of the oil in the P port reaches to the set pressure of the spring, the pressure oil acts on the adjust valve through the piston and opens the adjust valve. Then, the pressure oil passes through the inside of the piston, orifice B, A chamber, ring orifice, and drilled hole D in order, and flows out to the tank circuit around the socket.

"D"

31. Ring orifice “C” - The pressure in “A” chamber drops because the adjust valve is open, consequently the pressure oil in the P port flows out to the tank circuit through the drilled hole “E”.

"E" - When the pressure on the P port drops lower than the spring set pressure of the adjust valve, the adjust valve is pushed against the seat by the adjust valve spring force of the adjust valve and the pressure in “A” chamber is equal to the pressure in the P port, consequently the adjust valve is also pushed against the seat and returns to the former condition (Fig. 24-19).

24-34

24. SYSTEMS COMPONENTS â&#x20AC;˘ Suction operation When the negative pressure is generated in the P port, the oil is supplied through the tank circuit. When the pressure of the tank circuit from the P port rises, the socket is pushed up. Consequently, the space between the body seat and the socket opens, and the oil flows from the tank passage into the P port and the space fills with the oil.

â&#x20AC;˘ Operation of anti-cavitation valve When the negative pressure is generated in the P port, the oil is supplied through the tank circuit. When the pressure from the (P) port rises, the valve is pushed up. Consequently, the space between the body seat and the socket opens, and the oil flows from the tank passage into the P port and the space fills with the oil. 24

27 28

24. Tank passage 27. Body seat 28. Shutter

24-35

24. SYSTEMS COMPONENTS 24.1.5

SWING MOTOR

24.1.5.1 TECHNICAL FEATURES

HYDRAULIC DIAGRAM Port NAME A

Main port

Tank port

Dimensions PF3/8

Discharge port

Slewing parking brake release port

Slewing parking brake pilot port

PF1/4

Rotating direction: inlet A port: clockwise (Seen from shaft side): inlet B port: counter clockwise

Items Item no.

Specifications Type

Hydraulic motor Parking brake Pressure relief valve Reduction unit

Slewing gearbox

PLC-120-18B-1FS2-8284A

Slewing motor

PM-1B-22B-FS2-4572A

Displacement

cm3/rev

22.1

l/min

33.8

73.0

Release pressure

MPa

Min 2.5, Max 4.9

Set pressure

MPa

21.0 at 34 L/min

Cracking pressure

MPa

16.5 at 1 L/min

Delivery Static friction torque

Reduction ratio

17.7

Weight (with Reduction unit)

24-36

Approx. 40

24. SYSTEMS COMPONENTS 24.1.5.2 CONSTRUCTION COMPONENTS 242

510

411 409 407 405 404 410 406 412

403

408

402

412

401

301 302 304 305 244

303

A A-A

235 236 245 238 223 218 231 224

201 217 225 221 215 205 232 212 204

237

213

234

206

233

209 505

507

306

208 503

506

203

207 501

511

226

210 502

214

130 504

124

202

107

129

118

127

111

105

106

216

117

103

110

109 123

119

113

125

102

136

108

114 101 116 128 115 112 104

24-37

512

508 509

B-B

24. SYSTEMS COMPONENTS No.

NAME

Q.TY

No.

NAME

Q.TY

No.

NAME

Q.TY

101 Housing

204 Cylinder

301 Cover

102 Carrier 1

205 Valve plate

302 Check valve

103 Carrier 2

206 Piston

303 Cap

104 Pinion shaft

207 Shoe

304 Spring

105 Internal gear A

208 Shoe holder

305 O-ring

106 Spur gear 1

209 Cylinder holder

306 O-ring

107 Spur gear 2

210 Swash plate

401 Seat

108 Sun gear 1

212 Cup

402 Cup

109 Sun gear 2

213 Pin

403 Poppet

110 Pin 1

214 Filter

404 Piston

111 Pin 2

215 Spring

405 Cover

112 Seal ring

216 Ball bearing

406 Spring

113 Thrust collar

217 Ball bearing

407 Spacer

114 Collar

218 O-ring

408 O-ring

115 Roller bearing

221 Snap ring

409 O-ring

116 Roller bearing

223 Screw M12 x 35

410 O-ring

117 Roller

224 Pin

411 O-ring

118 Roller

225 Pin

412 Back-up ring

119 Thrust washer

226 Pin

501 Valve block

123 Snap ring

231 Piston

502 Spool

124 Snap ring

232 Spring B

503 Piston

125 Spring pin

233 Friction plate

504 Stop

127 Pin

234 Separator plate

505 Spring (1)

128 Oil seal

235 O-ring

506 Spring (2)

129 O-ring

236 O-ring

507 Spring seat

130 Screw M8 x 25

237 Back-up ring

508 Cap

136 Ring

238 Back-up ring

509 O-ring

201 Body

242 Screw M16 x 15

510 O-ring

202 Housing

244 Screw M8 x 50

511 Cap

203 Shaft

245 O-ring

512 Cap

24-38

24. SYSTEMS COMPONENTS 24.1.5.5

OPERATING

(1) Operating slewing motor This hydraulic motor of an axial piston (swash plate) type converts the hydraulic energy furnished by the pump into rotary motion. Oil supplied through the control valve from hydraulic pump is directed to the valve plate (1). This oil enters port A (7) of the valve plate and the oil flows into the cylinder bore in the cylinder (2) aligned with port A (7) and pushes the piston (3). The force on the piston is converted by the swash plate (4) into rotary motion, which is transmitted to the shaft (5) splined to the cylinder (2). Return oil from the cylinder bore flows out port B (6) of the valve plate (1). In the case of reverse rotation, the oil flows into port B (6), and the return oil flows out port A (7).

Fig. 24-20 Operation of hydraulic motor (2) Operation of parking brake The parking brake operates to fix the output shaft of the slewing motor mechanically when the slewing motor stops. â&#x20AC;˘ Operation when the brake pressure release is blocked: When the brake release pressure is blocked, brake piston (1) is pressed in the direction arrow of the above Fig. 24-21 by the action of spring (2). At this time, the two friction plates (4) fixed inside the semicircular groove of the cylinder (3) are sandwiched between 3 separator plates (6) fixed to the housing (5). As the result, cylinder (3) is unable to turn by the frictional force between friction plates (4) and separator plates (6), thereby fixing the output shaft of the slewing motor. â&#x20AC;˘ Operation when the brake release pressure is continued: When the brake release pressure is through, it is directed to chamber (7) in Fig. 24-21 below. The pressure then overcomes the action of spring (2) and moves brake piston (1) in the direction of arrow in Fig. 24-21 below. The result is that the friction plates (4) and the separator plates (6) are released by the frictional power and the cylinder (3) rotates.

24-39

2 1 5 7 4 6 3

2 1 8 7 4 6 3

Fig. 24-21 Operation of parking brake

24. SYSTEMS COMPONENTS (3) Operation of hydraulic valve 1) Shockless relief valve The shockless valve is made up of a poppet (1), spring and the piston (2) that changes two steps stroke. The IN and OUT ports of the hydraulic motor are closed when the hydraulic motor stops. The motor attempts to keep slewing by inertia of the upper structure. This produces pressure (braking pressure) on the OUT port side by the pumping action of the motor. The shockless relief valve relieves the braking pressure by the following two step actions, in order to absorb the shocks at motor stop and prevent the motor from breaking down at the same time. The shockless relief valve also operates to absorb shocks the same way when the motor starts up. a) 1st Stage As pressure P1 flowing into the hydraulic motor increases, pressure corresponding to the spring action F1 causes the poppet (1) open. b) 2nd Stage The pressure P1 flows into “secondary chamber” (3) through the “orifice B and A” (4-5) which causes the piston to push to the stroke end (4). This reduces the length of the spring and increases the spring force. The pressure P1 rises to a set value Ps. The above-mentioned 2-step action absorbs shocks which occur when the hydraulic motor starts and stops. 2) Check valve After accelerating slewing of the upper structure, when the speed is being reduced by half-lever, the supply flow rate from pump to port A (6) is lowered. But if the upper structure is slewed at a comparatively high speed, the pressure in the (C) section is lowered to negative pressure making lubrication necessary. However, when the pressure of port B (7) is equal to or lower than the working pressure of cushion relief valve the oil of (C) section led through port A (6) is discharged to the control valve through port B (7). As a result, the flow rate from the control valve does not satisfy the specialized oil quantity. To prevent this, the make-up check valve (8) is installed to supply necessary oil into the (C) section.

24-40

Fig. 24-22 Operation of shockless relief valve 6

Fig. 24-23

24. SYSTEMS COMPONENTS 3) Action of hydraulic parking brake (P/B) timer When the parking brake operates as the upper structure produces inertia, the hydraulic parking brake timer operates to delay the operation of the parking brake for a certain time length. a) When the parking brake is released; If the pressure flows into the brake release command secondary pilot pressure port (PP), it overcomes the force of spring (505) and pushes spool (502) to the positions in Fig. 24-24 and in the figure above. At this time, the brake release pressure on primary pressure port (PB), passes through the arrow in Fig. 24-24 above, and flows in the brake piston chamber, and releases it. b) When the parking brake acts; If the pilot pressure at the brake releasing command secondary pilot pressure port (PP) is blocked, spool (502) is pushed back to the position in the figure below by the force of spring (505). The brake release pressure at the brake releasing pressure port (PB) is blocked by spool (502) and block the pressure supply to the chamber of the parking brake piston. The pressure of the parking brake piston chamber is pushed out by the force of the spring in the parking brake and flows out to the DR port through the passage indicated by an arrow in the figure below: On that occasion, the oil that is flowing out is regulated by the orifice of piston (503), flows out to the DR port slowly, and delays the action of the parking brake for a certain time length.

Fig. 24-24 Operation of hydraulic parking brake timer When the brake releasing command secondary pilot pressure flow into port PP;

When the brake releasing command secondary pilot pressure is blocked at port PP;

24-41

Fig. 24-25 Operation of hydraulic parking brake timer

24. SYSTEMS COMPONENTS (4) Reduction Unit (Planetary 2 stage) This slewing reduction unit for the slewing motor is made up of two stage planetary gear sets. It converts highspeed rotary motion from the slewing motor (4) into low speed and high-torque motion to rotate the pinion shaft (3). Refer to the Fig. 24-45, sun gear 2 (S2) is splined on the output shaft of the slewing motor (4) and the rotation of sun gear 2 (S2) performs primary reduction through gears (S2), (b2), and (a2). After primary reduction, rotation performs secondary reduction through gears (S1) (splined to carrier 2), (b1), and (a1). After secondary reduction, rotation is transmitted to the pinion shaft splined to carrier 1 creating slewing force. The gear ratio of the two-stage planetary gear can generally expressed by: R=

Zs1 x Zs2 Zs1+Za1 Zs2+Za2

Where: Â&#x2030; Zs1, 2 : S1, 2 Number of teeth Â&#x2030; Zs1, 2 : a1, 2 Number of teeth 4

1 3

Fig. 24-26 Operation of slewing reduction

24-42

24. SYSTEMS COMPONENTS 24.1.6

TRANSLATION MOTOR

24.1.6.1 TECHNICAL FEATURES

E. Oil filling port F. Oil level check port G. Oil drain port No. A, B

NAME Bucket roll-in/oil drain

D1, D2 Oil drain port P 1 st / 2 nd speed select port P2, P3 Pressure gauge port

SIZE PF1/2 PF1/4 PF1/8 PT1/8

The relation between rotating direction of reduction unit and oil inlet and outlet port (View from X side) Oil outlet Rotating direction Oil inlet port port Clockwise A B Counterclockwise B A

24-43

24. SYSTEMS COMPONENTS Model (type) Reduction unit

GM06VA

Rated output revolution (1st / 2nd)

rpm

30.9 / 52.2

Output torque (1st / 2nd)

5710 / 3280

Reduction ratio

1 / 68.6

Displacement (1st / 2nd)

cm3/rev

Working pressure Hydraulic motor

Parking brake

Rated output revolution (1st / 2nd) Delivery

26.4 / 15.3

MPa

23.0

rpm

2119 / 3583

L/min

57.1

2-Speed shifting pressure

MPa

3.5

Automatic 2-speed shifting pressure

MPa

18.5

Static friction torque

64.7

Releasing pressure

MPa

0.89

Weight

24-44

24. SYSTEMS COMPONENTS 24.1.6.2 CONSTRUCTION COMPONENTS

I L M N

H. I. L. M. N.

Reduction unit Hydraulic motor Brake valve Parking brake High and low speed change mechanism

O. Q. R. S. T.

24-45

Control valve Hydraulic pump High speed Low speed Hydraulic circuit

24. SYSTEMS COMPONENTS

B-B

A-A

24-46

24. SYSTEMS COMPONENTS No. 1 2 3 4 5 6 7 9 11 12 13 14 22 24 27 28 29 30 31 33 35 37 39 40 41 42 43 44 45 47

NAME Hub Mandrel Carrier Sun gear (1) Planetary gear (1) Sun gear (2) Planetary gear (2) Thrust washer (1) Thrust collar (4) Thrust washer (3) Cover Coupling Ring nut Ball bearing Roller bearing Roller bearing Inner race Inner race Floating seal kit Seal ring Plug with flange O-ring O-ring Cap Edge bolt Ball Parallel pin O-ring O-ring Ring Hexagon head screw

Cylinder and piston kit 102 Shaft 103 Swash plate 104 •Cylinder block •Piston kit ••Piston assembly 105 •••Piston 106 •••Shoe Piston kit •Piston assembly 107 Retainer plate 108 Thrust washer 109 Timing plate 110 Washer 112 Piston 113 Spring 114 Spring

Q.TY

No.

1 1 1 1 3 1 4 2 4 7 1 1 1 2 3 4 3 4 1 2 1 1 1 2 7 1 2 2 1 1 2 1

115 116 132 135 139 145 149 150 151 132 135 139 145 149 150 151 161 162 163 167 177 190

1 1 1 1 9 1 1 1 1 1 1 1 2 1 8 1

201 221 223 224 225 226 227 228 230 236 237 241 243 252 254 263 264 266 268 273 275 276 279 280 299

24-47

NAME Friction plate Separator plate Oil seal O-ring O-ring Snap ring Ball bearing Ball bearing Roller Seal ring O-ring O-ring Snap ring Ball bearing Ball bearing Roller ••Piston ••Shoe •Seal ring Pivot Parallel pin Spring Rear flange assembly • Rear flange kit •• Rear flange • Plug • Spool • Plug • Stopper • Plug • Valve • Spring • Spring • O-ring • O-ring Parallel pin Edge bolt • Hexagon socket plug • Hexagon socket plug •• Spool •• Oil stopper • Spring • Ball • O-ring • Orifice • Orifice • Filter • Plug with flange • Name plate

Q.TY 1 2 1 1 1 1 1 1 3 1 1 1 1 1 1 3 1 1 1 2 2 1 1 1 1 2 1 2 2 2 2 2 2 2 2 2 6 4 4 1 1 1 1 2 1 1 1 1 1

24. SYSTEMS COMPONENTS 24.1.6.3 OPERATION 24.1.6.3.1

Reduction unit

1. Operation This reduction gear unit is composed of two stage planetary gear mechanism. The reduction gear reduces the high speed of hydraulic motor and converts it low-speed, high-torque rotation. 2. Operation description The rotation of hydraulic motor shaft is transmitted to sun gear (4) of the first stage which is linked with shaft (102) in spline. Sun gear (4) is meshed with three planetary gears (5), and three planetary gears (5) mesh with hub (1) while rotating on their axis. At that time, the hub is rotated by the rotation of the planetary gears (5). The hub rotation is transmitted to carrier which is connected to planetary gears (5), and that causes sun gear (6) rotation of the second stage. The rotation of the gear (6) is transmitted to the hub via four planetary gears (7) of the second stage. The generated rotation of reduction gear is output rotation. (7)

(5) (4)

(102)

(6) (3)

(1)

24.1.6.3.2

Hydraulic motor section (Brake valve, parking brake, high and low speed change mechanism)

1. Operation 1) Hydraulic motor Hydraulic motor is referred to as a swash plate type axial piston motor which converts the pressure oil power fed by pump into rotary motion. 2) Brake valve a. Travel motor controls the force of rotational inertia of the body to brake and stop the rotation smoothly. b. Check valve function to prevent hydraulic motor from cavitation. c. Open the port to release the parking brake force at travel motor operation, and close the port at a standstill. 3) Parking brake The parking brake is used to the prevent machine from running away or slipping while parking on a slope using the friction plate type brake mechanism, and is installed on the hydraulic motor. 4) High / Low speed shifting mechanism By means of changing the tilt angle of the swash plate to change the stroke volume of piston with help of the function on the shifting valve and control piston, the speed is shifted to high speed with low torque or low speed with high torque.

24-48

24. SYSTEMS COMPONENTS 2. Operation 1) Hydraulic motor Hydraulic oil fed by pump enters rear flange (201) of travel motor, and is led from timing plate (109) to cylinder block (104) through brake valve mechanism. This pressure oil is led to only the one side of Y1 - Y2 tied between top dead point and bottom dead point of piston (105) stroke. And the pressure led to one side of cylinder block pushes 4 or 5 pistons (105), generating the power {F (N) = 100 x P (MPa) x A (cm2)}. This power enters on swash plate (103), but swash plate is fixed having an angle (α) against axis of drive shaft (102), and divided into component of force (F2, F3). And the radial component of force (F3) generated various torque (T = F3 x ri) against line Y1 - Y2. The total torque [T = ∑ (F3 x ri)] is connected to turning effort, and rotates cylinder block (104) through piston (105). This cylinder block (104) is connected with drive shaft (102) with spline, and rotates drive shaft to transmit torque. 2) Brake valve a. Operation (Brake released) The pressure oil is led to through port (A), opens valve (227), and led to port (C) on the section side of hydraulic motor to rotate hydraulic motor. At the same time, the pressure oil enters chamber (b) through passage (a) from the small hole of spool (223), and exerts on the end of spool to generate the force. Then the force of spring (228) slides the spool placed on the neutral position leftward. The sliding of spool forms the space (passage) between spool and rear flange with spool groove. This passage is connected to port (D) and port (B) of the return circuit of the hydraulic motor, and the return oil returns to tank side, enabling hydraulic motor to rotate. Then, the sliding of spool leads pressure oil to port (P). The pressure oil led to port (P) moves piston (112) of parking brake, and releases parking braking force. (For details, refer to item “Parking brake”). If pressurized oil is supplied from port (B) the movements of spool (223) and valve (227) are reversed so that the hydraulic motor is rotated reversely.

24-49

24. SYSTEMS COMPONENTS b. Stop / Stall (braking action) If pressurized oil supply through the port (A) is suspended while travelling, the hydraulic force to push up the spool is lost, and the spool (223) which is slided to left side, tries to return to the neutral position through the stopper (225) due to the spring (228) force. At that time, through the oil in the chamber (b) tries to flow out to the port (A) side through the passage (a) in the spool, its flow is restricted and some back pressure is generated by the throttle effect in the passage (a) controlling the return speed of the spool. At the same time, the hydraulic motor tries to rotate with its inertia force even though the pressurized oil is suspended, and the return oil from the hydraulic motor tries to return to the port (B) side from the port (D) through the passages on spool groove and rear flange. When the spool entirely return to the neutral position, the passage on the hydraulic motor of the oil return side is completely closed by the spool, and the hydraulic motor ceases its rotation. While machine working, the brake valve smoothly stops rotation of the hydraulic motor which tries to rotate with its inertia force, by means of throttling the return side passage of the hydraulic motor, generating back pressure due to shape of the spool groove and controlling the return speed of the spool. On the other hand, when braking is operated, the hydraulic motor tries to rotate with its inertia force and to intake oil with its pumping function. However, because the intake side is closed its passage with the spool, the oil supply is suspended. This causes cavitation in the hydraulic motor. To prevent the cavitation, the valve (227) is operated by very slight negative pressure to open the passages of port (A) side and intake port (C) of the hydraulic motor. And when pressurized oil is supplied through the port (B), each motion of the above mentioned parts becomes symmetrical right and left to stop the hydraulic motor.

24-50

24. SYSTEMS COMPONENTS c. Self-travelling While machine is being operated, as the travel speed is increased due to steep slope, the oil flow rate of the hydraulic motor is higher than the supply flow rate of the hydraulic oil pump. The rotation of the hydraulic motor in this case is called a self-travelling (Overrun). While self-travelling, the oil pressure is lowered similar to the stopping condition. Then brake valve is moved similar to the stopping condition, throttles passage in the return side of hydraulic motor, and generate backing pressure. In addition, the force of inertia decreases the revolution of hydraulic motor to revolution having a balance with the supply flow rate of pump.

3) Parking brake a. Traveling The pressure oil led trough brake valve actuates on spool (223) of brake valve on the hydraulic motor section, opens passage to parking brake, and is led to cylinder chamber (a) compressed of spindle (2) and piston (112) on the reduction gear section. If the pressure of oil which is 0.89 MPa (129 psi) or higher it exceeds the force of spring moving piston (112) toward rear flange (201) side. This movement of piston (112) reduces the push power to separator plate (116) and friction plate (115), and makes the movement of friction plate (115) which is installed to cylinder block (104) on hydraulic motor section free releasing the brake power to cylinder block (104).

24-51

24. SYSTEMS COMPONENTS b. Stopping If pressure oil from brake valve is cut, and the pressure in cylinder chamber (a) lowers 0.89 MPa (129 psi) or less, the piston (112) goes to rightward by the force of spring (113). Also, the force of the spring pushes mating plate (116) and friction plate (115), which is in a free state because piston (112) is pushed, against spindle (2) on the reduction gear section. The frictional force produced by the push power stops the rotation of cylinder block (104), and transmits braking torque 32.4 Nm to hydraulic motor shaft. And since oil is controlled through the proper oil passage, it results in smooth operation.

4) High / Low speed shifting mechanism a. Low speed When the pilot pressure (10) is not supplied through the port (D), the valve (263) is pushed up to the upper position due to the spring (266) force and pressurized oil through the port (A) or (B), the pressurized oil is cut off at port (C), and oil in the chamber (P) is released into the drain (D) (motor case) through the valve (263). Accordingly, the tilt angle of the swash plate (103) becomes the maximum and low speed rotation of the hydraulic motor.

1 resulting the maximum stroke volume

Y P

D. Drain

24-52

24. SYSTEMS COMPONENTS b. High speed When 3.5 MPa of the pilot pressure (10) is supplied through the port (P), it defeats the spring (263) force and pressurized oil through the port (A) or (B) to push down the valve (263) to lower position, the pressurized oil at the port (C) is led to the chamber (P) through the valve (263), and the piston (161) pushes the swash plate (103) up to the plane X and maintain it at its position. At that time, the tilt angle of the swash plate becomes the minimum

2 resulting the minimum stroke volume and high speed rotation of the hydraulic motor.

D. Drain c. Automatic shifting to low speed during high speed operation If the load is increased while high speed operation, the oil pressure at the port (A) or (B) is also increased. And when the oil pressure reaches to 18.5 MPa, it excesses the pilot pressure (10) of 3.5 MPa, and the valve (263) is pushed up to upper position, and oil in the chamber (P) is released into the drain (D) (motor case) through the valve (263). At that time, the swash plate (103) gets touch with the plane Y of spindle, and the tilt angle of swash plate becomes the maximum

1 and is maintained at its position resulting low speed rotation.

Y P

D. Drain

24-53

24. SYSTEMS COMPONENTS 24.1.7

CONTROL VALVE

24.1.7.1 TECHNICAL FEATURES

G (P)

(F) D C (E) F

P D

E C A G

Fig. 24-27 General view Port no.

A, B, C, D

E, F

G (Drain)

Rated working pressure

MPa

22.6

←

3.4

0.5

Pressure test

MPa

30.9

←

30.9

1.0

L/min

PF1/2

PF3/8

PF1/4

PF3/8

Delivery Port size Revolution Weight

rpm

Less than 15

Approx 22

24-54

24. SYSTEMS COMPONENTS 24.1.7.2 CONSTRUCTION COMPONENTS

1 11 10

8 6

P F E D C B A G

15 13 7, 17 4

Fig. 24-28 Construction No.

NAME

Q.TY

No.

NAME

Q.TY

STEM

SEAL RING

BODY

SEAL RING

FLANGE

SNAP RING

SPACER

SCREW M10 x 30

PLUG

SEAL

SPRING WASHER

NAME PLATE

BACK-UP RING

O-RING

CLEVIS

O-RING

24.1.7.3 OPERATION The swivel joint is installed on the slewing center of the machine, and plays a role to continuously connect the oil circuit regardless of the slewing angle of the upper frame.

24-55

24. SYSTEMS COMPONENTS 24.1.8 CYLINDERS 1. TECHNICAL FEATURES

Fig. 24-29 General view of cylinder A. Fully retracted length B. Fully extended length

C. Part no. and manufacturing no. stamp position

E45B SR

Unit: mm

Stroke

Centre distance of mounting pins Full extend B / Full retract A

Cushion

Dry weight kg

ø90 / ø50

704

1743 / 1039

Rod side

Lifting (cab)

ø90 / ø50

680

1719 / 1039

Rod side

Digging

ø80 / ø50

717

1825 / 1108

Rod & Head

Bucket

ø75 / ø45

546

1378 / 832

None

Swing

ø90 / ø50

567

1510 / 943

None

Dozer

ø95 / ø55

200

700 / 500

None

Cylinder bore / Rod diameter

Lifting (canopy)

Cylinder

E50B SR - E55B

Unit: mm

Stroke

Centre distance of mounting pins Full extend B / Full retract A

Cushion

Dry weight kg

ø100 / ø55

699

1768/ 1069

Rod side

Lifting (cab)

ø100 / ø55

666

1753 / 1069

Rod side

Digging

ø90 / ø50

716

1836 / 1120

Rod & Head

Bucket

ø75 / ø45

546

1378 / 832

None

Swing

ø90 / ø50

567

1510 / 943

None

Dozer

ø95 / ø55

200

700 / 500

None

Cylinder

Cylinder bore / Rod diameter

Lifting (canopy)

24-56

24. SYSTEMS COMPONENTS 24.1.8.1 CONSTRUCTION AND FUNCTION Boom cylinder

17 16 15

12 Fig. 24-30 Construction of boom cylinder

No.

NAME

Q.TY

No.

NAME

Q.TY

CYLINDER LINER

13 SEAL RING

CYLINDER ROD

14 BEARING

BUSHING

15 SEAL RING

CYLINDER HEAD

16 BACK-UP RING

CUSHION BEARING

17 DUST SEAL RING

PISTON

18 O-RING

LOCKNUT

19 BACK-UP RING

10 WEAR RING

20 O-RING

11 SEAL RING

21 DUST SEAL RING

12 SEAL RING

24-57

24. SYSTEMS COMPONENTS Arm cylinder

3 4

17 16 15

NAME

Q.TY

No.

NAME

Q.TY

CYLINDER LINER

14 BEARING

CYLINDER ROD

15 SEAL RING

BUSHING

16 BACK-UP RING

CYLINDER HEAD

17 DUST SEAL RING

CUSHION BEARING

18 O-RING

PISTON

19 BACK-UP RING

LOCKNUT

20 O-RING

10 WEAR RING

21 DUST SEAL RING

11 SEAL RING

23 CUSHION BEARING

12 SEAL RING

24 RING

13 SEAL RING

25 RING

24-58

Fig. 24-31 Construction of arm cylinder No.

24. SYSTEMS COMPONENTS Bucket cylinder

16 15

Fig. 24-32 Construction of bucket cylinder No.

NAME

Q.TY

No.

NAME

Q.TY

CYLINDER LINER

14 BEARING

CYLINDER ROD

15 SEAL RING

BUSHING

16 BACK-UP RING

CYLINDER HEAD

17 DUST SEAL RING

PISTON

18 O-RING

LOCKNUT

19 BACK-UP RING

10 WEAR RING

20 O-RING

11 SEAL RING

21 DUST SEAL RING

13 SEAL RING

24-59

24. SYSTEMS COMPONENTS Swing cylinder

3 4

17 16 15

Fig. 24-33 Construction of swing cylinder No.

NAME

Q.TY

No.

NAME

Q.TY

CYLINDER LINER

14 BEARING

CYLINDER ROD

15 SEAL RING

BUSHING

16 BACK-UP RING

CYLINDER HEAD

17 DUST SEAL RING

PISTON

18 O-RING

LOCKNUT

19 BACK-UP RING

10 WEAR RING

20 O-RING

11 SEAL RING

21 DUST SEAL RING

13 SEAL RING

24-60

24. SYSTEMS COMPONENTS Dozer cylinder

3 4

20 19

17 16 15

Fig. 24-34 Construction of dozer cylinder No.

NAME

Q.TY

No.

NAME

Q.TY

CYLINDER LINER

14 BEARING

CYLINDER ROD

15 SEAL RING

BUSHING

16 BACK-UP RING

CYLINDER HEAD

17 DUST SEAL RING

PISTON

18 O-RING

LOCKNUT

19 BACK-UP RING

10 WEAR RING

20 O-RING

11 SEAL RING

21 DUST SEAL RING

13 SEAL RING

24-61

24. SYSTEMS COMPONENTS 24.1.8.1.1

Function (Example for boom cylinder)

1. Fundamental function This is a kind of hydraulic actuator, and converts the energy in pressurized oil supplied by the hydraulic pump to a large force linear direction by means of the piston, as well as changing over the operating direction for either extension or retraction by means of actuating the valve lever to change over the direction of pressurized oil flow. Such conversion of energy force and change over the operating direction are of the fundamental function of this cylinder. 2. Function of each Parts The following description is based on a cylinder with a typical structure (boom cylinder). 1) Cylinder head The cylinder head assy also works as a bearing by means of pressing the bushing (14) into the cylinder head (4). The oil leakage is prevented by insersion of the seal ring (15) into the bore of cylinder head. The dust invasion is protected by pressing the seal ring (17) into the bore of cylinder head. By means of fitting with the cushion bearing (5) at adjacent to the fully extended position of the cylinder, a high oil pressure is generated to absorb the cylinder shock at the fully extended position. And the cylinder head has another function of charging and discharging highly pressurized oil from the inside of cylinder tube to the port.

Fig. 24-35 Cylinder head assy No. 1

NAME CYLINDER LINER

13 RING 16 BACK-UP RING 18 O-RING 19 BACK-UP RING 20 O-RING a. Bushing (14) The bushing (14) is pressed into the bore on cylinder head to support the cylinder rod. Along with the wear ring installed in the outer periphery of the piston, the bushing (14) bears the radial load acting on the cylinder, and performs a linear movement against the cylinder rod at a high pressure, thus minimizing the eccentricity which negatively affects the sealing effect by supporting one end of it. b. Oil seal ring (17) The seal ring (17) is located at the entrance where the cylinder rod comes in and out. Its function is to protect invasion of dust and water into the cylinder to secure good sealing effect of the seal ring (15), as well as to remove dust and mud adhered on the piston rod.

24-62

24. SYSTEMS COMPONENTS 2) Piston assy The piston assy has the seal ring (11) which is inserted at the centre portion of the piston (6), to prevent leakage of pressurized oil from either chamber of left or right to the other chamber. The wear rings (10) are inserted in both sides of the seal ring (11) to bear radial load imposed on the cylinder, and also to catch contaminations.

Fig. 24-36 Piston assy a. Seal Ring (11) The location of seal ring (11) is the centre of piston. The seal ring (11) is to seal the circular gap between the piston and the cylinder tube utilizing a tension of the O-ring, to form both chambers of high pressure side and low pressure side isolating from each other making the piston as the border. b. Wear Ring (10) Two wear rings are provided at both sides of the seal ring (11) directly getting in touch with the cylinder tube. Along with the bushing (14), the slide rings (10) bear radial load imposed on the cylinder, perform linear movement against inside face of cylinder at high facial pressure, and minimize the eccentricity of cylinder rod that badly affects to the sealing effect by supporting it at one end. And the slide ring has another function of burying and catching contaminations between the cylinder tube and the slide rings. c. Cushion Bearing (5) The cushion bearing (5) is located between the piston and the stepped portion of cylinder rod. This cushion ring has the inner seal ring (12), this causes the seal ring has floating mechanism. This floating mechanism absorbs the shock at plunge of cushion bearing. It has the function to form a circular gap adjacent to the fully extended position, and to throttle the oil to absorb the collision speed of cylinder at the fully extended position to soften the shock. d. Cushion bearing (23) The cushion bearing (23) is located at the end of piston rod. At the full retracting of cylinder rod, cushion bearing (23) plunges into hole of cylinder bottom, and forms a circular gap and throttles the oil flow. Consequently the collision speed of rod slows down and the shock of collision is absorbed. No.

NAME

CYLINDER LINER

LOCKNUT

24 RING 25 RING

24-63

24. SYSTEMS COMPONENTS

24.2

ELECTRICAL EQUIPMENT

24.2.1

ELECTRICAL EQUIPMENT LIST Group

Diode

Electric fittings

Lights

Engine

Relay

Code

Part Name

D-1

DIODE

D-2

DIODE

D-3

DIODE

D-4

DIODE

D-12

DIODE

D-13

DIODE

D-14

DIODE

D-18

DIODE

E-1

FUSE BOX

E-2

GENERATOR (ALTERNATOR)

E-3

HORN

E-4

FUSIBLE LINK (45A)

E-6

GAUGE CLUSTER

E-7

POWER SOCKET

E-8

AIR HEATER

E-10

RADIO (OPT)

E-11

OVERLOAD BUZZER

E-12

HEATER (OPT)

E-13

BATTERY

E-14

SEQUENCE BOX

E-15

FUSE BOX (OPT) (FOR COOLER)

E-16

RADIATOR

E-17

ENGINE CONDENSER

E-18

COMPRESSOR

E-23

ANTENNA

E-26

HOUR COUNTER

L-1

ROOM LAMP

L-2

BOOM WORKING LIGHT (55 W)

L-5

CAB / CANOPY WORKING LIGHT

M-1

STARTER MOTOR

M-2

WIPER MOTOR (CAB)

M-3

WASHER MOTOR (CAB)

M-4

DECELERATION MOTOR

M-6

FUEL PUMP

R-1

BATTERY RELAY

R-2

SAFETY RELAY

R-3

DECELERATION RELAY

R-6

TIMER UNIT

R-7

ENGINE STOP RELAY

R-8

CHARGE INDICATOR RELAY

R-9

CAB / CANOPY WORKING LIGHT

24-64

24. SYSTEMS COMPONENTS Group

Code

Relay

R-14

SLEW / SWING SELECT RELAY

SE-1

FUEL SENSOR

SE-2

ENGINE THERMO SENSOR

SV-1

LEVER LOCK SOLENOID

SV-2

2-SPEED SELECT SOLENOID

SV-3

ENGINE STOP SOLENOID

SV-5

POWER SHIFTING SOLENOID (Radiator specifications)

Sensors

Solenoid

Part Name

PSV-D NIBBLER OPEN PROPORTIONAL SOLENOID (RIGHT SIDE) PSV-E NIBBLER CLOSE PROPORTIONAL SOLENOID (LEFT SIDE)

Switch

SW-1

(KEY) STARTER SWITCH

SW-2

WORKING LIGHTS SWITCH

SW-3

2nd SPEED SELECTOR SWITCH

SW-4

WIPER WASHER SWITCH

SW-5

ENGINE COOLANT TEMPERATURE SWITCH

SW-6

ENGINE OIL PRESSURE SWITCH

SW-7

HORN SWITCH

SW-9

LEVER LOCK SWITCH

SW-10 HEATER SWITCH (OPT) SW-11 DECELERATION SWITCH SW-15 HIGH AND LOW PRESSURE SWITCH SW-16 CONDENSER SPEED SHIFT SWITCH SW-35 HYDRAULIC NIBBLER ACTIVATION SLIDER SW-39 OVERLOAD PRESSURE SWITCH SW-40 OVERLOAD SWITCH

24-65

24. SYSTEMS COMPONENTS 24.2.2

ELECTRICAL EQUIPMENT SPECIFICATIONS

Name

Specifications

D-1, 2, 3, 4, 12รท14, 18 Diode Horn Engine stop solenoid Engine stop relay Travel 1, 2 speed solenoid Battery relay Slewing / swing Select relay Engine stop solenoid

Max rated

Current

Breakdown

400V

E-1 Fuse box

Radio, Wiper

30A

Heater

Relay Solenoid

30A F3 30A F4 10A F5 30A F6 10A

24-66

Working light Horn Cab light Engine stop solenoid Gauge cluster

24. SYSTEMS COMPONENTS Name

Specifications

E-2 Generator

Voltage

one of 10 A, two of 30 A

Rating speed

5000 rpm

Current

55 A

Weight

3.5 kg (8lb)

E-3 Horn

Fuse

12 V 4.5 A

Basic frequency

425 Hz

Allowable current

45 A 45A

45A

E-4

Rated voltage Nominal current

24-67

24. SYSTEMS COMPONENTS Name

Specifications

E-6 Gauge cluster

A A

Voltage of operation

12 V

No. Connection 1

Illumination (+)

Engine oil pressure (-)

Charge (-)

Engine coolant temperature (-)

Lamp power source -1 (+) [engine coolant, fuel, travel 2 speed]

Fuel (-)

Travel 2 speed (-)

Lamp power source-2 (+) [engine oil pressure, charge, air cleaner clogging]

Air cleaner clogging (-)

10 F/T IGN (+) 11 Fuel unit 12 F/T illumination GND (-) 13 Temperature unit A

Connector

24-68

24. SYSTEMS COMPONENTS Name E-7 Power socket

Specifications 12 V DC Voltage of opera(Water-proof tion type)

E-8 Air heater Engine starter

Rated voltage

11 V DC

Nominal current

36.5 A

Rated output

400 W

Insulation resistance

3 MΩ or more / 500 V Megger

E-10

Radio (OPT)

Voltage No. 1 2 3 4 5 6

NAME Display button Display Speaker Preset button 1÷6 Tune/time adjust Power/volume

24-69

12 V

24. SYSTEMS COMPONENTS Name

Specifications

E-11 Overload buzzer

Voltage

12 V

Current

15 รท 35 mA

E-12 Heater (OPT)

E-13 Battery

Type

95D31L

Voltage

12 V

Capacities

74 Ah

Weight with electrolyte

5.3 l

24-70

24. SYSTEMS COMPONENTS Name

Specifications

E-14 Relay

No. 1 2 3 4 5 6 A

NAME Supply Deceleration relay solenoid Travel 1,2 speed switch Push button deceleration Travel 1,2 speed solenoid Ground Pin arrangement

E-15 Fuse box (For cooler)

A 1 3

No. NAME 1

Bracket in the hatched area

Hole for M6

Arrangement of terminals and circuit diagram

E-23 Antenna

E-26 Hourmeter

Rated voltage

24-71

10 รท 80 V DC

24. SYSTEMS COMPONENTS Name

Specifications

L-1 Lights (cab)

Rated voltage

12 V

Bulb

12 V - 10 W

L-2 Work light

Effective area of lens

82cm2

Bulb

Halogen 12 V - 55 W

L-5 Cab work light

Effective area of lens Bulb

24-72

54 cm2 Halogen 12 V - 55 W

24. SYSTEMS COMPONENTS Name

Specifications

M-1 Starter motor

Rated voltage

12 V DC

Output

2.3 kW

Nominal time

30 Sec

Rotation direction

Clockwise as seen from pinion

Weight

5.3 Kg

24-73

24. SYSTEMS COMPONENTS Name

Specifications

M-2 Windshield wiper motor

Rated voltage Wiping angle

12 V 105° ± 3°

M-3 Washer motor

Rated voltage

12 V DC

M-4 Decelerator

Rated voltage

12 V

Stroke

36 ± 2 mm

Working force

11 Kg or more

Working time

1 or less

Working current

8.5 A or lower

24-74

24. SYSTEMS COMPONENTS Name

Specifications

M-6 Fuel pump

Rated voltage

12 V DC

Maximum working current

1.5 A or lower

Delivery

At open condition 400 cc/min or more

R-1.7 Battery relay Engine stop relay

Rated voltage Coil resistance Insulation resistance

24-75

12 V DC 72 Ω ± 10% 20 MΩ (500 V)

24. SYSTEMS COMPONENTS Name

Specifications

R-2 Relay Protection of starter 1

4 A

2 3 C

No. NAME 1

Key switch

Battery

Starter

Controller

Connector

Connection diagram

Rated voltage

12 V DC

Nominal

Continuous

Temperature range

-30 ÷ 80 °C

Nominal load

B terminal start (maximum 40 A)

R3, 8, 9, 14, 22÷25 Deceleration relay Charge indicator relay Slewing /swing relay

Rated voltage Insulation resistance

24-76

12 V DC 1 Ω or higher / 20 A, 20 °C

24. SYSTEMS COMPONENTS Name

Specifications

R-6 Relay Timer

No. NAME 1

Red (Acc)

Black (GND)

Red / White (Relay)

Yellow (Relay) Rated voltage

12 V

Exciting current

Timer

1sec

SE-1

44.3 121 (4.76") (1.74") 201 (7.91")

Fuel meter

117.5 (4.63")

1 2 3

R99.6

Rated voltage

No. NAME

12 V

Ground (black)

Float position

Full

1/2

Empty

Unit (yellow)

Resistance (Ω)

Thermistor (red)

+10 0

Gauge

Waning lamp

Thermistor

Fuel unit

Stay earth

Low fuel warning

Tank

Allowable (Ω)

)

(3.92"

0 -4

24-77

24. SYSTEMS COMPONENTS Name

Specifications

SE-2

M16 X 1.5

Engine thermo sensor

Temperature °C

100

Resistance value Ω

153.9

51.9

27.4

16.1

The figures in parentheses are reference values

Rated voltage

12 V DC

Type

Thermistor type

SV-1.2 Solenoid valve Safety lock lever / selection of 2nd speed

1 2 3

7.8±1.0 Nm 44±3 Nm 7.8±1.0 Nm

Rated voltage Relief valve set pressure Delivery

24-78

12 V DC 3.5 MPa 15 l/min (P port)

24. SYSTEMS COMPONENTS Name

Specifications

SV-3

Solenoid valve

Engine stop

No. NAME 1

Ground (black)

Pull coil (white)

Hold coil (red)

Connector

Stroke: 7.4 mm Rated voltage

12 V DC

Nominal current

Pull coil: 36.5 A Hold coil: 0.49 A

SV-5 Solenoid valve Power shift (Air-con spec.)

No. NAME 1

Cord colour: earth black

Power source cord colour: red

Ampère mark ΙΙ 2P

Rated voltage

12 V DC

Capacities

12 W

Operating pressure

4.9 MPa

Maximum delivery

160 l/min

24-79

24. SYSTEMS COMPONENTS Name

Specifications

PSV-D, PSV-E Nibbler open/close proportional solenoid

Power supply

12 V

Current

1600 mA

Coil resistance

3.2 ± 0.5 Ω

Max. working pressure

7 MPa

Flow rate

10 l/min

24-80

24. SYSTEMS COMPONENTS Name

Specifications

SW-1 Starter switch

SW-2 Switch Working light

SW-3 Switch 1

Travel 1, 2 speed

SW-4 Switch Wiper / washer

No. NAME 1

Auto return

Washing

Insulation resistance

24-81

1 Mâ&#x201E;¦ or more (DC 500 V Megger)

24. SYSTEMS COMPONENTS Name

Specifications

SW-5 M16 X 1.5

Sensor

Engine water temperature

SW-6

Operating temperature

ON: 110 ± 3 °C OFF: 100 °C or lower

Electric capacity

DC 12 V 1A

Insulation resistance

100 MΩ or more / 500 V Megger

Tightening torque

27 Nm

PT1/8

Sensor Engine oil pressure

Rated voltage

DC 6 V, 12 V, 24 V

Nominal load

5W (Lamp load)

Operating pressure

49 ± 1 kPa

Type Nominal Insulation resistance

OFF-(ON) momentary 125 V 3A (AC) 100 MΩ or more / 500 V Megger

SW-7 Horn switch

24-82

24. SYSTEMS COMPONENTS Name

Specifications

SW-9 Lever lock switch

Rated voltage

12 V DC

Nominal current

15 A

Insulation resistance

1 MΩ or more

Stroke

Switch ON: 2 ± 1 mm

SW-10 Heater switch (OPT)

No. NAME 1

Connector

Cap

SW-11 No. NAME 1

Free

Push

1 2 a

Deceleration switch (OPT)

Rated voltage

12 V DC (MAXIMUM: 16 V DC)

Insulation resistance

1 MΩ or more (500 V Megger)

24-83

24. SYSTEMS COMPONENTS Name

Specifications

SW-35 Hydraulic nibbler activation slider

Hydraulic breaker activation push-button

SW-35, hydraulic nibbler activation slider

24-84

24. SYSTEMS COMPONENTS Name

Specifications

SW-39

Overload pressure switch

Overload pressure switch Max Voltage

250 Volt

Max Current

Setting

11.5 (+5 -0) MPa

Max static pressure

60 MPa

Operating temperature

-5 +60 Â°C

SW-40

1 5

Overload switch No. NAME 1

Symbol mark

Connector (with lock)

Red (R)

Red / White

Switch

Terminal

24-85

24. SYSTEMS COMPONENTS

[NOTES]

24-86

31. WHOLE DISASSEMBLING AND ASSEMBLING TABLE OF CONTENTS 31.1 GENERAL DISASSEMBLY AND ASSEMBLY ................................................ 31-1 31.1.1 CONTENTS OF GENERAL DISASSEMBLY AND ASSEMBLY ............ 31-1 31.1.2 SPECIFICATION OF TIGHTENING TORQUE ...................................... 31-1

31. WHOLE DISASSEMBLING AND ASSEMBLING

31.1

GENERAL DISASSEMBLY AND ASSEMBLY

31.1.1

CONTENTS OF GENERAL DISASSEMBLY AND ASSEMBLY

This chapter consists in the following three sections: (1) EQUIPMENT.................................................................................................................................... No. index: 32 Part I: removing and installing assembly Part II: disassembling and assembling components 1) Hydraulic cylinder (2) UPPER SLEWING STRUCTURE.................................................................................................... No. index: 33 Part I: removing and installing assembly Part II: disassembling and assembling components 1) Hydraulic pump 2) Control valve 3) Pilot valve (ATT) 4) Pilot valve (travel) 5) Slewing motor 6) Swivel Joint (3) TRAVEL SYSTEM ........................................................................................................................... No. index: 34 Part I: removing and installing assembly Part II: disassembling and assembling components 1) Travel motor 31.1.2

SPECIFICATION OF TIGHTENING TORQUE

Tightening torque is indicated as follows, for example: T = 100 Nm (73.7 lbf•ft) Tolerance is ±10% unless otherwise specified. •Refer Index no. 11 TOOLS for standard tightening torque.

31-1

31. WHOLE DISASSEMBLING AND ASSEMBLING

[NOTES]

31-2

32. ATTACHMENT

TABLE OF CONTENTS 32.1 REMOVING AND INSTALLING ...................................................................... 32-1 32.1.1 ATTACHMENT ASSEMBLY AND NAME ................................................ 32-1 32.1.2 BUCKET ................................................................................................... 32-2 32.1.3 ARM ......................................................................................................... 32-4 32.1.4 BOOM ...................................................................................................... 32-7 32.1.5 SWINGING ............................................................................................. 32-10 32.1.6 BLADE ................................................................................................... 32-12 32.2 DISASSEMBLY AND ASSEMBLY ................................................................ 32-13 32.2.1 CYLINDER ............................................................................................. 32-13

32. ATTACHMENT

32.1

REMOVING AND INSTALLING

32.1.1

ATTACHMENT ASSEMBLY AND NAME

Fig. 32-1 Attachment name and position A. Boom foot pin

J. Bucket drive pin

B. Boom cylinder head pin

K. Bucket attaching pin

C. Boom cylinder rod pin

L. (L1 Upper) (L2 Lower) swing centre pin

D. Arm cylinder head pin

M. Swing cylinder rod pin

E. Arm cylinder rod pin

N. Swing cylinder liner pin

F. Boom top pin

P. Dozer pin

G. Bucket cylinder liner pin

Q. Dozer cylinder head pin

H. Bucket cylinder rod pin

R. Dozer cylinder rod pin

Idler link pin

32-1

32. ATTACHMENT 32.1.2 32.1.2.1

BUCKET REMOVAL OF BUCKET

(1) Operate the operating lever and place the bucket on the ground, so the bucket and arm connecting pins are not loaded. (2) Move the O-rings (3) toward the bucket bosses using a spatula. (3) In order to remove pin (K) which links arm and bucket, remove the ring (2) and the pin (1) by means of straight driver, and draw out pin (K). â&#x20AC;˘ If the pin does not come off easily, the pin is loaded. Take off the load by manipulating the operating lever.

Fig. 32-2 To place bucket on ground

â&#x20AC;˘ Take care so the dust seal between the arm and the bucket bosses is not damaged.

(4) Adjust the bucket by manipulating the operating lever so the pin (J) between the bucket link and the bucket is not loaded.

(5) Remove the ring (2) and pin (1) then pull out the pin (J).

(6) Remove bucket assembly. Weight: 96 kg - E45B SR 100 kg - E50B SR - E55B

4 1

4 3

B-B B

Fig. 32-3 Assembly of pin (A-A) 4. Seal ring J. Pin for bucket link K. Pin for arm

32-2

32. ATTACHMENT 32.1.2.2

INSTALLATION OF BUCKET

Installation is performed in the reverse order of removal, including the following workings:

CAUTION When aligning the pin position, do not put your finger in the pin holes in any circumstances, but align them visually. (1) Clean the welded part of the structures and check that there is no crack on the part. (2) Check that the dust seal is not damaged, and replace a faulty one if necessary. (3) Replace the worn pins and bushings according to the Section “ATTACHMENT DIMENSIONS” of “SPECIFICATIONS”. (4) When inserting the pin, coat the shaft with grease. • The bucket is mounted more easily if the bucket connecting rod is installed first. Fig. 32-4 Installation of bucket

32-3

32. ATTACHMENT 32.1.3 32.1.3.1

ARM REMOVAL OF ARM

(1) Making the arm cylinder and bucket cylinder (1) to the most retracting conditions, get touch the arm tip with the ground. (2) Shut off the engine and operate the arm control lever several times at the same moment, and the pressure in circuit is released. Then put the safety lock lever in the â&#x20AC;&#x153;Lockedâ&#x20AC;? position, and depress the air breather on the hydraulic oil tank, release the pressure in the tank.

Fig. 32-5 Arm removing posture

(3) Disconnect the 2 hoses connected to the bucket cylinder (1). Then apply plugs to the openings. : 27 mm (4) Lift up the arm cylinder body with a nylon sling in order not to exert any load to the pin (E). (5) Remove the capscrew and nuts that are preventing the pin (E) from coming out. Then remove the pin (E) and shims. : 19 mm (6) Placing a square timber under the arm cylinder, get down the cylinder. (7) Install the pin (E) to the original position, and install the capscrew and nuts that prevents the pin (E) from coming out. Applying a rope to the pin (E) and the arm tip, slightly lift it up in order not to exert any load to the pin (F).

Fig. 32-6 Sectional view of Installing pin

(8) Remove the capscrew that is preventing the pin (F) connecting the arm and boom, from coming out. Then pull off the pin (F).

: 36 mm (9) Remove the arm assembly paying attention to the stability of arm. Weight of arm assembly: approximately 164 kg - E45B SR (1.43 m) 179 kg - E45B SR (1.70 m) 175 kg - E50B SR (1.56 m) 205 kg - E50B SR (1.87 m), E55B

Fig. 32-7 Removal of boom assembly

32-4

32. ATTACHMENT (10) Removal of bucket cylinder (1) 1) Remove the capscrew that is preventing the rod pin (H) from coming out, then pull off the pin (H). : 24 mm 2) Remove the capscrew and nuts that are preventing the head pin (G) from coming out, then pull off the pin (G). : 17 mm

Fig. 32-8 Sectional view of Installing pin K. Shim W. Shim

3) Apply a nylon sling to the tube of bucket cylinder, and remove the cylinder. Weight: approximately 27 kg 32.1.3.2

INSTALLATION OF ARM

Installation is performed in the reverse order of removal, including the following workings.

CAUTION At the alignment of pin positions, never insert your finger into the pin holes. Make sure to align them with visual confirmation. (1) Make the welded area clean to inspect any cracks there.

(2) Check the dust seal (Q) for damages, and replace the faulty dust seal to new one (referring to Fig. 32-9 for the installing procedures). (3) Referring to the Section â&#x20AC;&#x153;ATTACHMENT DIMENSIONSâ&#x20AC;? of Specifications, replace the worn-out pin and bushing to new ones.

(4) Before installing the pin, apply grease to the shaft area. (5) Referring to Fig. 32-10, install the capscrews and nuts to prevent the pin from coming out. : 19 mm, 24 mm, 36 mm (6) Make sure to provide an appropriate clearance for thrust direction at the installation of pin referring to Fig. 32-10.

Fig. 32-9 Dust seal installation Q. Seal ring P. Boss R. Bushing

(7) For the adjustment for clearance, insert resin (plastic) shim first, then adjust the clearance with steel shims.

32-5

32. ATTACHMENT G H E

1.0รท1.5

W (H)

(G)

(F)

(E)

Fig. 32-10 Sectional view of installing pin K. The total clearance must be between 0.5 mm and 0.9 mm after adjusting the shims

S. The total clearance must be 0.5 mm or less after adjusting the shims

W. The total clearance must be between 0.1 mm and 0.5 mm after adjusting the shims

J. The total clearance must be between 0.6 mm and 1 mm after adjusting the shims

X. Total clearance must be between 0.1 mm and 0.5 mm after adjusting the shims

32-6

32. ATTACHMENT 32.1.4 32.1.4.1

BOOM REMOVAL OF BOOM

(1) Get down the boom from which the arm was removed, and support the boom end with a stable stand.

(2) Disconnect all hoses from the bucket cylinder, arm cylinder and boom cylinder, and apply plugs to all the openings.

A C

: 27 mm

(3) Disconnect the wiring for working light at the connector. (4) Removal of boom cylinder 1) Temporarily lift up the boom cylinder with a nylon sling to prevent the boom cylinder from falling down.

Fig. 32-11 Removal of boom assembly

2) Removing the capscrew and nuts that are preventing the rod pin (C) from coming out, remove the pin (C). : 19 mm 3) Retract the rod, then put the cylinder on a stable stand.

Fig. 32-12 Sectional view of Installing pin

4) Removing the capscrew that is preventing the head pin (B) from coming out, remove the pin (B).

5) Remove the boom cylinder. Weight: 46 kg - E45B SR 57 kg - E50B SR - E55B

(5) Removal of boom 1) Temporarily lift up the boom assembly in order not to exert any load to the boom foot pin (A). Weight of arm assembly: approximately 223 kg - E45B SR 273 kg - E50B SR - E55B

Fig. 32-13 Removal of boom assembly

2) Removing the capscrew that is preventing the boom foot pin (A) from coming out, pull off the pin (A). : 19 mm 3) Applying a sling to the boom assembly, remove the boom assembly.

32-7

32. ATTACHMENT (6) Removal of arm cylinder 1) Removing the capscrew and nuts that are preventing the head pin (D) from coming out, remove the pin (D). : 19 mm

(D)

2) Applying a nylon sling to the tube of arm cylinder, remove the arm cylinder. Weight: 42 kg - E45B SR 50 kg - E50B SR - E55B 32.1.4.2

(A)

Fig. 32-14 Sectional view of Installing pin

INSTALLATION OF BOOM

Installation is performed in the reverse order of removal, including the following.

CAUTION At the alignment of pin positions, never insert your finger into the pin holes. Make sure to align them with visual confirmation.

(1) Make the welded area clean to inspect any cracks there.

(2) Check the dust seal for damages, and replace the faulty dust seal to new one (referring to Fig. 32-15 for the installing procedures). (3) Referring to the Section â&#x20AC;&#x153;ATTACHMENT DIMENSIONSâ&#x20AC;? of Specifications, replace the worn-out pin and bushing to new ones.

(4) Before installing the pin, apply grease to the shaft area. (5) Referring to Fig. 32-16, install the capscrew and nuts to prevent the pin from coming out. : 19 mm (6) Make sure to provide an appropriate clearance for thrust direction at the installation of pin referring to Fig. 32-16. 32-16.

Fig. 32-15 Dust seal installation Q. Seal ring P. Boss R. Bushing

(7) For the adjustment for clearance, insert resin (plastic) shim first, then adjust the clearance with steel shims.

32-8

32. ATTACHMENT

1.0รท1.5

Fig. 32-16 Sectional view of installing pin W. The total clearance must be between 0.5 mm and 0.9 mm after adjusting the shims

S. The total clearance must be between 0.5 mm and 1 mm after adjusting the shims

K. The total clearance must be between 0.1 mm and 0.5 mm after adjusting the shims

Z. Apply Loctite #262

32-9

32. ATTACHMENT 32.1.5 32.1.5.1

SWINGING PREPARATION FOR REMOVAL

(1) To make the removing work easy, swing by around 30Â° for leftward. (2) Disconnect all hoses from the bucket cylinder, arm cylinder and boom cylinder, and apply plugs to all the openings. : 27 mm 32.1.5.2

REMOVAL OF SWING BRACKET AND CYLINDER

(1) Removal of swing bracket (A9)

C11

1) Removing the capscrew (C4) that is preventing the rod side pin (M) of swing cylinder (C11) from coming out, remove the pin (M).

: 19 mm

2) Install the boom foot pin (A) to the original position on swing bracket (A9), then temporarily lift it up.

3) Removing two capscrews (B8) (B9) those are preventing the pins (L1) (L2) from coming out, remove the pins (L1) (L2). : 19 mm

4) Remove the swing bracket (A9) Weight of swing bracket: 112 kg (2) Removal of Swing Cylinder (C11) 1) Disconnect 2 connecting hoses for the swing cylinder.

A A9

: 22 mm

2) Removing the capscrew (C5) that is preventing the head side pin (N) of swing cylinder from coming out, remove the pin (N). : 19 mm

3) Take out the swing cylinder (C11) from the front side. Weight of Swing Cylinder: 39 kg

A9 L1

Fig. 32-17 Swing portion

32-10

32. ATTACHMENT 32.1.5.3

INSTALLATION OF SWING BRACKET AND CYLINDER

Installation is performed in the reverse order of removal, including the following workings. (1) Check the dust seal for damages, and replace the faulty dust seal to new one. (2) Referring to the Section “ATTACHMENT DIMENSIONS” of Specifications, replace the worn-out pin and bushing to new ones. (3) Before installing the pin, apply grease to the shaft area. (4) Refer to Fig. 32-18 for the shim adjustment at pin installing portion. T

A A C

C-C

1.0÷1.5

Z Z

A-A

B-B Fig. 32-18 Sectional view of installing pin

S. Total clearance must be lower than 0.5 mm after adjusting the shims

W. The total clearance must be between 0.5 mm and 0.9 mm after adjusting the shims

T. Set this shim with the oil groove side positioned downward

Z. Apply Loctite #262

32-11

32. ATTACHMENT 32.1.6 32.1.6.1

BLADE REMOVAL

(1) Put a support (1) of appropriate height under the mounting side of dozer body, and make the dozer at a stable condition not to exert any load to the pin (P). (2) Disconnect the hydraulic hoses and apply a plug to the connecting portions. : 22 mm (3) Apply a nylon sling to the dozer cylinder (C1), and lift it up slightly not to exert any load to the pin (Q) of rod side.

B2, B3

Q C3, C4 C1

(4) Remove the capscrew (C3) and nuts (C4) that are preventing the pin (Q) from coming out, of rod side. Remove the pin (Q), and support (1) the cylinder (C1) with a wood block, etc.

: 19 mm (5) Remove the capscrew (B2) and nuts (B3) that are preventing the dozer body fixing pin (P) from coming out, and remove the two pins (P). (6) Gradually move the machine to backward to remove the dozer. Weight of blade (without cylinder): 170 kg - E45B SR 180 kg - E50B SR - E55B

Fig. 32-19 Removing/Installing of blade

(7) If necessary, remove the dozer cylinder by means of removing the pin (R) of head side. Weight of dozer cylinder: 27 kg 32.1.6.2

INSTALLATION

The installation is carried out with the reverse order of the removal paying attention for the following. (1) Referring to the Section â&#x20AC;&#x153;ATTACHMENT DIMENSIONSâ&#x20AC;? of Specifications, replace the worn-out pin and bushing to new ones. (2) Before installing pin (P), (Q) and (R), apply grease to their shaft area. (3) Referring to Fig. 32-20, install the nuts (2) for capscrew (3) to prevent the pin from coming out. : 19 mm Fig. 32-20 Tightening procedures for nuts

32-12

32. ATTACHMENT

32.2

DISASSEMBLY AND ASSEMBLY

32.2.1

CYLINDER

32.2.1.1

NECESSARY TOOLS

Though the required tools and jigs differ in types of cylinder, as a guide line, tools and jigs to be prepared are shown in Table 32-1. Tool/Jig Hammer

Observations 1. Steel hammer 2. Wooden or plastic hammer

Screwdriver

Several kinds of minus driver of small and large sizes

Chisel

Flat chisel

Vise

Capable to hold outer diameter of cylinder head and tube installing pin portion.

Tool/Jig

Observations

Gimlet

Sharp-point tool may be used in place of gimlet 1. For press-fitting the cylinder rod bearing (A)

Mask

2. For press-fitting bushing (B) 3. For press-fitting dust seal (C) 4. For reforming seal ring (D) 1. Slide calipers

Wrench

1. Spanner, Plier, Torque wrench 2. Extension pipe for wrench

Measuring device

2. Micrometer 3. Cylinder gauge 4. V-block

•

For the details of special jigs, refer to the end of this section.

32.2.1.2

GENERAL PRECAUTIONS

•

Carry out the disassembly and assembly works in a clean work shop, and always keep disassembled parts at clean conditions.

•

Prior to disassembly, thoroughly clean the cylinder externally.

•

Use caution not to give any damages to the parts while carrying out the disassembly / assembly works.

•

Thinly apply grease or hydraulic oil to seals prior to installation.

•

After the installation of O-ring, confirm there is no twist on it.

•

Apply clean hydraulic oil to each sliding portion before the installation.

•

Ensure each sliding portion for no burr and defect, and its smooth sliding operation.

•

This manual describes mainly for the boom cylinder as an typical example. Refer to 24.1.8 of SYSTEM COMPONENTS for the construction parts of the hydraulic cylinders when disassembling and reassembling the cylinders.

32-13

32. ATTACHMENT 32.2.1.3 â&#x20AC;¢

CYLINDER CONSTRUCTION (EXAMPLE OF BOOM CYLINDER)

See 24.1.8 CYLINDERS for other cases. 22

Fig. 32-21 Construction of boom cylinder No.

NAME

Q.TY

No.

NAME

Q.TY

Cylinder liner

Ring

Cylinder rod

Bushing

Seal ring

Cylinder head

Back-up ring

Cushion bearing

Dust seal ring

Piston

O-ring

Pipe

Back-up ring

Locknut

O-ring

Wear ring

Dust seal ring

Seal ring

Edge bolt

Seal ring

32-14

32. ATTACHMENT 32.2.1.4 •

DISASSEMBLY

The numbers in ( ) following to each part name are the Items corresponding to those in Fig. 32-21 unless otherwise noted.

(1) Disassembly of cylinder assembly 1) Fix the clevis portion of tube with a vice, and hold the other end with a wooden stand to hold the cylinder in level. 2) Drain hydraulic oil remained in the cylinder. • Slowly move the rod so that the hydraulic oil does not spray out.

Fig. 32-22 Disassembling cylinder assembly 3) Make straight the locking fin for the cylinder head (4). • Use cautions bending / straightening of locking fin, because locking fin and cylinder tube are made with one-piece. 4) Loosen the cylinder head (4). • Prior to loosening the cylinder head, extract the cylinder rod (2) by 100 ÷ 200 mm. • Cover the rod with an appropriate material to prevent it from unexpected dents. 5) Pull off the cylinder rod assembly from the tube.

Fig. 32-23 Disassembling cylinder assembly

• Pull the cylinder rod in straight not to give any damages on the sliding surface.

Fig. 32-24 Disassembling cylinder head (2) Installation of cylinder rod disassembly 1) Fix the cylinder rod assembly in level.

Fig. 32-25 Disassembling cylinder rod

32-15

32. ATTACHMENT 2) Remove ring (25) using snap ring pliers, and remove plate ring (24) and cushion ring (23). (Only for arm cylinder). â&#x20AC;˘ If cushion bearing (23) is left, the lock nut cannot remove. Remove cushion bearing before loosening lock nut (9).

3) Loosen lock nut (9) by means of torque wrench, and remove lock nut (9).

4) Remove piston (6).

32-16

32. ATTACHMENT 5) Remove cushion bearing (5). (Only for boom cylinder and arm cylinder)

6) Remove seal ring (12). (Only for boom cylinder and arm cylinder) • Expand the split on the seal ring as minimum as required to remove.

7) Remove the cylinder head (4). • Pull out the piston rod straightly not to give any damages on the rod surface.

(3) Disassembly of cylinder assembly

1) Remove the wear ring (10) from the piston (6). • Expand the split on the wear ring (10) as minimum as required to pull it off for axial direction. (Two points) 2) Remove the seal ring assembly (11). • Cut the piston seal ring (11) or remove it using a screwdriver.

Fig. 32-26 Disassembling piston assembly

32-17

32. ATTACHMENT (4) Disassembly of cylinder head assembly 1) Remove the O-rings (18), (20) and back-up ring (19) from the outer periphery of cylinder head (4).

Fig. 32-27 Disassembling cylinder head assembly 2) Removal of seal ring Remove the seal ring (15) and back-up ring (16).

Fig. 32-28 Disassembling cylinder head 3) Remove the dust seal ring (17). â&#x20AC;˘ Alternately tap inside of the metal ring of dust seal at several positions, as shown in the figure, to push it out step by step from the groove.

Fig. 32-29 Removing wiper ring 4) Remove the ring (13) using a gimlet and remove bushing (14) using a screw driver. â&#x20AC;˘ Take care to damage the head portion.

Fig. 32-30 Removing bushing

32-18

32. ATTACHMENT (5) Disassembly of clevis portion: 1) Remove the seal ring (21) from the clevis portion of cylinder tube (1) and the cylinder rod (2).

Fig. 32-31 Removing dust seal 2) Remove the pin (3). â&#x20AC;˘ Using a metal block (28), push it out with a press machine. 28

Fig. 32-32 Removing bushing

32-19

32. ATTACHMENT 32.2.1.5

ASSEMBLY

(1) Assembling clevis portion 1) With the installing jig (B), press-fit the bushing (3) into the cylinder rod (2) and the cylinder tube (1). • Before beginning working, apply hydraulic oil on the surface of parts.

B 3

Fig. 32-33 Installing pin bushing (3) 2) With the setting tool (29), install the dust seal ring (21). 29

Fig. 32-34 Install the dust seal ring z

(2) Assembling cylinder head 1) With installing jig (A), press-fit the bushing (14) and install ring (13). • Prior to the work, apply hydraulic oil on inner periphery of the cylinder head (4). • At press-fitting the bushing (14) into the cylinder head (4), make the top surfaces of them in level without step.

Fig. 32-35 Installing cylinder head 2) Install the back-up ring (19) and O-rings (18) and (20).

Fig. 32-36 Installing back-up ring and O-ring

32-20

32. ATTACHMENT 3) Installing seal ring Install the back-up ring (16) and seal ring (15).

Fig. 32-37 Installing seal ring 4) With the setting tool (C), install the dust seal ring (17).

Fig. 32-38 Install the dust seal ring (3) Assembly of piston portion: 1) Install the O-ring for the seal ring (11). In this case, stretch the O ring as minimum as required to install.

2) Install wear ring (10) for piston from rod side. (2 places) â&#x20AC;˘ Expand the split of wear ring as minimum as required.

32-21

32. ATTACHMENT 3) The O-ring of seal ring was extremely stretched at the installation, insert the piston subassembly (E) from the taper side of reforming jig (D) to reform the ring.

(4) Cylinder rod assembly 1) Keep clevis of cylinder rod (2) horizontal, and install the head sub-assembly (F). • Apply a light coat of hydraulic oil to the seal ring.

• Take care not to hit the seal against the thread of piston. F

2) Face the slit of seal ring (12) to the thread, and install the seal ring into groove of rod. Install the cushion bearing (5) on the rod from taper (G) side as shown in the photo.

• Take care of the direction of seal ring and cushion bearing. If the direction is mistaken, the cushion effect is not obtained.

G 5

32-22

32. ATTACHMENT 3) Install the piston sub-assembly (E) and lock nut (9).

• Insert the piston from the flat side of piston bore.

4) Tighten the lock nut (9) with torque wrench (I). Refer to the table of torque in the maintenance standard about the tightening torque for lock nut. I

5) Install the cushion bearing (23) of rod retracting side, plate ring (24) and ring (25). (Arm cylinder only)

• Place the flat portion (L) (2 places) of cushion bearing (23) toward the direction as shown in the right photo. • Confirm that the cushion bearing is movable after ring fixing. 25 23

(5) Assembly of cylinder: 1) Fix the tube in level, and install the rod assembly into it. • Upon installation, align the centre of the rod to the centre of the tube and install the rod in a straight position, paying attention not to damage the seal rings.

Fig. 32-39 Inserting cylinder rod assembly

32-23

32. ATTACHMENT 2) Loosen the cylinder head (4). â&#x20AC;˘ Apply hydraulic oil to the seal rings before installing them. â&#x20AC;˘ Tightening torque for cylinder head: See 32.2.1.6 (4) in MAINTENANCE STANDARDS .

Fig. 32-40 Installing cylinder head 3) Bend the locking fin on the tube to lock the cylinder head.

Fig. 32-41 Assembling cylinder assembly 32.2.1.6

MAINTENANCE STANDARD

(1) Inspection after disassembly 1) Inspection item Parts name Cylinder rod

Cylinder liner

Cylinder head

1. 2. 3. 4. 5.

Inspecting Portion Neck of rod Stepped part to which piston is attached Threads Bend Plated surface

Inspection item Presence of crack Presence of crack Presence of seizure, etc. Measure amount of bend 1. Plate wear 2. Rust 3. Defect

4. 5. 1. 2. 3. 4. 1.

Rod Bushing at mounting part Welded part of bottom Tube at mounting part Tube inside Bushing at mounting part Bushing

Wear of outside Wear of inside Presence of crack Presence of crack Defect Wear of inside 1.Wear of inside 2.Defect of inside

Remedy Replace Replace Recondition or replace Refer to rod bend 1. Replacement 2. Replacement 3. Recondition or replace Recondition or replace Replace Replace Replace Replace if oil leak is seen Replace Replace

(2) Repair procedure Replace sliding parts and seals according to the following references: 1 2 3 4

Bushing Seals and slide rings Pin bushing Rod

Where 1/4 of circumference is worn in copper colour. Replace them when cylinder is disassembled. Where severe scuffing is appeared. Where the bent 0.5 mm/m or more is appeared.

32-24

32. ATTACHMENT (3) Service limits Service limits represent the limits of wear on the sliding surfaces of the cylinder tube and the piston rod that have no such faults 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 0.25 mm (0.009 in). 2) Bend of piston rod The allowable bend of the rod is maximum 0.5 mm /1m (0.02 in / 3.3ft). For measurement, support both ends of the parallel section of the piston rod with V-blocks, set a dial indicator in the center between the two Vblocks turn the piston rod, and read the difference between the maximum and minimum values on the dial indicator. â&#x20AC;˘

Even if the bend is within the allowable limit, the cylinder may not operate smoothly because of localized bend. Beware of it during function test after installation. Replace the rod if the cylinder makes a squeaking noise or dose not operate smoothly.

Distance between Deflectional value V-blocks (V) of the dial gauge

Remedy

Replace

1/2

Fig. 32-42 Measuring method

(4) Tightening torque A. Cylinder head B. Piston assy

Unit: Nm Model

E45B SR

E50B SR E55B

Cylinder

Cylinder head A

Piston B

Boom

550

1500

Digging

420

1500

Bucket

390

830

Swing

550

1520

Dozer

600

1520

Boom

650

1860

Digging

550

1500

Bucket

390

830

Swing

550

1520

Dozer

600

1520

32-25

32. ATTACHMENT (5) Inspection after installation G

1) Unloaded performance test

a. Put the cylinder horizontally at unloaded condition.

F H

b. Apply pressure slowly and alternately through the ports at both ends to operate the piston rod 5 or 6 times. c. Check that the cylinder operates normally.

Fig. 32-53 Unloaded test E. Pump F. Tank G. Control valve H. Hydraulic cylinder

2) Leakage test •

External leakage.

a. Apply test pressure for 3 minutes each to the rod retraction side and to the rod extension side of the cylinder.

E F

b. Confirm that rod seals, cylinder head tightening part, and each weld are free from abnormalities, such as external leakage and permanent deformation. •

Fig. 32-54 Leakage test

Internal leakage

a. Disconnect the hose from the rod extension side of the cylinder.

E. Pump

b. Apply test pressure to the rod retraction side of the cylinder for 3 minutes.

G. Control valve

c. Measure the leakage from the rod extension side.

•

F. Tank H. Hydraulic cylinder Internal leakage

Leakage should be below 1 cc/min.

(6) Bleeding air from hydraulic cylinder Bleed air from the cylinder after removing or installing it, or after disconnecting a hydraulic pipe. 1) Start the engine, and let it idling for about 5 minutes. 2) Repeat the step of extending and retracting the cylinder 4 or 5 times at slow speed of engine. •

Move the piston rod 100 mm short of its stroke end. Do not extend or retract the rod until the end to prevent the relief condition.

3) Perform the above 2 procedures at high idling speed, then move the piston rod to its stroke end at low idling speed to reach the relief condition.

32-26

32. ATTACHMENT 32.2.1.7

JIG LIST

(1) Installing Jig (A) for Press Fitting of Rod Bushing. Applicable cylinder E45B SR

E50B SR - E55B

(Rod diameter; ØA45) Bucket (Rod diameter; ØA50) A

Boom Swing (Rod diameter; ØA55) Boom Dozer

(2) Install jig (B) for press-fitting the pin bushing. Applicable cylinder E45B SR

E50B SR - E55B

(Pin diameter; ØB45) Bucket Digging B

(Pin diameter; ØB50) Boom Swing (Pin diameter; ØB55) Dozer

32-27

32. ATTACHMENT (3) Installing Jig (C) for press fitting of dust seal Applicable cylinder E45B SR

E50B SR - E55B

(Rod diameter; ØC45) Bucket (Rod diameter; ØC50)

Boom Digging (Rod diameter; ØC55) Boom Dozer

(4) Reforming Jig (D) for Seal Ring (18) Applicable cylinder E45B SR

E50B SR - E55B

(Rod diameter; Ø75) Bucket (Rod diameter; Ø80) Digging (Tube diameter; Ø90) Boom Digging

A (Tube diameter; Ø95) Dozer (Tube diameter; Ø100) Boom

32-28

32. ATTACHMENT 32.2.1.8

POSSIBLE CAUSES FOR TROUBLE AND REMEDY

Trouble Conditions

Major possible causes

Remedy

• Foreign matter is caught by U-ring or • Remove foreign matter. wiper ring at its inside periphery. • Scuffing or fault on O-ring or wiper ring at • Replace each part with new one. its inside periphery. Oil leakage from sliding face • Scuffing on sliding face of piston rod. of piston rod. (A ring shape oil is formed on piston rod and enlarged resulting dripping down of oil).

• Grind sliding face with a fine oil stone. (less than 1.6S). • If leakage is not stopped by grinding, replace seals such as Uring, etc. with new ones. • If leakage is not stopped by replacing seals, replace piston rod.

• Peeling off of hard chrome plating. Oil leakage from outer • Damage to the O-ring. periphery of cylinder head. • Damages on back-up ring. Oil leakage portion.

from

welded • Damages on welded portion on tube.

Piston movement due to • leakage. (In case a static load • equivalent to the product of the multiplication between the • max. working pressure and the cylinder area is applied to • the rod, the maximum movement of the piston is larger than 0,5 mm (0.019 in) for 10 minutes).

• Re-plating of hard chrome on piston rod. • Replace. • Replace. • Replace.

Foreign matter is caught by sliding face of • Remove foreign matter. slide ring. Scuffing or faulty condition on sliding face • Replace. of slide ring. Scuffing on sliding face of seal ring • Replace. assembly. Damage to the O-ring.

32-29

• Replace.

32. ATTACHMENT

[NOTES]

32-30

33. SLEWING UPPER STRUCTURE TABLE OF CONTENTS 33.1 REMOVING AND INSTALLING ...................................................................... 33-1 33.1.1 CANOPY / CAB ..................................................................................... 33-1 33.1.2

GUARD (COVER) ................................................................................. 33-3

33.1.3

FLOOR PLATE ASSEMBLY ................................................................. 33-5

33.1.4

BATTERY .............................................................................................. 33-7

33.1.5

COUNTERWEIGHT .............................................................................. 33-8

33.1.6

PUMP .................................................................................................... 33-9

33.1.7

CONTROL VALVE .............................................................................. 33-11

33.1.8

SOLENOID VALVE ............................................................................. 33-15

33.1.9

FUEL TANK ........................................................................................ 33-16

33.1.10 HYDRAULIC OIL TANK ...................................................................... 33-20 33.1.11 AIR CLEANER .................................................................................... 33-23 33.1.12 ALTERNATOR .................................................................................... 33-24 33.1.13 SILENCER .......................................................................................... 33-25 33.1.14 CONTROL STAND ............................................................................. 33-26 33.1.15 STARTER MOTOR ............................................................................. 33-31 33.1.16 RADIATOR .......................................................................................... 33-32 33.1.17 ENGINE .............................................................................................. 33-34 33.1.18 PILOT VALVE ..................................................................................... 33-36 33.1.19 SWING MOTOR .................................................................................. 33-38 33.1.20 ROTARY CONTROL VALVE .............................................................. 33-40 33.1.21 UPPER FRAME .................................................................................. 33-43 33.2 DISASSEMBLY AND ASSEMBLY ................................................................ 33-45 33.2.1 HYDRAULIC PUMP ............................................................................ 33-45 33.2.2

CONTROL VALVE .............................................................................. 33-69

33.2.3

ATTACHMENT CONTROL VALVE .................................................... 33-87

33.2.4

TRAVEL CONTROL VALVE ............................................................... 33-96

33.2.5

SWING MOTOR ................................................................................ 33-101

33.2.6

ROTARY CONTROL VALVE ............................................................ 33-124

33. SLEWING UPPER STRUCTURE

33.1

REMOVING AND INSTALLING

33.1.1

CANOPY / CAB

33.1.1.1

CANOPY REMOVAL

(1)

Remove the floor mats (5) and (8).

(2)

Removing handrail (A3) Loosen the sems-screws M16x65 (A4) and M16x100 (A5) to remove the handrail (A3). : 24 mm

(3)

Removing canopy assembly 1) Disconnect the light harness (B1) that runs inside the support (A1) and is connected to the main harness with a connector. Fig. 33-1 Floor mat removal

2) Loose one capscrew M10x40 (A8) and four capscrews M12x55 (A7) to remove the canopy. : 17 mm and 19 mm Canopy weight: 85 kg (4)

A1 B2

Install the canopy in reverse order of the removal. Tighten the capscrews at the torque specified below: M10: 46 Nm M12: 79 Nm M16: 191 Nm

A2 A8 A3 A5 A4

Fig. 33-2 Removal of canopy assembly and handrail C. Harness outlet 33.1.1.2 33.1.1.2.1

CAB REMOVAL (Option) Cab removal preparation

(1)

Remove the floor mats (6) and (7).

(2)

Removing cab harness connector 1) Respectively disconnect 6P connectors of cab harness and cab connecting harness, 2P connector of washer motor, 3P connector of radio (optional) and so on. (See ELECTRICAL SYSTEM)

Fig. 33-3 Floor mat removal

33-1

33. SLEWING UPPER STRUCTURE 33.1.1.2.2

Cab removal

(1)

Remove the fuel filler cap (A2) and rubber cover (20).

(2)

Removing cover installed on rear of cab Loosen three sems-screws M6x25 (12) for installing the cover (B1). : plus screwdriver

(3)

Removing cab mounting screws Loosen six capscrews for mounting the cab. Two capscrews (1) M16x100 One capscrew (2) M16x50 Three capscrews (3) M12x50

: 19 mm and 24 mm â&#x20AC;˘

An extension tool about 1 m long is required for removing the capscrew item 1 (with mark *).

B1 12 A2 20

VIEW B Fig. 33-4 Outside of cab (4)

Lifting cab 1) Loosen the sems-screws M10x20 (C6) to remove the seat belt assembly (C2) in advance to prevent it from interfering with the cab during lifting. : 17 mm

2) Put slings through the lifting eyes on the cab top and lift up. Cab weight: 220 kg

Fig. 33-5 Cab assembly fastening positions D. Adjust the clearance between guard and cab rear bracket with shims (t 1,2, 2,0, 3,2)

33-2

33. SLEWING UPPER STRUCTURE (5)

Cab mounting Install the cab in reverse order of the removal. â&#x20AC;˘

In the fastening position of the capscrew (3), it is necessary to adjust the clearance with shims as shown in Fig. 33-5. Tighten screws to the torque specified below. M6: 4.4 Nm M10: 46 Nm M12: 79 Nm M16: 191 Nm

C2 C6

Fig. 33-6 Seat belt assembly removal 33.1.2 33.1.2.1 â&#x20AC;˘

GUARD (COVER) REMOVAL Fig. 33-7 shows the method for removing the cover of the canopy.

1 6

2 35

3 5 Fig. 33-7 Cover removal (1)

Removing bonnet assembly (3) Unlock and open the bonnet assembly (3). Loosen two sems-bolts M12x35 (35) of the hinge section (3-9) to remove the bonnet (3).

3-9

: 19 mm

35 3 Fig. 33-8 Bonnet assembly (3) removal

33-3

33. SLEWING UPPER STRUCTURE (2)

Removing cover assembly (5) Loosen three sems-screws M8x25 (33) to remove the cover assembly (5).

33 33

: 13 mm

5 33

Fig. 33-9 Cover assembly (5) removal (3)

Removing cover assembly (1)

1-8

1) Unlock the lock assy (1-8) to open the cover assembly (1). 2) Loosen four sems-screws M16x(50) to remove the cover assembly (30). : 24 mm

Fig. 33-10 Removing cover assemblies (4) and (5) (4)

Removing cover assembly (2) Loosen three sems-screws M10x25 (37) to remove the cover assembly (2).

: 17 mm (5)

Removing cover assembly (4) Loosen two M10x25 sems-screws (37) and two M14x30 (4) to remove the cover assembly (4). : 17 mm

2 37

(6)

Removing guard assembly (6)

1) Loosen two sems-screws (35) M12x35 and three sems-bolts (40) M10x20 and remove the guard. : 17 mm, 19 mm

(7) Removing cover assembly (9) 1) Loosen one sems-screws (40) M12x20 and remove the cover.

: 17 mm

Fig. 33-11 Cover assemblies (2) and (4) removal

33-4

33. SLEWING UPPER STRUCTURE 33.1.2.2

Assembly

Install the battery in reverse order of the removal. Tighten the capscrews to the torque specified below: M8: 24 Nm M10: 46 Nm M12: 79 Nm M16: 191 Nm 33.1.3

FLOOR PLATE ASSEMBLY

Remove floor plate together with the travel pilot valve assembly and the swing pedal in one piece. 33.1.3.1

FLOOR PLATE REMOVAL PREPARATION

(1)

Remove the floor mats (5) and (8). (See Section 33.1.1).

(2)

Remove the canopy or cab. (See Section 33.1.1).

(3)

Remove the covers (2) and (4) as well as the plates (3). : 13 mm

(4)

Remove the cover assembly (4) of the deck under the floor [See Section 33.1.2.1-(4)].

(5)

Disconnect electrical wiring for travel 2-speed selector switch from the connector portion. Fig. 33-12 Cover assembly (2) removal The figure is not for the standard canopy.

CAUTION In advance, disconnect the minus terminal of the battery to prevent danger of short circuit, etc. (6)

Removing travel pilot piping (prior to this work, release the pressure in the piping) Disconnect hoses of the travel pilot valve (A10) at the valve side position marked with * and then plug their openings. â&#x20AC;˘

A10

Attach a tag recording the valve connecting port to each of the disconnected hoses. For installation, tighten the hose fittings at the following torque:

A2 S/V

Tightening torque Nm Thread size Spanner used O-ring type (PF) (mm) fitting 1/4 19 26.5

30Â° flare type fitting 29.4

Pb6 Pa6 C/V C/V

Pb7 C/V Pa7 C/V

Fig. 33-13 Pilot piping disconnection NOTE: take care of the tightening torque as the pilot valve is made of aluminum.

33-5

33. SLEWING UPPER STRUCTURE (7)

Removing cable of swing pedal B4

1) Loosen four M8x20 sems-screws (B11) to pull out the support (B1) upward.

B11

: 13 mm

2) Pull out the pin (B6) and loosen the adjusting nut (B2) to disconnect the control cable (B4).

123

Fig. 33-14 Swing cable disconnection (8)

Removing of nibbler and breaker piping from solenoid valve (prior to this work, release the pressure in the piping) Disconnect hoses of the solenoid valve (1) at the valve side position marked with * and then plug their openings. â&#x20AC;˘

Attach a tag recording the valve connecting port to each of the disconnected hoses. For installation, tighten the hose fittings at the following torque: Tightening torque Nm Fig. 33-15 Pilot piping removal

Thread Spanner used Fitting type 30Â° flare type size (PF) (mm) O-ring fitting 1/4 19 36.3 29.4

NOTE: take care of the tightening torque as the pilot valve is made of aluminum.

33.1.3.2 (1)

FLOOR PLATE REMOVAL

Remove the M8x20 sems-bolts (6). : 13 mm

(2)

Remove the floor plate assembly (1). 1

Fig. 33-16 Floor plate (1) removal The figure is for the standard 33.1.3.3 (1)

ASSEMBLING FLOOR PLATE

Assemble the floor plate in reverse order of the disassembly. Sems-screws (6) M8: : 13 mm Tightening torque: 23.5 Nm

33-6

33. SLEWING UPPER STRUCTURE 33.1.4 33.1.4.1

BATTERY PREPARATION FOR REMOVAL

(1)

Remove the floor mats (5) and (8).

(2)

Remove cover (4).

(3)

Remove the cover assembly (5) on the left lower side

Fig. 33-17 Floor section removal preparation 33.1.4.2

REMOVAL

(1)

Unclip and remove the rubber (5).

(2)

Disconnect the negative side terminal of the cable

(3)

Then, disconnect the positive side terminal of the cable

: 12 mm

CAUTION Follow the removal procedure of battery cable. Firstly disconnect the grounding side cable. Connect the grounding side finally. Failure to do so may result in dangerous situation due to spark.

A3 A2 A1

(4)

Loosen the M8 nut (A3) to remove the plate (A2) and the rod (A1).

Fig. 33-18 Battery removal

: 13 mm (5)

Take out the battery (B1) holding the straps attached to it.

33.1.4.3

INSTALLATION

Install the battery in reverse order of the removal. Nut (7) M8: : 13 mm Tightening torque: 3.5 Nm

33-7

33. SLEWING UPPER STRUCTURE 33.1.5 33.1.5.1 (1)

(2)

PREPARATION FOR REMOVAL

Remove the cover assemblies (1), (3), (4), (5), (9) and guard assembly (6) as well as the bonnet assembly (3) (See Section 33.1.2).

A A

Lifting tools preparation •

Lifting jigs for counterweight (C) (See tool list)

•

Two M20x35 screws (A)

•

Wire rope (Nylon sling (B))

33.1.5.2 (1)

COUNTERWEIGHT

REMOVAL

Remove the plate (B7) and attach the lifting jigs for counterweight.

(2)

Put a rope through the lifting lugs and temporarily lift up the counterweight so that the rope is not slack. Counterweight weight: 270 kg for E45B SR 580 kg for E50B SR 929 kg for E55B

(3)

Loosen three M20x70 capscrew (B1)

B7 B7 A1

: 30 mm (4)

Remove the shims (B3), (B4) and (B5).

(5)

Remove counterweight (A1).

B3 B4 B5

B3 B4 B5 B1 B2

B1 B2 Fig. 33-19 Counterweight removal 33.1.5.3

INSTALLATION

(1)

Install the counterweight in reverse order of the removal.

(2)

Reinstall the shims (B3), (B4), and (B5).

(3)

Lifting counterweight Make sure that all the three fixing bolts can be manually screwed.

(4)

Apply Loctite #262 on the capscrews (B1) and tighten them together with the washer (B2). : 30 mm Tightening torque: 373 Nm

(5)

Fig. 33-20 Counterweight installation

Remove lifting jigs.

33-8

33. SLEWING UPPER STRUCTURE 33.1.6 33.1.6.1

PUMP PREPARATION FOR REMOVAL

(1)

Remove the cover assembly (4) and (5) (See Section 33.1.2).

(2)

Remove the counterweight (See Section 33.1.5).

(3)

Depressurize the hydraulic oil tank and drain the hydraulic oil (See Section 33.1.11). •

(4)

B1 B34 A1

Spread a vinyl sheet under the pump to prevent contamination due to oil leakage.

Remove the filler neck (C1) of the fuel supply port to improve workability. Two capscrews M10x20 (C7) Fig. 33-21 Filler neck removal A1.Fuel tank

: 17 mm Tightening torque: 46 Nm 33.1.6.2 (1)

REMOVAL

Disconnecting hoses and fittings connected to the pump •

Attach a tag to each hose for identification.

1) Loosen four M12x35 capscrews (16) to remove the tube (14).

: 10 mm 2) Remove the pilot delivery hose (B25).

: 22 mm

3) Remove the main pump delivery hoses (8), (9) and (10).

: 27 mm (2)

Loosen two M12x30 capscrews (C4) to remove the pump (C8) (See figure 33-23).

: ball joint type 10 mm Pump weight: 35 kg

20 13 B25

Fig. 33-22 Pump removal

33-9

33. SLEWING UPPER STRUCTURE 33.1.6.3

INSTALLATION

Install the pump in reverse order of the removal according to the tightening torque and sealant instructions. (1)

Apply grease to the spline part of the pump input shaft. Grease: M62 or equivalent (Molybdenum disulfide extreme pressure multipurpose grease)

(2)

Insert the pump spline part to the coupling.

(3)

Fix the pump by the capscrew (C4).

C5 C8 C9

: ball joint type 10 mm (4)

Install the main pump delivery hoses (8), (9), and (10), and the pilot delivery hose (B25) (See Fig. 33-22). C4

Tightening torque Nm Thread Spanner used Fitting type size (PF) (mm) O-ring 3/8 22 73.5 1/2 27 108

(5)

30° flare type fitting 49.0 78.5

C10

Tighten the capscrew (19) to install the suction tube (14). : 10 mm

(6)

When the suction hose (12) is removed, apply sealant on the inserted portion of the hose and fix the tube with the clip (20).

Fig. 33-23 Pump installation C4. 85.3 Nm C5. 85 ÷ 94 Nm (63 ÷ 69 lbf•ft) Apply no Loctite as microcapsule coating has been applied. C8. Apply grease C9. Air bleed valve C10. 64.7 Nm (48 lbf•ft) Apply Loctite #262

: minus driver T = 5.4 Nm (7)

Supply the tank with hydraulic oil (approximately 42 litres).

(8)

Loosen the air bleed valve of the pump to release air from the casing, and fill it with hydraulic oil (See Fig. 33-23). : 10 mm

(9)

Reinstall each component removed in the above removal preparation.

(10) After starting the engine, release air (See Section 33.1.10.3).

33-10

33. SLEWING UPPER STRUCTURE 33.1.7

CONTROL VALVE

33.1.7.1

PREPARATION FOR REMOVAL

(1) Unlock and open the right upper cover (1). (2) Remove the right lower cover (4) (See Section 33.1.2.1-(3)). â&#x20AC;˘ Spread a vinyl sheet under the control valve to prevent contamination due to oil leakage. (3) Release the residual pressure in the circuit and the pressure in the hydraulic oil tank. 33.1.7.2

REMOVAL

(1) Disconnecting hoses Disconnect all the hoses connecting to the control valve, and attach blind plugs and tags recording the installation place. â&#x20AC;˘ Remove the return hose to the hydraulic oil tank to improve workability. S/M B

P2 P1

A17

S/J E

A R

A12

S/C R

A18

A15 B3

S/J D S/J C

A14

A11

A10

B9 P A2

8 P A1

S/M A

A20

P A3

A2 S/J F

A13 A3

A19

S/C H

A16 A5

S/J B

A21 A6

S/J A

A17 A7

A9 A8 UR

C/O A9

O/C IN 18 S/M T 21 H/T Fig. 33-24 Main hydraulic hose disconnection C/O. Cooler oil (upper)

S/C. Swing

A. Arm

H/P. Hydraulic pump

S/J. Swivel joint

B. Boom

H/T. Hydraulic tank

S/M. Slewing motor

U. Bucket

33-11

33. SLEWING UPPER STRUCTURE

P/V 5 D5

P/V 1 Pb2

Pb3

A7 P/V 3

Pb6

P/V 7 D7

Pb7

D3 P/V 3 Pb8 Pb9

D1 P/V 1 Pa2 Pa3

P/V 6 D6 D8 P/V 8

Pb6

Pa9

A15 P/V 2

Pa8

P/V 2

D4 P/V 4

D2 P/V 2 Pa8’

Pb1

C/V Pa4C/V Pb4

Pb4

C/V Pa8C/V Pa8’

Pa8 Pa4 Pa1

8 P/V 1 Pa8

Fig. 33-25 Pilot hydraulic hose disconnection C/B. Control block P/V. Pilot valve S/V. Shuttle valve

33-12

Pb7

A8 P/V 4

33. SLEWING UPPER STRUCTURE (2) Disconnecting cable

B14

Turn the rod end (B14) to disconnect the control valve C/V from the swing cable (B4).

B4 C/V

Fig. 33-26 Cable disconnection (3) Removing control valve 1) Loose four M10x50 capscrews (2) and two M12x40 capscrew (13) to remove the control valve (A1) with the bracket (1).

: 17 mm, 19 mm Weight of removed parts: approximately 46 kg 2) Loosen three M10x25 capscrews (4) and one M8x80 to remove the control valve (A1).

11 1

: 13 mm, 17 mm Weight: approximately 35 kg

13 2 3 5

6 9 Fig. 33-27 Control valve removal

33-13

33. SLEWING UPPER STRUCTURE 33.1.7.3

INSTALLATION

(1)

Install the control valve in reverse order of the removal.

(2)

Attach the capscrews (4) and one capscrew (11).

CAUTION

2 1

Clean the mounting surface and take care to prevent deformation of the valve. : 13 mm,17 mm Tightening torque: M8 - 24 Nm M10 - 65.7 Nm (3)

Attach the capscrew (2). : 17 mm, 19 mm Tightening torque: M10 - 65.7 Nm M12 - 79 Nm

(5)

Operate the attachment to check the performance.

(6)

Check the tank and piping for oil leakage and oil level.

T/L B

30Â° flare type fitting 29.4 49 78.5 118 -

Thread Spanner used Fitting type size (PF) (mm) O-ring 1/4 19 36.3 3/8 22 73.5 1/2 27 108 3/4 36 162 1 41 255

D S/C

Tightening torque Nm

A S/E S/O T/R

Tighten the hose fittings to the following torque:

S/T

(4)

Fig. 33-28 Control valve removal A. Arm section B. Boom section D. Dozer section S. Switch S/C. Slewing section S/T. Supply and travel straight S/E. Service section S/O. Swing section T/R. Travel (right) section T/L. Travel (left) section U. Bucket section

33-14

33. SLEWING UPPER STRUCTURE 33.1.8 33.1.8.1

SOLENOID VALVE PREPARATION FOR REMOVAL

(1) Unlock and open the right upper cover (1). (2)

Remove the right lower cover (2) (See Section 33.1.2.1-(3)).

33.1.8.2 (1)

REMOVAL

Disconnecting hoses Disconnect all the hoses connected to the solenoid valve (B1). Then attach a plug and a tag recording the connecting port to each of their openings. â&#x20AC;˘

Item (B33) is a drain hose for the hydraulic oil tank. When disconnecting this hose, take care of oil leakage.

(2)

Disconnecting connector Disconnect two connectors connected to the main harness.

(3)

Removing solenoid valve Loosen two M8x20 capscrews (B5) to remove the solenoid valve (B1). : 13 mm

33.1.8.3

REMOVAL OF NIBBLER AND BREAKER SOLENOID VALVE

(1)

Disconnecting hoses Disconnect all the hoses connected to the solenoid valve (C1). Then attach a plug and a tag recording the connecting port to each of their openings.

(2)

Disconnecting connector Disconnect two connectors connected to the main harness.

(3)

Removing solenoid valve Loosen two M10x20 capscrews (C15) to remove the solenoid valve (C1). : 17 mm

Fig. 33-29 Solenoid valve removal

33-15

33. SLEWING UPPER STRUCTURE 33.1.8.4 (1)

INSTALLATION

Install the solenoid valve in reverse order of the removal. Tighten the fittings at the following torque:

Piece

Name

Tool (mm)

Torque (Nm)

Nut (M8)

33.3

Thread size (PF)

Spanner used (mm)

O-ring type fitting

30Â° flare type fitting

B24

Clip

2.94

1/4

36.3

29.4

B34 C15

Capscrew (M10) Capscrew (M10)

65.7 21.5

3/8

73.5

33.1.9 33.1.9.1

17 17

Tightening torque (Nm)

FUEL TANK DISASSEMBLY PREPARATION

(1)

Remove the floor mats (5) and (8), the floor covers (2) and (4), and the floor plate (1) (See Section 33.1.3.1).

(2)

Remove the cover assembly (4) on the left lower side (See Section 33.1.2.1-(4)).

(3)

Remove the battery (See Section 33.1.4.2).

Fig. 33-30 Fuel drain A1.Fuel tank

33-16

33. SLEWING UPPER STRUCTURE (1)

Disconnecting suction hose

A15

1) Remove the clip (20). : minus driver

2) Remove the hose (11). : minus driver

A15.Cap boot (2)

Removing return oil hose and drain oil hose Disconnect each hose from the position marked with *. : 19, 22 and 36 mm : minus driver

Return oil hose removal - Nibbler and breaker hose removal

33-17

33. SLEWING UPPER STRUCTURE (3)

Removing hydraulic oil tank Loose four M12x30 capscrews (B1) to remove the hydraulic oil tank (A1) and shim (B3). : 17 mm Weight: approximately 37 kg

B1 B2 B3

(1)

Clean hydraulic oil tank, hose, and components.

(2)

Install the tank in reverse order of the disassembly. The specified tightening torque is shown in the following table: •

Apply Loctite #262 to B1.

Piece

Name

Tool (mm)

B1 B14 7

Capscrew (M12) Plug (PF 3/8) Cap screw (M8) Cap screw (M10)

17 22 13

Torque (Nm) 46 73.5 33.3

65.7

A1 B1 B2 B3

Clip

Minus driver Minus driver

Tightening torque (Nm) (lbf•ft) Thread size (PF) 1/4 3/8 1/2 3/4

4.4 2.94

(3)

After assembling, fill the tank with the specified hydraulic oil and check the oil level with the level gauge (A1-11) (See Fig. 33-36). Oil quantity: about 41 litres (11 gal)

(4)

Air bleeding 1) Start the engine. 2) Run the engine in low idle condition for two or three minutes. Then extend and retract each cylinder several times to bleed air from the circuit.

33-18

Spanner used (mm) (in) 19 (0.74) 22 (0.86) 27 (1.06) 36 (1.41)

O-ring type fitting

30° flare type fitting

36.3 (27) 73.5 (54) 108 (80) 162 (119)

29.4 (21) 49 (36) 78.5 (58) 118 (87)

33. SLEWING UPPER STRUCTURE 33.1.9.2 (1)

DISASSEMBLY

Open the fuel filler cap (B2) and loosen the drain cock (B10) to drain fuel. Tank capacity: 52 litre (13.70 gal)

(2)

Disconnect the hoses (2) and (3) for the fuel inlet and outlet, the hose (B4) for the fuel supply port, and two air bleed hoses (A3).

(3)

Loosen the M10x20 sems-screws (B9) to remove the flange (B11) together with the drain hose (B12).

A13 3 2

B9 B11

: 17 mm (0.66 in) (4)

Disconnect connector (A13) for the level sensor.

(5)

Remove two M10x20 capscrews (B7).

B12

: 17 mm (0.66 in) (6)

Remove the fuel tank (A1) together with the bracket assembly (B14).

B2 B14 B33 B4

Fig. 33-31 Fuel tank removal 33.1.9.3

INSTALLATION

Assemble the fuel tank in reverse order of the removal and tighten the screws to the specified torque shown in the following table: Piece B7 B9 B5 B33

Tool (mm) (in) Capscrew (M10) 17 (0.66) Sems-bolt (M10) 17 (0.66) Name

Clip

Torque (Nm) lbfโ ขft) 46.1 (34) 34 (25) 0.49 รท 0.78 (0.36 รท 0.57) Screwdriver 0.36 รท 0.58 (0.26 รท 0.42)

33-19

33. SLEWING UPPER STRUCTURE 33.1.10

HYDRAULIC OIL TANK

33.1.10.1

DISASSEMBLY PREPARATION

(1)

Swing approximately 90 degrees to the right to facilitate to remove the tank.

(2)

Unlock and open the right upper cover (1).

(3)

Remove the right lower cover (2) (See Section 33.1.2.1-(3)).

(4)

Remove the floor cover (2) (See Section 33.1.3.1).

(5)

Remove the inspection cover (1-3) of the control stand. Six M8x20 sems-bolts (1-5)

1-5

Fig. 33-32 Cover removal

: 13 mm (0.51 in) (6)

1-3

After releasing internal pressure of the hydraulic oil tank (A1), remove the plug (B14) below the solenoid valve to drain hydraulic oil. : 22 mm (0.86 in) Tank capacity: 41 litre (11 gal) •

Spread a vinyl sheet under the solenoid valve to prevent contamination around the valve due to oil leakage.

•

Releasing tank pressure Press the cap boot of breather assembly (A14) with a finger to release the internal pressure (See Fig. 33-34).

CAUTION

(7)

Press and hold the boot until air-relieving sound stops. Remove the control valve (See Section 33.1.7.2).

B14

(8)

Remove the solenoid valve (See Section 33.1.8.2).

(9)

In addition, remove the harness and hose clamped on the tank. •

Fig. 33-33 Draining hydraulic oil A1.Hydraulic oil tank B1.Solenoid valve B14.Plug

Remove the multi-control valve (option) if it is equipped.

33-20

33. SLEWING UPPER STRUCTURE 33.1.10.2 (1)

DISASSEMBLY

Disconnecting suction hose

A15

1) Remove the clip (20). : minus driver

2) Remove the hose (11). : minus driver

Fig. 33-34 Suction hose removal A15.Cap boot (2)

Removing return oil hose and drain oil hose Disconnect each hose from the position marked with *.

20 S/M

23 S/M 11 P/V

: 19 (0.74 in), 22 (0.86 in), and 36 mm (1.41 in)

D13

: minus driver

P/V

17 A13

6 P/V A14 C/V

S/V

B24

P/V

Fig. 33-35 Return oil hose removal

33-21

33. SLEWING UPPER STRUCTURE (3)

Removing hydraulic oil tank Loose four M12x30 capscrews (B1) to remove the hydraulic oil tank (A1) and shim (B3). : 17 mm (0.66 in) Weight: approximately 37 kg (82 lbs)

B1 B2 B3

A1 B1 B2 B3

Fig. 33-36 Hydraulic oil tank removal 33.1.10.3

ASSEMBLY

(1)

Clean hydraulic oil tank, hose, and components.

(2)

Install the tank in reverse order of the disassembly. The specified tightening torque is shown in the following table: •

Piece B1 B14 16 17

Apply Loctite #262 to B1. Tool (mm) Torque (in) (Nm) (lbf•ft) Capscrew (M12) 17 (0.66) 46 (34) Plug (PF 3/8) 22 (0.86) 73.5 (54) Minus Clip 4.4 (3.3) driver Minus Clip 2.94 (2.2) driver Name

Tightening torque (Nm) (lbf•ft) Thread size (PF) 1/4 3/8 1/2 3/4

(3)

After assembling, fill the tank with the specified hydraulic oil and check the oil level with the level gauge (A1-11) (See Fig. 33-36). Oil quantity: about 41 litres (11 gal)

(4)

Air bleeding 1) Start the engine. 2) Run the engine in low idle condition for two or three minutes. Then extend and retract each cylinder several times to bleed air from the circuit.

33-22

Spanner used (mm) (in) 19 (0.74) 22 (0.86) 27 (1.06) 36 (1.41)

O-ring type fitting

30° flare type fitting

36.3 (27) 73.5 (54) 108 (80) 162 (119)

29.4 (21) 49 (36) 78.5 (58) 118 (87)

33. SLEWING UPPER STRUCTURE (5)

Rechecking oil level Stop the engine in the posture shown in Fig. 3337 to recheck oil level. In addition, ensure no oil leakage is found on each part.

Fig. 33-37 Posture for stopping engine 33.1.11 33.1.11.1

AIR CLEANER DISASSEMBLY PREPARATION

Open the rear bonnet assembly. 33.1.11.2 (1)

DISASSEMBLY

Loosen the clip (9) and (10) to remove the air hoses (3) and (5). : minus driver

(2)

Loosen two M20x25 sems bolt (12) and a M10x30 sems-bolts (16), then to remove the air cleaner assembly (1).

: 13 mm (0.51 in)

10 5

3 10

1 12

11 11

16 Fig. 33-38 Air cleaner removal 9. Control stand 33.1.11.3

ASSEMBLY

Assemble the air cleaner in reverse order of the disassembly. •Tightening torque Sems-bolts (11): 23.5 Nm (17 lbf•ft) Sems-bolts (12) and (16): 46.1 Nm (34 lbf•ft)

33-23

33. SLEWING UPPER STRUCTURE 33.1.12 33.1.12.1

ALTERNATOR DISASSEMBLY PREPARATION

(1) Remove the cover at the lower right of the seat (See Section 33.1.10.1 -(5)). (2) Disconnect the negative side terminal of the battery. (3) Remove the guard assy (6) (See Section 33.1.2.1(6)). 33.1.12.2

DISASSEMBLY

(1)

Disconnect the connector and remove the nut (M6) for the terminal B.

(2)

Remove the capscrews (1), (2), and (3). : 13 mm (0.51 in)

(3)

Remove the V-belt and the generator.

3 2

1 Fig. 33-39 Generator removal

33-24

33. SLEWING UPPER STRUCTURE 33.1.12.3

ASSEMBLY

(1)

Assemble the generator in reverse order of the disassembly.

(2)

V-belt tension Press the middle of the V-belt with a thumb to adjust the deflection within the following range: Deflection: 10 mm (0.39 in) to 15 mm 0.59 in)

Fig. 33-40 Generator terminal B. Nut for terminal B tightening torque 5.9 รท 9.8 Nm (4.4 รท 7.2 lbfโ ขft) C. Clip E. To fusible link 33.1.13 33.1.13.1

SILENCER DISASSEMBLY PREPARATION

((1) Remove the bonnet assembly (3) (See Section 33.1.2.1-(1)). (2) Remove the cover assembly (5) (See Section 33.1.2.1-(2)). 33.1.13.2 (1)

DISASSEMBLY

Loosen three M8x20 sems-bolts (8) to remove the cover (16).

9-2

: 13 mm (0.51 in) (2)

Remove M8 nut (19) to loosen the clamp (4), and loosen four M8 nuts (9-1) to remove U bolt (27) then disconnect the exhaust tube (3).

: 17 mm (0.66 in) (3)

(4)

Loosen four M8 nuts (9-2) fastening the exhaust manifold for the engine to remove the silencer. : 13 mm (0.51 in)

27 9-1

9-1 14

Loosen four M8x20 capscrews (14) to remove the muffler (1).

19 4 3 Fig. 33-41 Muffler removal

33-25

33. SLEWING UPPER STRUCTURE 33.1.13.3

ASSEMBLY

Install the muffler in reverse order of the removal and tighten the screws and nuts to the specified torque shown in the following table: Tool Torque (Nm) (mm) (in) (lbfâ&#x20AC;˘ft) 8 Sems-bolt (M8) 13 (0.51) 23.5 17) 9-1 Nut (M8) for U-bolt 13 (0.51) 10.8 (9.0) 9-2 Nut (M8) for manifold 13 (0.51) 23.5 (17) 14 Nut (M8) 13 (0.51) 23.5 (17) 19 Nut (M8) 13 (0.51) 23.5 (17) 33.1.14 CONTROL STAND Piece

33.1.14.1

Name

DISASSEMBLY PREPARATION

(1) Remove the canopy and the handrail (See Section 33.1.1). (2) Remove the floor covers (2) and (4), and the plates (3) (See Section 33.1.3.1). (3) Remove the covers (1), (2), (4), (5), (6) and (9) for the guards, and the bonnet (3) (See Section 33.1.2). (4) Remove the counterweight (See Section 33.1.5). (5) Disconnect the negative side terminal of the battery. 33.1.14.2

DISASSEMBLY

(1)

Remove the air cleaner (See Section 33.1.11).

(2)

Removing throttle cable (15)

1) Pull out the pin (10) and remove the pin (6). 2) Loosen the adjusting nut (M8) to remove the cable. (3)

Removing deceleration motor (option) 1) Disconnect the connector. 2) Loosen the adjusting nut (M8) to remove the cable. 3) Loosen three M8x20 sems-bolts (12) to remove the deceleration motor (8).

Fig. 33-42 Control cable removal

: 13 mm (0.51 in) (4)

Removing filler neck (fuel supply port)

1) Pull out the hose (B4) connected to the fuel tank. 2) Loosen two M8x20 capscrews (B34) to remove the filler neck (B1). : 13 mm (0.51 in)

B34 A1

Fig. 33-43 Filler neck removal

33-26

33. SLEWING UPPER STRUCTURE (5)

Disconnect the air bleed hose (A3) for the fuel tank (A1).

B9 B11

B12

B2 B14 B33 B4

Fig. 33-44 Air bleed hose disconnection (6)

PILOT VALVE REMOVAL FOR DOZER 1) Disconnecting hoses Disconnect all the hoses connected to the Pilot valve (10). Then attach a plug and a tag recording the connecting port to each of their openings.

S/V A2 P

2) Removing pilot valve Loosen two M8x20 capscrews (11) to remove the pilot valve.

1 2

C/V Pa1

C/V Pb1

Fig. 33-45 Pilot valve removal for dozer (7)

Removing seat and front stand cover Loosen four M8x20 sems-screws (15) to remove the seat assembly (7) and the front stand cover (1) in one piece. : 17 mm (0.66 in)

1 6

Fig. 33-46 Seat and cover removal

33-27

33. SLEWING UPPER STRUCTURE (8)

Removing heat insulation cover Loosen two M6x12 sems-bolts (11) to remove the cover (4).

11 4

: 10 mm (0.39 in) Loosen three M8x20 sems-screws (16) to remove the cover (3).

: 13 mm (0.51 in)

Fig. 33-47 Cover removal (9)

Disconnecting pilot hose

1) Disconnect the hose of the right pilot valve (R) under the pilot valve (See Section 33.1.18.2).

2) Disconnect the hose of the left pilot valve (L) from the control valve and solenoid (B1) valve (B1) sections (See Sections 33.1.7.2 and 33.1.8.2). â&#x20AC;˘

When a multi-control valve (option) is equipped, disconnect hose at the multi-control valve section.

Fig. 33-48 Pilot hose disconnection (10) Removing heater hose (option)

1) Loose four sems-bolts (15) M8x20 to remove the cover (14). : 13 mm (0.51 in) 2) Loosen five sems-screws (15) M8x20 to remove the cover (20).

20 15

: 13 mm (0.51 in) 3) Remove the engine side clips (5), and disconnect the hose (1) and 6). 4) Loose four sems-bolts (12) M8x16 to remove the heater (2). : 13 mm (0.51 in)

6 1 15

Fig. 33-49 Heater hose disconnection

33-28

33. SLEWING UPPER STRUCTURE (11) Disconnecting harness See below drawing to disconnect the harness connected to the instrument harness and main harness. 11 12 3

20 21

10 15

8 6

SV-1 E-13 SV-2

19 H-5

E-3

H-4

To canopy light

19. B (-)

To boom

20. Connect with cab harness (cab spec.).

GND connector

21. Connect with decel motor (OPT)

10. Ground

E-3. Horn

11. Connection with a heater relay harness. (OPT)

E-13 Battery

12. Connect main harness to eng. harness.

H-4. Starter cable

14. Relay assy

H-5. Battery ground cable

15. Connect with fuel sensor

SV-1.Operating lever lock sol.

16. Connect with two speed select sw.

SV-2.Two-speed selection solenoid

17. PB (+)

33-29

33. SLEWING UPPER STRUCTURE (12) Removing control stand Remove M8 (A12), M10 (A14) and M12 (A15) sems-bolts for fastening the stand in addition to the sems-bolts already removed to disassemble the canopy and floor covers.

A12

A15

: 13 mm(0.51 in), 17 mm (0.66 in) and 19 mm (0.74 in) Weight of removed stand: approximately 55 kg (120 lbs) •

A14

Before lifting the control stand, ensure that harnesses and hoses are already disconnected.

Fig. 33-50 Control stand removal

(13) Removing support

B6, B7

B6 B7

1) Remove the M8x16 capscrew (A10) for the clamp (A6) of the oil cooler hose (A2). : 13 mm (0.51 in) 2) Loose four capscrew M16x50 (30) and remove the support (11).

: 24 mm (0.94 in) Weight: approximately 45 kg (99 lbs)

30 31 32

11 30, 31, 32 Fig. 33-51 Support (7) removal 33.1.14.3

INSTALLATION

(1) Install the control stand in reverse order of the removal. Tighten the capscrews and sems-bolts at the torque specified below:

Thread size

Tool (mm) (in)

M6 M8 M10 M12 M16

10 (0.39) 13 (0.51) 17 (0.66) 19 (0.74) 24 (0.94)

Tightening torque (Nm) (lbf•ft)

Tightening torque (Nm) (lbf•ft) 4.4 (3.3) 23.5 (17) 46.1 (34) 79.4 (59) 191 (141)

Spanner Thread size O-ring type 30°flare type used (mm) (PF) fitting fitting (in) 1/4 19 (0.74) 36.3 (27) 29.4 (22) 3/8 22 (0.86) 49 (36)

33-30

33. SLEWING UPPER STRUCTURE 33.1.15 33.1.15.1

STARTER MOTOR PREPARATION FOR REMOVAL

(1)

Remove the floor cover (See Section 33.1.3.1).

(2)

Remove the seat and the front stand cover, loosen three M10x20 sems-bolts (15), and remove the seat assembly (7) and the front stand cover (1) in one piece. : 17 mm (0.66 in) Tightening torque: 41.6 Nm (33 lbf•ft)

(3)

Disconnect the negative side terminal of the battery.

1 6

Fig. 33-52 Seat and cover removal 33.1.15.2

REMOVAL

(1) Remove the M8 nut for the terminal B of the starter. : 13 mm (0.51 in) (2) Disconnect connector on the terminal S of the starter. (3) Loosen two fastening bolts (1) to remove the starter. : 19 mm (0.74 in)

Fig. 33-53 Starter removal 1. Starter motor 2. M8 B terminal tightening torque 7.4 ÷ 9.8 Nm (5.4 ÷ 7.2 lbf•ft)

B. Fasten with a screw for starter motor tightening torque 1.7 ÷ 2.4 Nm (1.3 ÷ 1.8 lbf•ft) C. Clip

3. M8 M terminal 4. S terminal 1.7 ÷ 2.4 Nm (1.3 ÷ 1.8 lbf•ft) 33.1.15.3

INSTALLATION

Install starter in reverse order of the removal.

33-31

33. SLEWING UPPER STRUCTURE 33.1.16 33.1.16.1 (1)

RADIATOR DISASSEMBLY PREPARATION

Remove the right side cover assemblies (1), (2), (6) and (9), and the bonnet assembly (3) (See Section 33.1.2).

(2)

Remove the counterweight (See Section 33.1.5).

(3)

Remove the duct (13) for the radiator. Three M8x20 capscrews (20).

(4)

Remove the fan guard (A15). Two M8x30 capscrew (A19).

(5)

Remove the support (11) (See Section 33.1.14.2(13)).

11 20

â&#x20AC;¢ In order to facilitate the work, remove the related covers and components if necessary.

33-32

Fig. 33-54 Duct removal

33. SLEWING UPPER STRUCTURE 33.1.16.2 (1)

DISASSEMBLY

Draining water from radiator 1) Remove the radiator cap. 2) Loosen the clip (A8), then remove the plug (A14) to drain water. Volume: Approximately 2.6 litres

(2)

A19 A15 A4

B2 B3

Draining hydraulic oil in oil cooler 1) Release the pressure in the hydraulic circuit. 2) Remove the oil cooler hoses (18) and (19) loosening two clip (16), and then plug the inlet/outlet ports of the oil cooler and the openings of the hoses.

(3)

Disconnect the hose (A4) of reservoir (A5) by removing the clip (A8).

(4)

Remove the radiator hoses (A1) and (A2) fixed by clip (A7). Tools: Cutting pliers and minus screwdriver

(5)

Removing radiator Loose three M10x30 (B3) and four M8x25 (B6) capscrews to remove the radiator assembly.

(1)

A14

Fig. 33-55 Radiator disassembly

18 19

ASSEMBLY

Assembly the radiator in reverse order of the disassembly.

(2)

Apply Loctite #262 on the capscrews (B3) to fix the radiator by them.

(3)

Apply PERMATEX #98D to the fittings of radiator hoses (A1) and (A2) prior to the connection.

(4)

Install the fan (28) and the protection (27), adjusting their positions (26) (See Fig. 33-57).

Fig. 33-56 Draining hydraulic oil in oil cooler

Tightening torque for related parts

B6 B3 (5)

Tightening torque Name Tool (mm) (Nm) Nut (M8) 13 23.5 Capscrew 17 46.1 (M10)

27 27.5

Piece

: 13 mm (0.51 in) and 17 mm (0.66 in) Weight: 23 kg (51 lbs)

33.1.16.3

Feed cooling water (LLC: Long Life Coolant) See Maintenance section of the OPERATION AND MAINTENANCE MANUAL for the mixing ratio of LLC.

Fig. 33-57 Fan installation

33-33

33. SLEWING UPPER STRUCTURE 33.1.17

ENGINE

33.1.17.1

PREPARATION FOR REMOVAL

(1)

Remove the side cover and the bonnet (See Section 33.1.2).

(2)

Remove the canopy (See Section 33.1.1).

(3)

Remove the negative side terminal of the battery.

(4)

Remove the counterweight (See Section 33.1.5).

(5)

Remove the control stand (See Section 33.1.14).

(6)

Remove the air cleaner (See Section 33.1.11).

(7)

Remove the silencer (See Section 33.1.13).

(8)

Remove the radiator (See Section 33.1.16).

(9)

Remove the pump or disconnect the hose connected to the pump (See Section 33.1.6).

33.1.17.2 (1)

Disconnecting fuel hose Disconnect each hose from the position marked with

(2)

REMOVAL

Disconnecting cable connector (For details, see ELECTRICAL SYSTEM)

30 32

1) Disconnect the terminal B of the starter motor (M-1) from the positive cable of the battery (See Section 33.1.15.2). 2) Disconnect the grounding cable of the engine. (3)

Removing engine

CAUTION

Prepare a worktable capable of enduring the weight of the engine and stably receiving the removed engine. 1) Loose four M12x120 capscrews (12) fixing the engine on the rubber mount (6) and (7) to remove the engine. : 19 mm (0.74 in) 2) Lifting engine Pass a wire rope through the two lifting eyes at the top of the engine and lift the engine. Weight: Approximately 170 kg (370 lbs)

Fig. 33-58 Fuel hose removal 30.Fuel filter 31.Fuel feed pump 32.Water separator

3) Place the engine stably on the worktable.

33-34

33. SLEWING UPPER STRUCTURE 33.1.17.3

INSTALLATION

(1) Install the engine in reverse order of the removal. See the following table for the tightening torque and the sealant:

Tightening torque for related parts Tool Tightening torque Piece Name (mm) (Nm) Capscrew 46.1 10 and 11 19 Apply Loctite #262 (M10) Capscrew 79.4 12 22 (M12) Apply Loctite

•

Use the mount rubber (6) with identification color of “blue” (three places).

•

Use the mount rubber (7) with identification color of “black” (one place).

6, A 11

Fig. 33-59 Removing engine

33-35

33. SLEWING UPPER STRUCTURE 33.1.18 33.1.18.1

PILOT VALVE PREPARATION FOR REMOVAL

Since the same method applies to the right-hand and the left-hand pilot valve, only the method for the righthand is described. (1)

Disconnect the negative side terminal of the battery.

(2)

Release the residual pressure in the circuit and the pressure in the hydraulic tank.

(3)

Remove the right and left control boxes and the control panel.

(4)

Loosen sems-bolts (10) to remove the cover assembly (A3) and (A4) (See Fig. 33-60).

10 10 10 A4 10

Fig. 33-60 Cover removal (Right control box)

: Torx driver (T25) 33.1.18.2 (1)

(2)

REMOVAL

Disconnect each hose at the position marked with * and attach a plug and tag to facilitate installation. Shift the boot and remove four capscrews (A2).

C/V Pb10

A1 4

TANK

C/V

Pb8

: 10 mm (0.39 in) (3)

Remove the pilot valve (A1).

C/V Pa8

S/V A2

C/V Pa10

Fig. 33-61 Hose removal

33-36

33. SLEWING UPPER STRUCTURE 33.1.18.3 (1)

INSTALLATION

Install the pilot valve in reverse order of the removal to the following tightening torque:

1) Attaching sems-bolts (20). : Torx driver (T25) Tightening torque 0.27 Nm

Installing hoses, etc.

R 8

Tightening torque (Nm) Thread size Spanner used O-ring 30Â° flare (PF) (mm) type fitting type fitting 1/4 19 36.3 (27) 29.4 (22) 3/8 22 49 (36)

6 5 7

Fig. 33-62 Pilot valve port location NOTE: take care of the tightening torque as the pilot valve is made of aluminum. (2) Pressurize the hydraulic tank (See Section 33.1.10.3). (3)

Operate the attachment to check the performance.

(4)

Check the tank and piping for oil leakage and oil level.

1. Bucket (H) 2. Bucket (R) 3. Boom (H) 4. Boom (R) 5. Slewing (L)

33-37

6. Slewing (R) 7. Arm (H) 8. Arm (R) L. Left side R. Right side

33. SLEWING UPPER STRUCTURE 33.1.19 33.1.19.1

SWING MOTOR PREPARATION FOR REMOVAL

(1) Remove the floor mat, the floor plate and the cover (See Section 33.1.3.1). (2) Release the residual pressure in the circuit and the pressure in the hydraulic tank. 33.1.19.2 (1)

REMOVAL

Disconnect six hoses (A17), (A20), (20 Tank), (21), (22) and (23) tank connected to the slewing motor.

A20 C/V

: 22 and 27 mm

C/V

A17 Fig. 33-63 Main hose disconnection

20 21

C/V

23 S/J

22 Fig. 33-64 Main hose disconnection (2)

Remove three pilot hoses (B31), and (B37) connected to the slewing motor. : 19 mm

B31 S/V

C/V

B37 Fig. 33-65 Pilot hose removal

33-38

33. SLEWING UPPER STRUCTURE (3)

Loosen five M16x40 capscrews (1) to remove the slewing motor (A1).

A1 1

: 24 mm [a long type approximately 300 mm in length required]. Weight: approximately 40 kg

Fig. 33-66 Slewing motor removal 33.1.19.3

INSTALLATION

(1) Install the motor in reverse order of the removal according to the tightening torque shown below. 1) Apply Loctite #515 on the entire circumferential surface for mounting the slewing motor (1). 2) Install the capscrews (3) for fixing the motor. (A1) : 24 mm Tightening torque = 216.6 Nm Apply Loctite #262 to the capscrew. 3) Connect the hoses â&#x20AC;˘

Fill the casing with hydraulic oil through the motor drain port prior to connecting drain piping. Tightening torque

Thread size (PF) 1/4 3/8 1/2

Spanner used (mm) 19 22 27

O-ring type fitting 36.3 73.5 108

30Â° flare type fitting 29.4 49 78.5

(2) Check the hydraulic oil tank for the oil level. Supply oil if necessary. (3) At the start, run the motor in the low idling condition of the engine for a few minutes to check for oil leakage and abnormal noise.

33-39

33. SLEWING UPPER STRUCTURE 33.1.20

ROTARY CONTROL VALVE

33.1.20.1

PREPARATION FOR REMOVAL

(1)

Lift the machine by approximately 30 cm and insert support blocks under the four crawlers, namely front, rear, right and left, to secure the working area under the machine.

(2)

Remove the cover (2) of the floor plate (See Section 33.1.3.1).

(3)

Loosen four M10x25 capscrews (A5) to remove the under cover (A4).

Fig. 33-67 Lifting machine

: 17 mm (4)

Release the residual pressure in the circuit and the hydraulic tank.

(5)

Disconnect the hose of the slewing motor (See Section 33.1.19). â&#x20AC;˘

Remove the canopy to facilitate to remove the swivel joints. A4

Fig. 33-68 Undercover removal

33-40

33. SLEWING UPPER STRUCTURE 33.1.20.2 (1)

REMOVAL

Remove the upper-side drain hoses (A22), connector (1) and elow (2).

S/M Dr

: 19 mm (2)

Disconnect all the other hoses connected to the swivel joint. â&#x20AC;˘

A22

Attach a plug and tag to each of the openings.

Fig. 33-69 Drain hose disconnection

A21 C/V

A17

B32

S/J

S/V

C/V C/V

S/J

A18

S/J

Fig. 33-70 Upper side hose disconnection A4

A3 F B P

A D P

A2 P

G D2

A A

A3 B

Fig. 33-71 Lower side hose disconnection

33-41

33. SLEWING UPPER STRUCTURE (3)

Removing stopper Loosen two M12x40 capscrews (A7) to remove the stopper (A2). : 19 mm [a long type approximately 300 mm in length required].

Fig. 33-72 Stopper removal (4)

Removing swivel joint Loose four M12x35 capscrews (C2) to remove the swivel joint (C1) downward.

C2 C1

: 22 mm Weight: 22 kg

Fig. 33-73 Swivel joint removal 33.1.20.3 (1)

INSTALLATION

Install the swivel joint in reverse order of the removal to the tightening torque shown below.

1) Install the capscrews (C2). : 22 mm Tightening torque = 181 Nm Apply Loctite #262 to the capscrews.

2) Install the capscrews (A6). : 19 mm (0.74 in) Tightening torque = 115 Nm Apply Loctite #262 to the capscrews. 3) Connect the hoses. Tightening torque (Nm) Thread Spanner used O-ring type size (PF) (mm) fitting 1/4 19 36.3 3/8 22 73.5

(2)

Reinstall all the removed parts.

(3)

Pressurize the hydraulic tank.

(4)

Check the performance.

30Â° flare type fitting 29.4 49

Fig. 33-74 Connecting port relation AL.(Upper) forward AR.(Lower) reverse BL.(Upper) forward BR.(Lower) reverse L. Dozer (H) R. Dozer (R) TL.Travel motor (left) TR.Travel motor (right) D1. Discharge D2. Discharge P. Solenoid valve control

33-42

33. SLEWING UPPER STRUCTURE 33.1.21 33.1.21.1

UPPER FRAME PREPARATION FOR REMOVAL

(1) Remove the floor plate and the floor cover (See Section 33.1.3). (2) Remove the canopy (See Section 33.1.1). (3) Remove the guards (See Section 33.1.2). (4) Remove the counterweight (See Section 33.1.5). (5) Drain hydraulic oil from the hydraulic tank (See Section 33.1.10.2). (6) Disconnect the upper-side hoses from the swivel joint (See Section 33.1.19.2). (7) Remove the stopper for the swivel joint (See Fig. 33-72). (8) Remove the attachment (See the “BOOM” section of the Chapter of ATTACHMENT). (9) Needed tools • Lifting device for upper frame. See section “Tools”. • Two screws M20x110 • Two nuts M20 • Two nuts M20 33.1.21.2

REMOVAL

(1)

Provide match-marks on the slewing bearing Provide match marks between the upper frame (1) and the outer race of slewing bearing (2).

(2)

Lifting upper frame temporarily

4,5

1) Attach the upper frame lifting jigs to the rear end of upper frame using the counterweight mounting holes.

Fig. 33-75 Slewing bearing and upper frame

2) Temporarily lift the upper frame at three points applying wire ropes (1) on a position of the swing-bracket mounting hole for the front side and on two places of the rear end of the upper frame (1). (3)

Removing bolt for mounting upper frame (1) Loosen one reamer bolt (5) and nineteen capscrews (4) fixing the outer race of the slew bearing to the upper frame. : 22 mm

(4)

Removing upper frame (1) Slightly lift the upper frame to ensure safety. Then remove it and place on a worktable capable of enduring the weight. Weight: approximately 1420 kg for E45B SR Weight: approximately 1450 kg for E50B SR

Fig. 33-76 Lifting upper frame W.Wire rope UL.Upper frame lifting jig

33-43

33. SLEWING UPPER STRUCTURE 33.1.21.3

INSTALLATION

(1)

Install the upper frame (1) in reverse order of the removal.

(2)

Cleaning contact surface Clean the bottom surface of the upper frame and the top surface of the slewing bearing. Fig. 33-76 •

(3)

4,5

Apply Loctite #515 (3) over the entire circumference of the outer race inside of the capscrew. 2

Lifting method 1) Apply wire ropes to the upper frame (1) and lift up horizontally.

Fig. 33-76 Slewing bearing installation

2) Check the match-marks provided at the disassembly. 3) Slowly lower the upper frame while aligning the match-marks and watching the engaging condition between the slewing pinion gear and the internal gear of the inner race of slewing bearing (2). (4)

Installing slewing bearing (2) and upper frame (1) 1) Apply Loctite #262 on a reamer bolt (5) and fifteen capscrews (4) and temporarily tighten them. 2) Tighten the screw (6) and the opposite screws on the front, rear, right and left in pairs alternatively (7) to the specified tightening torque. : 22 mm, T= 181 Nm Apply Loctite #262 to the bolt and capscrews. 3) Fill the grease bath portion surrounding the gear teeth of the slewing bearing with about 4.8 kg of “NISSEK NEW MOLYKNOCK”

(5)

Install the components removed in the above removal preparation to the original position and check the performance.

33-44

Fig. 33-77 Reamer bolt position

33. SLEWING UPPER STRUCTURE

33.2

DISASSEMBLY AND ASSEMBLY

33.2.1

HYDRAULIC PUMP

33.2.1.1

CONSTRUCTION COMPONENTS

3 No. 1 2 3 4 5 7 8 9

NAME Shaft assy Swash plate assembly (Hanger assembly) Rotary group Cover assy Spring assy Gear pump assembly Housing assembly Trochoid pump assy

33-45

33. SLEWING UPPER STRUCTURE 33.2.1.2

DISASSEMBLY AND ASSEMBLY

33.2.1.2.1 (1)

Tools and Jig

Tools Name

Q.ty

Plastic hammer

One each 1

Snap ring pliers

Torque wrench

Socket wrench

Allen wrench

As required As Adhesive agent required

Size (Nominal) 4, 5, 6, 8 and 10 Medium type For hole (for snap ring 22) For shaft (for snap ring 20) Possible to tighten to the specified torque Possible to tighten to the specified torque

Grease

Loctite type â&#x20AC;&#x153;high tack #98â&#x20AC;?

(2) Jig 1. Working bench Plate which is used to place the pump facing downward If the shaft end does not contact with work bench, the square timber is available instead of it. 2. Bearing assembling jig

33.2.1.2.2

Cautions during assembling and dissembling

(1) Cautions for disassembling 1) Never attempt operating the adjusting screw unless absolutely necessary. 2) Take utmost care during disassembly not to knock or drop each part. (2) Cautions for assembling 1) Wash each part thoroughly. 2) During assembling, take utmost care not to damage the part or allow foreign materials to enter. 3) As a rule, the O-ring and oil seal should not be reused. 4) In our assembly work, the torque wrench is used to control the torque. Be sure to use the torque wrench.

33-46

33. SLEWING UPPER STRUCTURE 33.2.1.2.3 (1)

Disassembly

Removing gear pump 1) Remove two capscrews (M10x25). : 8 mm

2) Remove the coupling.

(2)

Removing trochoid pump 1) Remove three M5x12 capscrews. : 4 mm

2) Remove the case, side plate (A) and gear. â&#x20AC;¢

Use two M5x50 screws.

33-47

33. SLEWING UPPER STRUCTURE 3) Take the gear out of the casing.

4) Remove the side plate (A) from the casing.

5) Remove the side plate (B) from the cover.

6) Remove the key of the shaft

33-48

33. SLEWING UPPER STRUCTURE (3)

Disassembling main pump 1) Removing cover Remove three (M12x30) and one (M12x55) capscrews. : 10 mm

2) Removing the cover in a horizontal condition. â&#x20AC;˘

Be careful because the control plate is provided to the back side. When the cover is difficult to remove, knock lightly with a plastic hammer.

3) Removing control spring section a) Remove two springs (inside and outside) and the guide.

4) Remove the spring seat.

33-49

33. SLEWING UPPER STRUCTURE 5) Lay the pump on the side and take out the rotary group from the shaft.

6) Remove hanger.

7) Remove shaft. Remove snap ring with plier. Snap ring plier (for hole: Ă¸72)

8) Remove oil seal casing using two minus screwdriver.

33-50

33. SLEWING UPPER STRUCTURE 9) Remove O-ring.

10) Tap lightly rear end of shaft with plastic mallet, and remove shaft.

11) Remove hanger. Remove four socket bolts (M6x16) and plate. : 5 mm

12)Remove distance piece.

33-51

33. SLEWING UPPER STRUCTURE 13) Remove bearing.

14) Remove hanger.

15) Removing cover. Remove control plate.

16) Removing control piston. Remove two socket bolts (M8x25). : 6 mm â&#x20AC;˘

Loctite #270 is applied on the threaded part of socket bolt, so remove it only when required.

33-52

33. SLEWING UPPER STRUCTURE 17) Remove cylinder and parallel pin. â&#x20AC;˘

Take care not miss those O-ring fitted on cylinder section. (2 pc.)

18) If equipped, remove piston for air-conditioner mode. NOTE: these parts may not to be equipped depending on pump type.

19) Remove piston.

20) Remove three disk springs and spring seats.

33-53

33. SLEWING UPPER STRUCTURE 21) Removing control spring seat. Remove two socket bolts (M8x30) and remove cover. : 6 mm

22) Remove spring seat.

23) Remove shaft. Removing bearing. Remove snap ring from shaft, using snap ring plier. Snap ring plier (for shaft: Ă¸28, Ă¸30)

24) Place bearing in the vise, and lightly tap rear end of shaft with plastic mallet then remove bearing from shaft.

33-54

33. SLEWING UPPER STRUCTURE (4) Disassembling gear pump (GSP2) 1) Loose four socket bolts (M10x20). : 8 mm

2) Remove the cover.

3) Remove the square ring.

4) Remove plate, guide and O-ring.

33-55

33. SLEWING UPPER STRUCTURE 5) Remove the drive gear, idle gear and side plate.

33.2.1.2.4

Assembly

Assemble the main pump in reverse order of disassembly. (1) Assembly of main pump 1) Installing hanger assy. Install hanger in housing.

2) Install bearing.

3) Install distance piece and check the preload of bearing is 0.1 Âą 0.02 mm confirming the distance by means of micrometer and depth micrometer.

33-56

33. SLEWING UPPER STRUCTURE 4) Install the plate with four socket bolts (M6x16). : 5 mm Torque: 1.35 Nm

5) Assembling shaft assy. a) Place bearing on the pedestal, and press-fit shaft with jig. When there is no press, drive the shaft with jig and plastic mallet in the same manner as the above. 10

b) Fix snap rings and bearing. Snap ring plier (for shaft: Ă¸28, Ă¸30)

c) Install shaft in housing and tap the spline end with a plastic mallet lightly to fit outer race of bearing into the hole of housing completely.

33-57

33. SLEWING UPPER STRUCTURE 6) Apply grease on O-ring and fit it.

7) Install seal casing with oil seal in housing straight along axis. â&#x20AC;¢

Apply grease on oil seal lip.

8) Fix snap ring to housing and fix shaft.

9) Assembling rotary group. Install ten pistons in retainer of rotary group.

33-58

33. SLEWING UPPER STRUCTURE 10) Apply grease on three parallel pins, fit it in the cylinder block.

11) Apply grease on sphere portion of guide.

12) Install guide between retainer and cylinder block and insert pistons in the holes of cylinder block.

13) Assembling rotary group. Install plate in hanger. In this case, apply grease on the rear surface of plate to prevent dropping. R

A. Apply grease G. Ground site

F. Front R. Rear

33-59

33. SLEWING UPPER STRUCTURE 14) Align rotary group with spline of shaft, and install it to inside of housing. â&#x20AC;˘

Apply grease on sliding surface of piston shoe and sliding surface to the control plate of cylinder block.

15) Apply grease on the sphere portion of spring seat and install it to hanger in housing.

16) Fit two springs, inner and outer.

17) Fit spring seat and three disk springs to cover assy.

D/S S/S D. Direction of fitting D/S. Disk spring

33-60

33. SLEWING UPPER STRUCTURE 18) Install control piston.

19) If equipped, install the air-conditioning control piston. NOTE: these parts may not to be equipped depending on pump type.

20) Apply grease on O-rings, and fit them to cylinder.

21) Apply grease on two parallel pins (Ă¸10) and one parallel pin (Ă¸7.5) and install them to cylinder.

33-61

33. SLEWING UPPER STRUCTURE 22)Install cylinder with two socket bolts (M8x25). â&#x20AC;˘

Apply Loctite #270 to thread portion. : 6 mm Tightening torque: 3.25 Nm

23) Install spring seat in control spring section.

24) Install cover with two socket bolts (M8x30). : 6 mm Tightening torque: 3.25 Nm

25) Apply grease to rear surface of control plate and install it on the cover to align the hole with parallel pins.

33-62

33. SLEWING UPPER STRUCTURE 26) Fit five O-rings (2 kinds), on mating face of cover.

27) Install cover parallel to the attaching surface of housing.

28) Install cover with three socket bolts (M12x30) and one socket bolt (M12x55). : 10 mm Tightening torque: 110 Nm

(2) Assembling trochoid pump 1) Insert the key in the shaft. T

C. Cover side R. Round side T. Trochoid pump side â&#x20AC;˘ Insert the key directing the round side to the trochoid pump side.

33-63

33. SLEWING UPPER STRUCTURE 2) Install side plate (B) on the cover.

3) Install side plate (A) and the plate on the casing.

4) Place the gear in the casing. â&#x20AC;˘

Install directing the match mark face to side plate (B) side. M

I O

I. Inner rotor M.Matchmark O.Outer rotor 5) Install casing to cover.

33-64

33. SLEWING UPPER STRUCTURE c) Install the drive gear, (G) idle gear and side plate into the housing.

(3) Assembling gear pump 1) Fit the square ring to the plate on the assembling side of gear pump (GSP2). Then pay attention to the suction and delivery. S

D S

S. Suction side D. Delivery side 2) Install the drive gear and idle gear in the side plate.

3) Install the drive gear, idle gear and side plate into the housing.

33-65

33. SLEWING UPPER STRUCTURE 4) Insert O-ring into the guide, and install it to the plate. G

G. Guide L. Large chamfered side 5) Install the plate, guide and O-ring into the housing. Then pay attention to the suction and delivery direction.

D. Delivery side S. Suction side 6) Fit the square ring.

7) Install the cover to the housing.

33-66

33. SLEWING UPPER STRUCTURE 8) Fix the housing and the cover with four M10x20 capscrews. : 8 mm Tightening torque: 55 รท 69 Nm

9) Install O-ring on attaching surface of gear pump.

(4) Installing gear pump 1) Fit the coupling to the shaft end on the main pump side.

2) Connect the gear pump to the main pump. Fix the gear pump with 2 socket bolts (M10x25). : 8 mm Tightening torque: 62 Nm

33-67

33. SLEWING UPPER STRUCTURE 33.2.1.3

MAINTENANCE STANDARD

(1) Parts replacement standard Piece Piston assembly (1) and cylinder block (2) 1

Replacement criterion Remedy • Visual inspection • Replace. To be free from flaw, galling and wear. (Especially the sliding section) • Check clearance between the piston (1) outer diameter and inner diameter of the cylinder block (2). D-d 0.06 mm

Piston shoe (3) and piston (4)

• Piston shoe (3) and piston (4) 4

• Replace.

• Check the play in the axial direction of the piston (4) and shoe shaft (3). 0.2 mm

Shaft

• Shaft

• Replace.

• Check the wear of the oil seal (5).

Wear amount

0.025 mm

5. Oil seal installing range

Control plate

Guide (6) retainer (7)

• Check the sliding surface for • Replace it when flaw. the flaw is severe.

and 6

• Check if it is free form galling • Replace it in a set and step wear. if it is impossible to repair. • Check if it is free form galling • After repairing and step wear. with lapping, clean it to remove the lapping compound.

33-68

33. SLEWING UPPER STRUCTURE 33.2.2

CONTROL VALVE

33.2.2.1

TECHNICAL FEATURES 15

19 18

20 12

Fig. 33-79 No.

Name

Q.TY

No.

Name

Q.TY

Dozer section

End cover

Slewing section

Main pressure relief valve P1, P2

P3 inlet and travel straight conflux section 1

Main relief valve P3

Arm section

Pressure relief valve

Service section

Pressure relief valve

Swing section

Anticavitation valve

Travel (right) section

Tie bolt (L=303)

P1 and P2 inlet section

Tie bolt (L=143)

Travel (left) section

Nut

Boom section

Manual operation

Boom lock section

33-69

33. SLEWING UPPER STRUCTURE The control valve is roughly classified into the following four sections. •Manual operation section:

swing

•Pilot section:

travel right and left, boom, arm, bucket, slewing, independent travel and conflux, dozer blade, service(nibbler and breaker

•Accessory section:

P1 and P2 inlets, and P3 inlet (common with travel straight and conflux)

•Accessory section (valve): P1, P2, P3 main relief, overload relief, anti cavitation, boom lock * For respective operation section, only typical example is described. (1) Manual operation: swing (Item 6) No. 1 2a 2b 2c 2d 2e 2f 2g 3 4 5 6 7 8 9 10 11 12 13 14 15

Name Body Spool O-ring Dust wiper Retainer holder Spring seat Spring Spool end O-ring Dust wiper Retainer holder Screw M6x12 Screw M6x22 Cover Load check valve Spring (for check valve) Plug (for check valve) O-ring Cap O-ring Anticavitation valve

Q.TY 1 1 1 1 1 2 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1

12 11

9 10

14 13

2g 6

Fig. 33-80

33-70

2b 2c 2d 2e 2f

33. SLEWING UPPER STRUCTURE (2) Pilot operation: slewing (Item 2) No. 1 2a 2b 2c 2d 2e 3 4 5 6 7 8 9 10 11 12

Name Body Spool Spring seat Spring Spool end Spring seat O-ring Pilot cover “A” Pilot cover “B” Screw M6x45 Load check valve Spring (for check valve) Plug (for check valve) O-ring Cap O-ring

Q.TY 1 1 1 1 1 1 2 1 1 4 1 1 1 1 1 1

10 9

7 8

12 11

4 6

Fig. 33-81 (3) Main relief valve (P1, P2, P3) and overpressure relief valve No. Name Q.TY 1 Socket 1 Pressure regulating 2 1 valve 17 3 11 10 14 3 Piston 1 4 Body 1 5 Poppet 1 6 Set screw 1 7 Lock nut M14 1 8 Spring (adjust valve) 1 Spring (pressure 9 1 regulating) 10 O-ring 1 11 Back-up ring 1 12 Seat (adjust section) 1 13 O-ring 1 13 1 2 9 12 14 O-ring 2 15 O-ring 1 16 O-ring 1 17 Back-up ring 1 Drawing A. (Only for overpressure relief valve and P3 main relief valve) Fig. 33-82

33-71

33. SLEWING UPPER STRUCTURE (4) Anti cavitation valve No. 1 2 3 4 5 6 7 8

Name Anticavitation valve Body Cap Spring Back-up ring O-ring O-ring O-ring

Q.TY 1 1 1 1 1 1 1

1 Fig. 33-83

33-72

33. SLEWING UPPER STRUCTURE 33.2.2.2

PRECAUTIONS FOR DISASSEMBLY

CAUTION Precautions (These precautions must be observed to guarantee safety). The disassembly and assembly have fundamentally to be carried out at Manufacturer’s plant, but it they cannot be avoided, observe following precautions. (1) All hydraulic equipment is machined in precision and consequently the clearance of each part is very small. Therefore when disassembling and assembling, place the machine in the clean area to prevent it from the entry of dust, earth and sand. (2) Before disassembly, prepare the valve construction drawing to understand the construction clearly. (3) When removing the control valve from the machine, never forget to cap every port to prevent dust, etc from entering. Before disassembly, check again that every port is capped and clean the outer surface of the assy. The work should be carried out on the appropriate work bench which is covered by clean paper or rubber mat. (4) When it is required to leave it in the removed condition, apply rust preventives or seal them to protect them from rusting. (5) The control valve should be transported or moved holding the main body. Especially, after removing the pilot cover, carefully handle it paying attention not to touch the exposed surfaces. (6) Even when the movement is not smooth, never strike it. (7) In addition, after assembly of equipment, various tests {relief setting, leak test, flow resistance (pressure loss) test} are required, but these tests require hydraulic test equipment. Therefore, don’t remove the equipment which is impossible to adjust through respective test, even if the disassembly is possible technically. 33.2.2.3

REQUIRED TOOLS AND OTHERS

Preliminary preparation of the following tools is required for the disassembly and the assembly of the control valve. In addition, the following tools are necessary for the disassembly and the assembly of this valve, but the tools necessary for the disassembly and the assembly of the port connection and the link joint are not included. Tools Allen wrench Wrench Socket wrench Torque wrench Torque wrench Magnet Pliers Screw driver (–) Tweezer

Q.TY One each One each One each 1 1 1 1 1 1

Observations 4, 5, 8, 10 mm 13, 19, 21, 22, 30 mm 13, 19, 22 mm 1.96 ÷ 19.6 Nm 19.6 ÷ 117.7 Nm

Prepare wash oil, hydraulic oil, grease, Loctite #242, tag and marker (felt-tip pen) beforehand.

33-73

33. SLEWING UPPER STRUCTURE 33.2.2.4

DISASSEMBLY

(1) Drawing the spool out Place the control valve on work bench directing the actuator port upward. 1) In case of hydraulic pilot switching type, How to take out the spool for slewing is as follows. (See Figure 33-80 and Figure 33-83). First, loosen and remove 2 washer socket bolts (6) with Allen wrench of 5 mm. Then, remove pilot cover (9). The spring section of the slewing spool is disposed, so draw out and take out spool assembly (2a-2e) slightly and horizontally (parallel to the spool hole) from the body holding the spring section. Other pilot spools can be taken out from the same face by the same procedure. Then, check that the O-ring (3) on the flange bottom installing the pilot cover on the body side is not separated.

Fig. 33-83 Hydraulic pilot switching type 2) In case of manual switching type, How to remove this type as an example of the swing spool is as follows. (See Figures Fig. 33-79 and Fig. 33-84). First, loosen and remove 2 socket bolts (7) with Allen wrench of 5 mm. Then, remove end cover (8). The spring section of the swing spool is exposed; therefore, carefully draw out the spool assy (2a-2g) horizontally, and parallely to the spool opening from the body (1) which contains the spring section. Then, pull the spool assembly carefully, or the spool seal [dust wiper (2c) and O-ring (2b)] moves to the edge section of the spool and the lip section may be damaged. Replace the removed O-ring with new one. If it absolutely has to be used, check that it is free from flaw, deformation and foreign matter adhered.

Fig. 33-84 Manual switching type 3) Precautions when replacing spool When replacing the spool, in no case should the spool be disassembled, but replace it with the new spool assembly.

33-74

33. SLEWING UPPER STRUCTURE 4) In case of independent travel spool (See Figure 33-85) First, loosen and remove the two sems-screws (5) with an Allen wrench of 5 mm. Then, remove pilot cover (4). Remove the disposed spring section of the travel straight spool. Pull out the spool assembly (2a-2e) slowly and horizontally (in parallel to the spool hole axis) from the valve by holding the end of the independent travel spool. At this time, ensure that the O-ring (3) in the bottom of the flange installing the pilot cover on the main body side is in place without coming off. Further loosen three socket bolts (17) with an Allen wrench to remove the body assemblies (13-16) and the piston (10). At this time, ensure that O-rings (11) (12) in the installing surface of the body assembly on the main body side is in place without coming off.

Fig. 33-85 P3 supply and travel straight sections (2) Relief valve (Code: RV) How to remove the overpressure relief valve (Code: ORV) First, fix the valve on the work bench or ask people to hold down the valve. Then loosen the hexagonal section (opposite to the flat one, 30, 22) of RV and ORV with a wrench of 22 mm (0.86 in), 30 mm (1.18 in). At that time, donâ&#x20AC;&#x2122;t remove the valves applying spanner to the opposing flat, 19.

WARNING The set pressure of the RV and ORV differs at the position, so tag every valve with respective attaching position. And handle the removed RV and ORV paying attention not to damage the seat section. The RV and ORV are essential for the performance and safety, but donâ&#x20AC;&#x2122;t disassemble the RV and ORV because it is very difficult to reset the pressure. When there is a failure, replace the assembly.

33-75

33. SLEWING UPPER STRUCTURE (3) How to disassemble load check valve First, fix the valve on the work bench or ask people to hold down the valve. Loosen plug (9) at the center of the valve upper surface with allen wrench of 8 mm. It may be difficult to loosen the plug because O-ring (10) gets caught in the thread. Then, donâ&#x20AC;&#x2122;t force it to loosen, but tighten the plug once again and loosen it again. Take out spring (8), load check valve (7) through the hole used to remove the plug with tweezers or magnet. The item numbers in Fig. 33-86 correspond to that of the swing section in Fig. 33-79. The travel switching, boom lock valve and service switching sections having different forms can be disassembled in the same manner. 9 10

8 8

8 7 7

Fig. 33-87 Load check valve A. Load check valve (dozer, slewing, B. Load check valve (Travel right and C. Load check valve (Service switcharm, swing, boom, bucket) left switching, P3 supply section) ing section) (4) Disassembling lock valve If the lock valve became abnormal, replace it with new one as assembly. The disassembling procedures described below are for reference only to check the cause for abnormality. At first, loosen three socket bolts (27) with a 5 mm Allen wrench. Then remove the lock valve cover (14).

WARNING Pay attention not to damage the piston guide (12) that protrudes from the bottom of lock valve cover (14). Subsequently, the lock valve (6-10) and the needle valve (11) appear; pull out both of them. Remove and store the needle valve first, because it is easily pulled out. Do not disassemble the lock valve, store it as assembly (6-10).

Fig. 33-88 Fix the lock valve cover with a vise, loosen and remove the bush (18) with a 8 mm (0.31 in) allen wrench.

33-76

33. SLEWING UPPER STRUCTURE

WARNING At first, fix the lock valve cover with a vise at the side faces other than the port face. Remove the pistons C (17), A (15) and lock valve spring (16) with a pair of tweezers or a magnet through the bore for plug. Mark on the pistons (C) and (A) to identify the assembled direction. Do not disassemble the piston guide (12), and store it at assembly with the lock valve cover. Loosen the ball retainer (21) with a 4 mm Allen wrench. Remove the Ă¸7steel ball (20) with a magnet through the bore for ball retainer.

Fig. 33-89 (5) Disassembling other parts Remove the other parts, not described in par. (1) through (3), in the following procedures: 1) Service section Plug for actuator part (See Fig. 33-89.) Fix the valve directing the actuator port upward. Loosen and remove plug (11) on both right and left sides of the upper surface of the service change section with spanner of 21 mm (or socket wrench).

Fig. 33-89 Service section 2) Pilot cover of hydraulic pilot switching section (See Fig. 33-83). Loosen and remove two socket bolts (6) with an Allen wrench of 5 mm. Remove the pilot cover (5) horizontally. At the same time, ensure that the O-ring (3) in the bottom of the flange for securing the pilot cover on the main frame side is in place without coming off. 3) Spool seal of manual switching section (See Fig. 33-84). Loosen and remove two socket bolts (6) with an Allen wrench of 5 mm. The oil seal retainer (5) is also removed simultaneously. Remove the spool seal [O-ring (3) and dust wiper (4)] through the spool hole on the side of the main frame, paying attention not to damage the spool seal and switching main frame. Donâ&#x20AC;&#x2122;t reuse the O-ring. When it is required to be used again, check that it is free from flaw, deformation, foreign matter adhered, and so on before installation.

33-77

33. SLEWING UPPER STRUCTURE (6) Disassembling main frame of switching section The figures in parentheses following the part names in the description are the item numbers used in the outline view. Loosen and remove four M8 nuts (20) for fastening the main frame of the switching section on the valve side with a wrench (socket wrench) of 13 mm. Pull eight tie-bolts (18), (19) from the side and remove each main frame of the switching section. Then, care should be taken not to miss various O-rings fitted on the mating face of respective main frames. Do not remove a number of plugs screwed in the unnecessary holes for valve manufacturing of the main frame of the switching section unless required. (7) Cautions for disassembling

WARNING The removed parts should be carried and stored carefully to prevent damage and contamination. And when the removed parts are applied, stored, or carried in the removed condition, fill up the holes after the removal of parts with cap, tape, etc. to protect it from entry of dust, dirt, etc. (8) Disassembling anticavitation valve

WARNING Since the anticavitation valve is essential for the performance, replace it with the new assembly if necessary. Procedures for disassembling the valve to check for abnormality is shown below for reference. The figures in parentheses following the part names in the description are the item numbers in the cross-sectional drawing (Fig. 33-82). Firstly, hold the hexagonal section having width across flats of 22 mm with a vise lightly. Loosen and remove the plug (3) with an Allen wrench of 8 mm. Remove the spring (4). Then push in the anti-cavitation valve (1) from the seat side while taking care not to damage the seat section. Pull out the O-ring (6) and back-up ring (5) from the side from which the plug (3) was removed while taking care so that the rings are not damaged by the internal thread of the body (2). (9) Relief valve (Code: RV) Disassembly of overpressure relief valve (Code: ORV)

WARNING Since the overload relief valve is essential for the performance and safety and the resetting of the pressure is very difficult, replace it with the new assembly when an abnormality is detected. For reference, how to disassemble for checking the abnormality is shown below. The figures in parentheses following the part names in the description are the item numbers in the cross-sectional drawing (Fig. 33-81). First, hold the body (5) with a vise at the hexagonal section of the opposing flat, 22. Loosen and remove adjusting screw (7) with allen wrench of 4mm. Take out spring (9), the poppet (6) and spring guide (16) with tweezers, etc. Then, loosen and remove plug (4) with spanner of 19 mm, and the remaining parts can be taken out at the same time. And take out socket (1), piston (3), spring (10) and pressure regulating valve (2) in order.

33-78

33. SLEWING UPPER STRUCTURE 33.2.2.5

PRECAUTIONS WHEN ASSEMBLING

CAUTION Precautions (Observe the following standards to guarantee safety). (1) The unevenness of tightening torque and the contamination by dust during assembly may cause a failure. And observe the tightening torque specified in the description. (2) When assembling, check up on the valve construction drawing, identify the number of part, and ensure that there is no installation error and omission of part, etc. (3) After cleaning the parts required to use with cleaning solvent, immerse them in hydraulic oil as required and reassemble them. (4) Before applying Loctite, clean and decrease the surface sufficiently, and apply it to two threads. (The application of an excessive quantity of Loctite may cause a malfunction resulting in it squeezing out). 33.2.2.6

PRECAUTIONS WHEN FITTING SEALS

CAUTION Precautions (Observe the following standards to guarantee safety). (1) Replace seals with new ones when assembling. (2) Ensure that seals are free from deformation and flaw coming about when handling them. (3) Apply grease or hydraulic oil to the seals and seal fitting section to make the sliding smooth, unless otherwise specified. (4) Do not stretch the seals too much. Otherwise they may be permanently deformed. (5) Pay attention not to roll the O-ring when fitting. Because it is difficult for the twisted O-ring to be restored naturally after fitting, and it may cause oil leakage. 33.2.2.7

ASSEMBLY WORK

(1) Perform assembling work referring to the drawings in â&#x20AC;&#x153;Disassemblyâ&#x20AC;? Section. (2) Assembling procedure 1) Assembling the main frame of the switching section (See Fig. 33-79). Put all sections of main frame in order as shown in Table 33-2 directing the actuator port downward. SECTION (Block)

MARK AQ10

Dozer

Slewing

P3 inlet

Arm

Service

B/Swing

Travel right

P1, P2 inlet

Travel LH

Boom

Bucket

End cover

33-79

33. SLEWING UPPER STRUCTURE

NOTE: the symbols are engraved on the upper surface of the main frame of the switching section (actuator port face).

CAUTION Then, check that the mating surface of the main frame of each switching section is free from dust, etc. and the Oring is securely fitted in the groove. And, insert eight tie bolts (18)(19) through the main frame of the switching section from the side, and tighten eight M8 nuts to the specified torque with socket wrench of 13 m. Tightening torque = 19.6 Nm Observe the specified torque. When the lock nut is not tightened to the torque other than specified, it may cause a distortion and oil leakage of the main frame. At this time, donâ&#x20AC;&#x2122;t tighten the lock nuts at a time, but tighten four lock nuts to make uniform in several times. Tighten the lock nuts making the upper and lower, and right and left sides uniform with a plastic hammer, etc. following the sketch drawing, or make them uniform with press, etc. after tightening. 2) Assembling load check valve Put the load check valve of the valve on the work bench directing the actuator port upward. a. Sections other than travel, P3 supply and service (See Fig. 33-87) Place load check valve (7) in the hole at the center of the valve in normal condition (direct the cap section downward), and check that it is placed in at the center. Fit spring (8) on the guide of the load check valve. Tighten the plug by hand so that the guide of the load check valve can be fitted on the guide of plug (9), and the spring can be in place.

CAUTION Then, check that O-ring (10) is fitted on the plug. Screw in with a certain amount, and tighten it to the specified torque with allen wrench of 8 mm. Tightening torque = 39.2 Nm b. Travel, P3 supply sections (See Fig. 33-87) Additional equipment section (See Figure 33-87) Place the load check valve (7) in the hole at the centre of the valve in the normal direction (direct the cap section downwards), and check that it is correctly centered. Apply grease to the spring (8) and fit the plug (9) in the guide.s

CAUTION Then, ensure that the O-ring (10) is fitted on the plug (9). Tighten the plug by hand so that the guide of the load check valve installed on the main frame of the switching section can be fitted on the guide of the plug after checking that the check valve spring does not drop even when the plug is reversed up and down in this condition. Screw in with a certain amount, and tighten it to the specified torque with allen wrench of 8 mm. Tightening torque = 39.2 Nm Assemble it paying attention to the correct position where two types of the load check valve are installed. 3) Assembling RV and ORV

CAUTION Tighten the (RV) and (ORV) to respective port for installation to the specified torque. Tightening torque = 39.2 Nm Observe the specified torque. When the respective valve is not tightened to the torque other than the specified, it may cause a distortion and oil leakage of the connection. Since the pressure settings of RV and ORV on each places differ, install them on the position as they were in order not to make a mistake referring to the tags attached when disassembling.

33-80

33. SLEWING UPPER STRUCTURE 4) Assembling spool assembly a. In case of hydraulic pilot switching type, (See Fig. 33-84) Insert respective spool assembly in the spool holes of the main frame of the switching section paying attention to the positions and directions so as not to make a mistake, after checking that respective spool assembly and the spool holes of the main frame of the switching section are free from dust, etc. and also O-ring (3) is securely fitted on the bottom of the flange of the main frame of the switching section (2 places before and after the main frame of the switching section). Then, apply a slight hydraulic oil to the spool before insertion.

CAUTION Then, don’t force the insertion of the spool due to the difficulty to getting in, or it may cause malfunction, etc. Next, check that the spool moves smoothly by getting it in and out several times by hand, and be sure that there are no unsmooth movements or catching. Where there is no above feeling of the physical disorder, replace the set of the spool assembly and the main frame of the switching section. And, install pilot cover (4) on the flange section of the main frame of the switching section from the spring side of the spool assembly securely, and install it on the main frame of the switching section by tightening washer socket bolt (6) with Allen wrench of 5 mm. Tightening torque = 9.8 ÷ 10.8 Nm Fit the flange section on the opposite end of the main frame of the switching section so that pilot cover (5) snaps into the flange section of the main frame of the switching section after checking that O-ring (7) is placed in, and then install it on the main torque of the switching section with flange socket bolt (6) tightening with Allen wrench of 5 mm (0.19 in) to the specified torque. Tightening torque = 9.8 ÷ 10.8 Nm b. In case of manual switching, (See Fig. 33-85) Insert respective spool in the spool holes of the main frame of the switching section paying attention to the position and direction after checking that respective spool assembly and the spool holes of the main frame of the switching section are free from dust, etc.

CAUTION At the time, don’t tighten 2 socket bolts at a time, but tighten them slightly and alternately several times to make uniform. And, fit O-ring (3), dust wiper (4) and oil seal retainer (5) in order on the spool prevented from the opposite end of the main frame of the switching section, and tighten socket bolt (6) with Allen wrench of 5 mm. Tightening torque = 9.8 ÷ 10.8 Nm At this time, pay attention to the direction of the dust wiper (direct the lip outwards). Do not tighten the screws at one time, but tighten 2 socket bolts slightly so that oil seal presser is inserted in parallel.

33-81

33. SLEWING UPPER STRUCTURE c. In case of P3 supply and travel straight spools (See Fig. 33-86) Ensure that the travel straight spool, P3 supply and spool hole for the main frame of switching section are free from dust, and that the O-rings (3) is securely fitted in the flange bottom of the main frame of the P3 supply section (three places in front and back of the main frame of supply section). Then install the piston (10) in the flange section (the side of two O-ring grooves) of the main frame. Insert the socket bolts (17) to the pilot body assembly (16 - 19) to fix it temporarily to the main frame. At this time, roughly adjust the vertical and horizontal orientations of the pilot body against the main frame. Tighten three socket bolts with an Allen wrench of 5 mm to the specified torque equally. Tightening torque = 9.8 ÷ 10.8 Nm Apply a small amount of hydraulic oil to the travel straight spool assembly and insert it through the spool hole opposite to the side where the pilot body assembly was installed, without mistaking front and rear orientation.

CAUTION Do not use excessive force to push in the spool if it is sticking. Further fit the pilot cover (4) in the flange section of the main frame securely, and tighten the sems-bolt (6) with an Allen wrench of 5 mm (0.19 in) at the specified torque to fix the install the cover to the main frame. Tightening torque = 9.8 ÷ 10.8 Nm Confirm the fact that the plug (18) has been surely installed to the port (G1/4) of the pilot cover (4). 5) Assembling lock valve If the lock valve became abnormal, replace it with new assembly. The assembling procedures described below are only for reference after disassembling to investigate the cause for abnormality. (See Fig. 33-88 and Fig. 33-89) At first, fix the lock valve cover (14) with a vise at the side faces other than the port face. After fixing, insert the piston A (15) into the bore on piston guide (12) paying attention to its direction. Then insert the lock valve spring (16) and piston C (17) into the bore on the lock valve cover paying attention for its direction. After that, tighten the plug (18) with 8 mm (0.31 in) allen wrench to the specified torque. Tightening torque = 39.2 ÷ 49 Nm

CAUTION At that time, confirm the fact that the O-ring (19) has been surely installed to the plug. If the pistons (A and C) are difficult to insert, do not try to insert them by force. It may lead to malfunction. After the insertion of pistons (A and C), confirm smooth movement of them by taking them in and out with hand for several times. If the movement is not so smooth, replace the pistons (A and C) to new ones together with the lock valve cover as assembly. After setting the ø7 steel ball (20) to the place, tighten up the ball retainer (21) at the specified torque. Tightening torque = 7.8 ÷ 9.8 Nm

CAUTION At that time, confirm the fact that the O-ring (22) has been surely installed to the ball retainer. After confirming that the flat O-ring (3-5) has been securely installed on the inserting side of the lock valve, set the lock valve assembly (6-10) and the needle valve (11), and insert them into the bore of the lock valve. Set the lock valve cover to piston guide, which is protruding from the bottom of lock valve cover (14), slowly press the lock valve cover until getting touch with the lock valve body. At that time, confirm that the needle valve (11) is surely placed on the seat inside the lock valve cover. Then tighten the socket bolts (27) with the 5 mm (0.19 in) Allen wrench to the specified torque. Tightening torque = 9.8 ÷ 10.8 Nm

33-82

33. SLEWING UPPER STRUCTURE

CAUTION At the tightening, make sure to tighten up three socket bolts alternatively so that the lock valve cover does not incline. 6) Assembly pf pressure relief valve and overpressure relief valve The relief valve is essential for the performance and safety, and it is very difficult to reset the pressure. Therefore, in case of the abnormality, replace it with a new assembly. The assembling procedures described below are only for reference after disassembling to investigate the cause for abnormality. The figures in parentheses following the part names in the description are the item numbers in the crosssectional drawing (Fig. 33-82). First, place spring guide (16) in adjusting screw (7) and then place spring (9) in. Then, shake the adjusting screw lightly and be sure that the interference of spring guide (16) and spring (9) is sufficiently ensured. If the interference is insufficient, spring (9) pops out or the protrusion from adjusting screw (7) becomes larger. Thereafter fit poppet (6) in plug (4) and tighten adjusting screw (7) (spring guide (16), spring (9) are already fitted.) lightly. At that time, tighten lock nut M14 (8) lightly. And place spring (10) and piston (3) in poppet (2), and place it in socket (1). And tighten body (5) and plug (4) to the specified torque after checking that piston (3) is inserted in the hole of the top end of plug (4). Tightening torque = 58.8 Nm And adjust the pressure by adjusting screw (7) with Allen wrench of 4 mm (0.15 in) and tighten lock nut M14 (8) to the specified torque. Tightening torque = 19.6 Nm Assemble the relief valves in the reverse procedure of the disassembly paying attention to the direction and order and observing the specified torque. Failure to do so may result in oil leakage or breakage. 7) Assembling anticavitation valve The anticavitation valve is essential for the performance and safety, so in case of abnormality replace it with a assembly. For reference, the procedure for disassembly and assembly is shown below. The figures in parentheses following the part names in the description are the item numbers in the crosssectional drawing (Fig. 33-83). First, place anti cavitation valve (1) in body (2), and place spring (4) in it. Then tighten the plug to the specified torque. Tightening torque = 58.8 Nm Assemble the anti cavitation valve by the reverse procedure of the disassembly paying attention to the direction and order and observing the specified torque. Failure to do so may result in oil leakage or breakage.

33-83

33. SLEWING UPPER STRUCTURE 33.2.2.8

Maintenance standard

Parts inspection Part name Main frame of switching section

Criterion and corrective action 1) Replace it when there is flaw on the following section. • Sliding section against the spool, especially land section where the hold pressure is applied. • Seal pocket section where the spool is placed in or flange section • Seal section of the port in contact with O-ring • A damaged seat section of the pressure relief valve and of the overpressure relief valve may cause malfunction, etc. Spool 1) Existence of scratch, rust and corrosion 1) Replace it when there is scratch on the peripheral sliding surface 2) Insert spool in the hole of the main frame 2) In case the spool is not smooth, repair or of the switching section, stroke it while replace it. rotating. Load check valve 1) Damage of load check valve and spring 1) In case there are flaws and scratches on the seat section, repair or replace it. 2) Insert load check valve in plug and 2) When it moves smoothly, normal, but if it experimentally operate it. moves unsmoothly, replace it. Around spring 1) Rust, corrosion, deformation and 1) Replace it when the movement is unsmooth breakage of spring, spring seat, plug, and or there is damage causing poor durability. cover Around of seal of 1) Hardening, deformation and flaw of O-ring 1) Replace spool 2) Deformation and flaw of dust wiper 2) Replace 3) Rust, corrosion and deformation of oil seal 3) Repair or replace retainer Pressure relief valve 1) Rust on outer surface 1) Replace Pressure relief valve 2) Contact surface of valve seat 2) In case there are flaw and dent, replace it. 3) Spring in abnormal condition 3) Replace 4) O-ring, back-up ring 4) Replace all parts, as a general rule. 33.2.2.9

Inspection item 1) Existence of scratch, rust and corrosion

Cause of failure and corrective action

(1) When abnormal condition is detected, check on the control valve, pump, cylinder, and motor for abnormality or failure on the circuit. For that, measure the pilot pressure, delivery pressure of the pump, load pressure, etc. And when a part of them is required to disassemble for checking, follow the procedure of the disassembly and assembly in the above description. (2) Since dust is very harmful for hydraulic equipment, pay attention to the dust proof. When a part of them is required to disassemble, before starting the work take a measure for dust protection. (3) Handle the movable section carefully. Even if there is a slight flaw, repair it with oil stone or replace it. When replaced, clean them. (4) Handle O-ring, etc. carefully in order not to damage the gasket surface. These flaws will cause oil leakage.

33-84

33. SLEWING UPPER STRUCTURE 1) Control valve Defect 1. Each attachment does not function, or the actuation is slow. (Poor power) Or there is no response.

2) When spool is placed on the neutral position, the natural drop of the cylinder is large.

3) When the cylinder is set to the raise position, the cylinder moves downward reversely when starting the operation.

Cause 1) Malfunction of relief valve • Dust caught between pressure regulating valve and seat. * • Dust caught between poppet and seat. * • Pressure regulating valve is stuck. * • Breakage or permanent set in fatigue of spring. * • Loosen of adjusting screw.

Corrective action 1) Measure the pressure of relief valve • Replace the assembly. * • Replace the assembly. * • Replace the assembly. * • Replace the assembly. *

• Readjust it, and tighten the lock nut to the specified torque. 2) Dust caught between the main frame and 2) Disassemble and clean. spool, or stuck In case of severe flaw, replace the main frame and spool. 1) The space between the main frame of the 1) Replace spool. switching section and the spool is too large. 2) The spool is not returned to the neutral 2) Measure pilot secondary pressure. position completely. • Dust caught between the main frame and • Disassemble and clean, or when stuck, spool, or stuck. replace the main frame and spool together. • Breakage or permanent set in fatigue of • Replace spring. spring. 3) Malfunction of overpressure relief valve 3) Measure the pressure of ORV. (ORV) Refer to the description marked with *. Refer to the description marked with *. 4) Malfunction of lock valve 4) Replace with a new lock valve section • Dust caught in the seat section of the lock assembly (including the lock valve main valve or needle valve. body). • Stick of the lock valve or needle valve. • Dust caught in the throttle of the lock valve. 1) Malfunction of load check valve 1) • Dust caught between load check valve and • Disassembly and cleaning. main frame. In case of the severe damage, replace the main frame and load check valve together. • Load check valve is stuck. • Ditto • Breakage and permanent set in fatigue of • Replace spring. spring.

* In case of abnormality marked with *, do not fail to replace with the new relief valve assembly.

33-85

33. SLEWING UPPER STRUCTURE 2) Relief valve The relief valve is essential for the performance and the safety, and it is difficult to reset the pressure other if there is no facility in service shop, so when abnormality occurs, don’t fail to replace the assembly. The handling method is for reference, replace the assembly as a rule. Defect 1. Pressure does not rise.

Cause Corrective action The pressure adjusting valve of each relief • Check that the engagement valve of valve, poppet and piston are stuck, kept respective valve doesn’t get matters open, or got caught dust in the seat section caught in it. of the valve. • Each part slides freely. • Clean all parts completely. 2) Relief pressure is The adjusting valve of respective valve is • Replace the damaged part. unstable. damaged, or the piston is stuck to the • Clean all parts completely. poppet. • Remove flaw on the surface. 3) The relief pressure is 1) Wear due to dust 1) Disassemble and clean it. not within the limit of 2) Lock nut and adjusting screw are loose. 2) Adjusting pressure set values. • Breakage and permanent set in fatigue of • Replace spring. spring 3) Malfunction of (RV) and (ORV) 3) Measure the pressure of RV and ORV. 4) Oil leakage. 1) Damage on each seat section 1) Replace the worn or damaged part. Wear of O-ring Check that respective part move smoothly before installing. 2) Respective part is stuck due to dust 2) Check that it is free from scratch, score entered. and foreign matter before installing.

33-86

33. SLEWING UPPER STRUCTURE 33.2.3

ATTACHMENT CONTROL VALVE

33.2.3.1

CONSTRUCTION COMPONENTS

1 (3)

2 (4)

Fig. 33-91 Attachment control valve A. Apply grease S. Shim for adjusting secondary pressure No. 301 302. 312

No. 101 151 201 211 212–1 212–2

Size M14 M14

NAME BODY PLATE SPOOL PLUG PUSH ROD PUSH ROD

Tightening torque (Nm) 47.1 68.6

Q.TY 1 1 4 4 2 2

No. 213 214 216–1 216–2 217 221

NAME SEAL O-RING SPRING SEAT SPRING SEAT WASHER 2 SPRING

33-87

Q.TY 4 4 2 2 4 4

No. 241–1 241–2 301 302 312 501

NAME SPRING SPRING JOINT M14 DISK ADJUSTING NUT M14 BELLOWS

Q.TY 2 2 1 1 1 1

33. SLEWING UPPER STRUCTURE 33.2.3.2 (1)

(2)

DISASSEMBLY AND ASSEMBLY

Tools No.

Name

Observations

Torque wrench

15 รท 100 Nm

Screw driver (-)

W = 2-3, 4-5

c d

Screw driver (+) Wrench

Drawing 22 mm and 32 mm

Jig Special jig: for disassembling and assembling the joint (301) (See Figure 33-92).

Fig. 33-92 Special jig 33.2.3.3 33.2.3.3.1

Disassembly procedure General cautions for disassembly

(1) Since all the parts are very precisely manufactured, carefully handle them without causing collision with each other or dropping. (2) Perform the work carefully without hammering or using excessive force even if the part is sticking. Otherwise burrs or damage may be produced, thus causing oil leaks and performance losses. (3) When leaving the parts in the disassembled condition, always take rust preventive and dust protective measures. Otherwise rust may be produced on other parts due to humidity or dust.

33-88

33. SLEWING UPPER STRUCTURE 33.2.3.3.2

Disassembly

(1)

Remove the handle lever (1) assembly and boot (2) from the casing (101).

(2)

Clean the pilot valve with white kerosene. â&#x20AC;˘

(3)

Screw a blind plug in each port in advance.

Hold the pilot valve with a vise by applying a copper or lead sheet. 2

101

Fig. 33-93 Handle lever disassembly (4)

Apply wrenches to the adjusting nut (312) and the disk (302) across the flats to loosen and remove them.

Fig. 33-94 Adjusting nut (312) removal (5)

Turn the joint (301) counterclockwise with a jig to loosen.

CAUTION When pulling off the joint, be careful that the joint is no sooner loosened than the plate (151), plug (211) and push rod (212) may pop up if the return spring (221) is too strong.

Fig. 33-95 Joint (301) removal (6)

Remove the plate (151).

Fig. 33-96 Plate (151) removal

33-89

33. SLEWING UPPER STRUCTURE (7)

If the return spring (221) is not strong enough, use a minus screwdriver to extract the plug (211) which remains in the body (101) due to the resistance to the O-ring’s sliding. •

Apply the tip of the flat screwdriver to the external groove of the plug (211) while preventing damage to the plug due to eccentric load.

CAUTION Make sure that the plug (211), when it opens, does not pop up due to the spring return force (221). (8)

Fig. 33-97 Spring (221) removal

Remove the push rod (212), plug (211), pressure reducing valve section assembly, and return spring (221) from the casing (101). •

Record the relation between the casing hole positions and these parts.

Fig. 33-98 Push rod (212) removal (9)

In order to disassemble the pressure reducing valve, shift the spring seat (216) laterally while pushing in the spring seat (216) to make the secondary pressure spring (241) deflect, and remove the valve from the spool (201) through the larger hole. •

Be careful not to damage the surface of the spool (201).

•

Do not push down the spring seat (216) by more than 6 mm. Fig. 33-99 Pressure reducing valve disassembly

(10) Separate the spool (201), spring seat (216), secondary pressure spring (241), and washer 2 (217). •

Handle these parts as an assembly until assembling.

Fig. 33-100 Pressure reducing valve disassembly

33-90

33. SLEWING UPPER STRUCTURE (11) Pull out the push rod (212) from the plug (211).

Fig. 33-101 Pulling out plug (211) (12) Remove the O-ring (214) and seal (213) from the plug (211). Remove the seal (213) using a small flat screwdriver and so on. (13) Cleaning parts 1) Clean the parts in a rough cleaning container containing white kerosene (rough cleaning). •

Immerse the parts in the kerosene to facilitate the removal of dust and oil. Otherwise the parts may be damaged due to using excessive force.

•

Check the white kerosene for contamination and use clean one. Otherwise, the parts may be damaged, and cause a reduction of performance after reassembly.

•

Do not dry the parts with compressed air. Otherwise, parts may be damaged due to dust or humidity or rust.

2) Put a part in a finish cleaning container containing white kerosene and turn the part slowly to sufficiently clean the part including its interior (finish cleaning). Dry parts by wiping off kerosene with clean rag. 3) Rust prevention of parts Apply rust preventive agent to the parts. •

Do not leave the parts without applying rust preventive agent. Otherwise rust may be produced, leading to malfunction after assembly.

33-91

Fig. 33-102 Seal (213) removal

33. SLEWING UPPER STRUCTURE 33.2.3.4

Assembling procedures

33.2.3.4.1

General cautions for assembling work

(1) Most of the general precautions for assembly operations are similar to those for assembly operations. (2) Remove metal chips or foreign substances from all the parts and ensure that the parts have no burrs or flaw prior to assembly. Remove burrs or flaws, if present, with a hone. (3) Replace the O-rings and back-up rings with new ones in principle. (4) Be careful not to damage the O-rings and back-up rings when fitting them. (Apply a small amount of grease to fit them smoothly.) (5) Apply grease to the parts to be installed in order to prevent them from dropping. (6) Tighten screws at the torque specified. Watch the torque using a torque wrench. (7) After finishing the assembly, screw blind plugs in all the ports to prevent dust intrusion. 33.2.3.4.2 (1)

Assembly

Insert the washer (217), secondary pressure spring (241), and spring seat (216) to the spool (201) in this order.

Fig. 33-103 Assembling spool (201) (2)

Shift the spring seat (216) laterally while pushing in the spring seat (216) to make the secondary pressure spring (241) deflect, and install the valve to the spool (201) through the larger hole. â&#x20AC;˘

Do not push down the spring seat by more than 6 mm.

Fig. 33-104 Assembling spool (201) (3)

Install the return spring (221) into the casing (101). Install the pressure reducing valve assembly into the casing (101). â&#x20AC;˘

Install these parts into the position before disassembling.

Fig. 33-105 Assembling spool (201)

33-92

33. SLEWING UPPER STRUCTURE (4)

Insert the O-ring (214) and seal (213) into the plug (211). •

Direct the lip of the seal (213) as shown below: 211 213 212 A

Fig. 33-106 Installing seal (213) (5)

Install the push rod (212) into the plug (211). •

Apply hydraulic oil to the surface of push rod (A).

Fig. 33-107 Installing push rod (212) (6)

Install the plug (211) assembly into the casing (101). If spring return is not strong (221), the assembly may stop due to sliding resistance of the O-ring (214). •

Do not use excessive force with the spool (201) inclined, otherwise, the hole in the valve body may be damaged.

Fig. 33-108 Installing plug assembly (211) (7)

If spring return (221) is too strong, install four assemblies at the same time using the plate (151) and temporarily fasten with the joint (301).

CAUTION Be careful to popping up of the plug assembly and plate (151).

Fig. 33-109 Installing joint (301)

33-93

33. SLEWING UPPER STRUCTURE (8)

Install the plate (151). Install the joint (301) to the casing (101) and tighten the joint to the specified torque using a jig.

Fig. 33-110 Installing joint (301) (9)

Install the disk (302) into the joint (301). Then install and tighten the adjusting nut (312) to the specified torque while holding the disk (302) with a wrench. â&#x20AC;˘

Do not change the position of the disk (302) during tightening.

CAUTION Screw in until the disk contacts with four push rods (212) equally. Carefully adjust the screwing position of the disk (302) because excessive screwing may result in secondary pressure generation at the neutral position of the lever, leading to malfunction of the actual machine.

Fig. 33-111 Installing disk (302)

(10) Apply grease to the rotating section of the joint (301) and the push rod (212). (11) Install the handle lever assembly and boot to the casing (101).

Fig. 33-112 Applying grease

33-94

33. SLEWING UPPER STRUCTURE 33.2.3.5

Maintenance standard

Piece Quantity of liquid lost

Spool

Push rod

Standard value Observations Replace with a complete set of pilot valve when Condition: the amount of leakage reaches more than 1000 cc/ Primary pressure: 2.94 MPa min or 2000 cc/min at the neutral position of the Oil viscosity: 23 mm2/s handle or during operation, respectively. Replace with a whole series of pilot valves if the The wear condition to the left is considsliding section is worn by more than 10 Âľm, if com- ered to correspond to the above amount pared to the non-sliding section. of leakage. Replace when a wear amount of the tip is more than 1 mm.

Unnecessary play in Replace when a play more than 2 mm due to wear Adjust the play generated in the tightenoperation section. and so on is found on the disk (302) or joint section ing/loosening section. (301) of the operation section. Stable operation Replace with a complete set of pilot valve when abnormal noise, hunting or primary pressure drop is generated during operation and the trouble cannot be remedied according to Section 33.2.3.6 TROUBLESHOOTING.

NOTE: Replace seal such as O-ring with new ones after every disassembly. 33.2.3.6

TROUBLESHOOTING

Defect Secondary does not rise.

Possible Cause pressure 1) Primary pressure is insufficient. 2) Springs (241-1, 241-2) are broken or fatigued. 3) Clearance between spool (201) and valve body (101) is abnormally large. 4) Play of handle portion is too much.

Secondary pressure is 1) Sliding parts are caught. unstable. 2) Tank line pressure varies. 3) Air has contained into pipeline. Secondary pressure is 1) Tank line pressure is high. high. 2) Sliding parts are caught.

33-95

Corrective action 1) Secure primary pressure. 2) Replace with new ones. 3) Replace assembly. 4) Disassembly and reassembly or replace handle portion. 1) Correct. 2) Return directly to oil tank. 3) Release air. 1) Return directly to oil tank. 2) Correct.

33. SLEWING UPPER STRUCTURE 33.2.4 33.2.4.1

TRAVEL CONTROL VALVE CONSTRUCTION COMPONENTS

A. Apply grease to bearing Fig. 33-113 Control valve (Travel) Torque (Nm)

29.4

No.

NAME

Q.TY

101

BODY

102

CASING (DAMPER)

201

COVER

202

PLUG

203

Torque (Nm)

No.

NAME

Q.TY

252

PLUG

261

O-RING

271

SCREW

301

SPOOL

GREASE NIPPLE

311

SPRING SEAT

210

SEAL

313

WASHER

211

O-RING

324

SPRING

212

O-RING

335

SPRING

213

O-RING

336

SPRING

214

PUSH ROD

413

CAM SHAFT

217

SHIM

414

BUSHING

218

SPRING SEAT

420

CAM

224

PISTON

471

BALL

225

BALL

472

ADJUSTING SCREW

251

PLUG

501

BELLOWS (BOOTS)

6.9 8.8

6.9

33-96

33. SLEWING UPPER STRUCTURE 33.2.4.2

DISASSEMBLY AND ASSEMBLY

(1) Special jig for disassembly and assembly Special jig 1 (for removal of bushing)

Fig. 33-114 Special jig 1 (2) Precautions for disassembly and assembly 1) Disassemble and assemble the pilot valve, making sure dust, dirt etc. do not enter into it. 2) Handle parts carefully not to damage. 3) Write down the installing positions of respective part during disassembly, and assemble respective part to the position as they were before. (3) Disassembling 1) Stop respective port (P, T, 1, 2, 3 and 4) of the valve with plugs and clean the outer surface. 2) Fix the cleaned valve with vise. 3) Remove bellows (501) from cover (201). 4) Remove set screw (472). : 6 mm 5) Contact pry bar (Ă¸7 or less) to one end of cam shaft (413), and strike it lightly with a hammer. 6) Remove cam (420). 7) Remove socket bolt (271). : 6 mm 8) Remove cover (201). 9) Remove the casing upper assembly and fix the assembly with vise, again. 10) Pull out the push rod (214) from the plug (202). 11) Remove plug (202) with grease cup (203), packing (210) and O-ring (212). 12) Remove piston (224). 13) Remove damping spring (336) from the casing. 14) Place spring seat (218) in casing (102) with tweezers. 15) Take out steel ball (225) using magnet. 16) Fix the lower casing assembly with vise, and take out O-rings (211 and 213) from casing (101). 17) Remove reduction unit valve assembly and return spring (335) from casing (101). 18) Place cover (201) on the flat bench transverse, apply bushing (414) to special jig 1, strike it lightly with hammer, and pull the bushing out. 19) To disassemble the reduction unit valve, first push the valve seat (311) diagonally, so that the spring (324) generates secondary pressure, remove the valve from the spool (301) through the bigger opening.

33-97

33. SLEWING UPPER STRUCTURE •

Handle the assembled unit as an assembly.

Fig. 33-115 20) Separate spool (301), spring (324) for secondary pressure setting, shim (217) and washer. •

Handle the assembled unit as an assembly. There may be assemblies where the washer is not installed.

21) Remove grease cup (203) from plug (202). 22) Remove O-ring (212) from plug (202). 33.2.4.3

ASSEMBLY

(1) Clean all parts before assembly, and dry them by means of compressed air. Don’t use a rag. •

Repair the parts damaged when being disassembled, clean them, apply oil to the moving section, and install the same parts on the positions where they are before.

•

Replace every O-ring and packing with new ones.

(2) Install washer (313), shim (217), spring (324) for resetting the secondary pressure, and spring seat on spool (301) in order. (3) Pass spool (301) through the larger hole of spring seat (311), push the spring seat in, and install it making the spring for the secondary pressure deflect and shifting the spring seat laterally. (4) Fix casing (101) with vise, and place spring (335) for return in casing (101). (5) Place the reduction unit subassembly described above par. 2) and 3) in casing (101). •

Install them on the positions as they were before.

•

When placing the reduction unit subassembly in, pay attention to the spool lower end so as not to bring into contact with the corner of the casing (C).

Fig. 33-116 (6) Place O-rings (211, 213) in casing (101). (7) Fix upper casing (102) with vise and place the steel ball in it. (8) Place spring seat (218) in casing (102) with tweezers. (9) Place damping spring (336) in casing (102).

33-98

33. SLEWING UPPER STRUCTURE (10)Install piston (224). (11)Place O-ring (212) in plug (202). (12)Place packing (210) in plug (202). â&#x20AC;˘

Pay attention to the direction when placing the packing (P) in.

â&#x20AC;˘

Apply grease slightly before placing packing (P) in.

Fig. 33-117 (13)Place grease cup (203) in plug (202). (14)Install push rod (214) on plug (202). (15)Place the push rod subassembly which is assembled by the procedures in par. 11) to 14) in casing (102). (16)Put cover (201) on the flat work bench, press bushing (414) with special jig 1, and press fit the bushing striking lightly. (17)Fix the lower cover assembly which is assembled by the procedures in paragraph 2) to 6) with vise, and install the upper cover assembly which is assembled by the procedures in paragraph 7 to 15) on it. (18)Install cover (201) on casing (102). (19)Tighten socket bolt (271) to the specified torque. (20)Install cam (420) on cover (201). (21)Insert cam shaft (413) from the outside pressing cam (420). (22)Apply Loctite #241 or equivalent to the thread of socket bolt. (23)Tighten socket bolt (472) to the specified torque. (24)Incline cam (420), apply grease to the top end of push rod (214), and fill grease cup (203) of plug (202) with grease. (25)After fitting the top end of bellows (501) in cam (420), fit the lower side in the groove of cover (201).

33-99

33. SLEWING UPPER STRUCTURE 33.2.4.4

TROUBLESHOOTING

Defect Causes Corrective action Secondary 1) Insufficient primary pressure 1) Secure primary pressure. pressure does not 2) Permanent set in fatigue of spring (324) for 2) Replace it with new one. rise. setting of secondary pressure. 3) The gap between spool and casing is too 3) Replace it with complete remote control large. valve. 4) The control section is loosened. 4) Replace parts of control section. Secondary 1) Sliding part is not smooth. 1) Repair unsmooth section. pressure is 2) Variation of pressure of tank line 2) Return oil to oil tank directly. unstable. 3) Air contamination in piping 3) Bleed air by operating several times. Secondary 1) Pressure of tank line is high. 1) Return oil to oil tank directly. pressure is high. 2) Sliding part is not smooth. 2) Repair unsmooth section. Damping does not 1) Air is accumulated in piston chamber. 1) Bleed air by operating several times. work. 2) Sliding part is not smooth. 2) Repair unsmooth section. 3) Permanent set in fatigue of damping spring 3) Replace it with new one. (336) 4) Gap between damping piston (224) and 4) Replace it with complete remote control casing (damper) (102) is too large. valve. 5) Malfunction of check valve 5)Disassemble and check on check valve section. 6) Orifice of damping piston (224) is too large. 6) Replace damping piston. Damping torque is 1) Sliding part is not smooth. 1) Repair unsmooth section. heavy. 2) Orifice of damping piston (224) is clogged. 2) Repair or replace damping piston.

33-100

33. SLEWING UPPER STRUCTURE 33.2.5 33.2.5.1

SWING MOTOR CONSTRUCTION COMPONENTS 242

510

411 409 407 405 404 410 406 412

403

408

402

412

401

301 302 304 305 244

303

A 235 236 245 238 223 218 231 224

A-A

201 217 225 221 215 205 232 212 204

237

213

234

206

233

209 505

507

306

208 503

506

203

207 501

511

226

210 502

214

130 504

124

202

107

129

118

127

111

105

106

216

117

103

110

109 123

119

113

125

102

136

108

114 101 116 128 115 112 104

33-101

512

508 509

B-B

33. SLEWING UPPER STRUCTURE No. NAME

Q.TY

No. NAME

Q.TY

No. NAME

Q.TY

101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 123 124 125 127 128 129 130 136 201 202 203 204

1 1 1 1 1 4 3 1 1 4 3 1 1 2 1 1 68 69 14 1 7 7 4 1 1 5 1 1 1 1 1

205 206 207 208 209 210 212 213 214 215 216 217 218 221 223 224 225 226 231 232 233 234 235 236 237 238 242 244 245 301 302

1 9 1 1 1 2 3 3 2 1 1 1 1 5 1 1 1 1 2 12 2 1 1 1 1 4 4 2 1 2

303 304 305 306 401 402 403 404 405 406 407 408 409 410 411 412 501 502 503 504 505 506 507 508 509 510 511 512

1 2 2 2 2 2 2 2 2 2 * 2 2 2 2 4 1 1 1 1 1 1 1 4 4 2 2 1

Housing Carrier 1 Carrier 2 Pinion shaft Internal gear A Spur gear 1 Spur gear 2 Sun gear 1 Sun gear 2 Pin 1 Pin 2 Seal ring Thrust collar Collar Taper roller bearing Taper roller bearing Roller Roller Thrust washer Snap ring Snap ring Spring pin Pin Oil seal O-ring Screw M8 x 25 Ring Body Housing Shaft Cylinder

Valve plate Piston Shoe Shoe holder Cylinder holder Swash plate Cup Pin Filter Spring Ball bearing Ball bearing O-ring Snap ring Screw M12 x 35 Spring pin Taper pin Parallel pin Piston Spring B Friction plate Separator plate O-ring O-ring Back-up ring Back-up ring Screw M16 x 15 Screw M8 x 50 O-ring Cover Check valve

33-102

Cap Spring O-ring O-ring Seat Cup Poppet Piston Cover Spring Spacer O-ring O-ring O-ring O-ring Back-up ring Valve block Spool Piston Stop Spring (1) Spring (2) Spring seat Cap O-ring O-ring Cap Cap

33. SLEWING UPPER STRUCTURE 33.2.5.2

DISASSEMBLY AND ASSEMBLY

(1) General precautions 1) Work at a clean place and take care so dirt, paint particles and water do not adhere to the parts. Prepare a container to put in removed parts. 2) Before removing it, clean the outside of the body to be free from dirt and remove paint at joints with a wire brush. 3) Put markings on jointing parts before removal so all parts are installed where they were. 4) Handle the removed parts carefully so as not to score them. 5) Clean the removed parts thoroughly in cleaning oil. 6) Inspect that the removed parts are not worn or seized abnormally and eliminate fins and burrs, using emery paper. 7) Replace seals and snap rings with new ones. (2) Tools No. 1 2 3 4 5 6 7

Tools required Torque Wrench (Pre-set type)

8 9 10 11 12 13

Allen wrench

14 15 20

Hammer Plastic hammer Others

Hexagon wrench for torque wrench

Torque Wrench (For single use)

Wrench Minus driver Snap ring pliers

45N (JIS B4650) 90N (JIS B4650) 180N (JIS B4650) Opposing flats Opposing flats Opposing flats T = 147.1 ± 19.6 Nm Opposing flat 36 Opposing flats Opposing flats Opposing flats Opposing flats Width ø 28 for hole ø 20, 30 for shaft

6 8 10

6 8 10 36 6 ÷ 10

Grease Oil (Specified hydraulic oil) Wire brush Emery paper Sealant (Three Bond #1305)

33-103

33. SLEWING UPPER STRUCTURE (3) Disassembling Of Hydraulic Motor 1) Loosen the socket bolts (130) fastening the hydraulic motor assy to the reduction and remove the hydraulic motor assy from the reduction unit. : 6 mm •

When removing the hydraulic motor assy from the reduction, open the drain port.

•

If it is hard to remove the assy, remove it by putting a flat-blade screwdriver into the mating surface of the body and remove burrs thoroughly.

2) Loosen socket bolt (244) and remove valve assy. : 5 mm •

Do not remove the valve assy except when necessary.

3) Remove the relief valve assy. : 36 mm •

Do not remove the relief valve assy except when necessary.

4) Remove plug (303), O-rings (305), spring (304) and check valve (302). : 8 mm

33-104

33. SLEWING UPPER STRUCTURE 5) Loosen socket bolt (223) and remove the body (201). : 10 mm •

Take care so valve plate (205) and spring (232) do not drop.

6) Remove valve plate (205), spring (232) and Orings (218) and (245).

7) Remove brake piston (231) assy from housing (202). Then remove O-rings (235), (236) and backup rings (237), (238). •

Brake piston (231) may be removed if air is blown slowly from brake release pressure port Pp.

•

On that occasion, blow air slowly so the brake piston does not pop up suddenly.

8) Remove two separator plates (234) and two friction plates (233).

33-105

33. SLEWING UPPER STRUCTURE 9) Remove cylinder (204) as an assy.

10) Remove the piston (206) assy and shoe (207), shoe holder (208), barrel holder (209), pin (213). •

The piston and the shoe can not be removed as they are caulked together.

•

Take care to miss the small parts.

•

When replacing the pistons because of the wear of the shoes, order nine pistons as a set. 207

11) Remove snap ring (221), retainer (212) and spring (215) from cylinder (204). 221 212 215 212

204

12) Remove shaft (203) and swash plate (210). •

In case the shaft is hard to remove, tap it lightly from the end face of the opposite side by means of a plastic mallet.

•

The ball bearing (216) is press-fitted onto the shaft; remove it only if necessary.

33-106

206

208

209

213

204

33. SLEWING UPPER STRUCTURE 13) Remove two filters (214) and pin (225).

(4) Disassembling of Reduction Unit 1) Remove sun gear (109).

2) Remove carrier assy (103) and carrier assy (102). 103

113

CARRIER 2 ASSY

102

CARRIER 1 ASSY 3) Remove the thrust collar (113) installed back side of the carrier assy (103).

33-107

33. SLEWING UPPER STRUCTURE 4) Remove the snap ring (123) of the carrier (103), then remove the thrust washer (119), spur gear 2 (107) and roller (118). •

107

Number of rollers (118): 23 rollers by one spur gear 2. 118

124 119

109

123

103

113

125

108 111

CARRIER 2 ASSY

5) Remove the snap ring (123), then remove sun gear 1 (108). •

Pin 2 (111) is fixed by spring pin (125) after press-fitting. Do not remove it except where necessary.

6) Remove the snap ring (124) of the carrier 1 (102), then remove the thrust washer (119), spur gear 1 (106) and roller (117). •

Number of rollers (117): 17 rollers by one spur gear.

•

Pin 1 (110) is fixed by spring pin (125) after press-fitting.

106 117

124

119 102

119 125 110

CARRIER 1 ASSY

33-108

33. SLEWING UPPER STRUCTURE 7) Remove ring (136) and split preload collar (114). •

Place the tip of a flat-blade screwdriver in the clearance between two preload collars and remove them by striking them with a hammer.

•

Since their clearance to the straight roller bearing has been adjusted, separate the ring and the preloaded collars only if necessary.

8) Remove pinion shaft (104). •

In order to keep the removing distance of pinion shaft, place a support of about 150mm under the flange of the casing and remove the pinion shaft by pressing the end face of it by press.

•

Since their clearance to the straight roller bearing has been adjusted, separate them only if necessary.

9) Remove the outer race of the straight roller bearings (115), (116) and oil seal (128). •

As the straight roller bearing and the outer race are difficult to remove, remove them only if necessary.

•

Do not reuse the oil seal.

10) Remove the inner race of the straight roller bearing (115) and seal ring (112) from the pinion shaft. •

The straight roller bearing is press-fitted into the inner race; separate them only if necessary.

•

Do not reuse the oil seal.

33-109

33. SLEWING UPPER STRUCTURE (5) Assembly of Motor 1) Drive the pin (225) into housing (202).

2) Install two filters (214) and parallel pin (226) into the housing (202). •

Direction of installing filter

Hydraulic Motor Side F

214

Reduction Unit Side F. Filter 3) Press-fit the ball bearing (216) into the shaft (203). •

Direction of ball bearing to press-fit in 216

203

S. Shield side 4) Install the swash plate (210) into shaft (203) and install it to the housing (202). •

Align the parallel pin (226) on the housing side with the pin hole of the swash plate.

33-110

33. SLEWING UPPER STRUCTURE 5) Install the cup (212) and spring (215) in the cylinder (204) and fix them with the snap ring (221).

6) Install the piston (206) assy and shoe (207) in the shoe holder (208) to make the shoe holder assy.

7) Install three pins (213) into cylinder (204). Fit two friction plates (233) and one separator plate (234) in that order of the figure. Make a cylinder assy by the shoe assy and cylinder holder (209).

8) Install the cylinder assy made up under para. 7) to housing (202) through shaft (203) till shoe (207) touches swash plate (210).

33-111

33. SLEWING UPPER STRUCTURE 9) First of all, install one separator plate (234) to the groove of housing (202).

10) On that occasion, install one friction plate (233) on the outer circumference of the cylinder assy to the groove of housing (202).

11) Install one separator plate (234) to the groove of housing (202).

12) Install O-rings (235), (236) and backup rings (237), (238) to assemble the piston assy (231).

237 235 231 236 238

33-112

33. SLEWING UPPER STRUCTURE 13) Installing the piston assy into the housing (202). •

On that occasion, coat the O-ring with a thin film of grease. Use care so the sealing material is not trapped in between.

14) Install spring pin (224) and ball bearing (217) to body (201).

15) Fit O-ring (218) on the cover (301).

16) Install the valve plate (205) on the cover (301). •

Install the valve plate by directing the metal lining surface toward the cylinder.

•

Coat the cover of the valve plate with a thin film of grease so the valve plate does not fall.

33-113

33. SLEWING UPPER STRUCTURE 17) Install twelve springs (232) into the hole of cover (301). •

Coat the spring seat with grease so the spring does not fall.

18) Install housing (202) and cover (301) together. •

Align the spring pin of cover (301) with the pin bore of housing (202).

•

Use care so the spring does not fall and is not bent.

19) Tighten socket bolt (223). : 10 mm, Tightening torque: 88.3 ÷ 112.8 Nm

20) Fit O-ring (305) to plug (303), install spring (304) and check valve (302) to cover (301), and tighten it. : 8 mm Tightening torque 58.8 ± 2.9 Nm

33-114

33. SLEWING UPPER STRUCTURE 21) Install the relief valve. : 36mm Tightening torque: 147.1 ± 19.6 Nm

22) Install two O-rings (306) to valve assy.

23) Install the hydraulic timer to housing (202) of the hydraulic pump with four socket bolts (130). : 6mm Tightening torque: 25.5 ÷ 32.4 Nm

24) Install timer valve assy. Tightening torque: 11.8 ± 1.0 Nm

33-115

33. SLEWING UPPER STRUCTURE (6) Assembly of reduction unit

128

1) Press-fit oil seal (128) into the casing (101). •

Press the oil seal so it does not tilt by means of a circular plate, paying attention to the installing direction of the oil seal.

101

74.5

R P

C. Circular plate R. Reduction side P. Pinion side 2) Install the seal ring (112) onto the pinion shaft (104). •

104

Direction of installation of seal ring.

P/H P/S

112

P/H. Pinion shaft side P/S. Pinion side 3) Press-fit the inner race of the taper roller bearing (115) into the shaft (104). •

After press-fitting it, coat the roller surface of the taper roller bearing with grease and rotate it so grease spreads all over the roller.

104

115

4) Press-fit the outer race of the taper roller bearing (116) into the casing (101).

33-116

116

33. SLEWING UPPER STRUCTURE 5) Press-fit the outer race of the taper roller bearing (115) into the casing (101).

6) Apply grease in the space in the casing (101) where the taper roller bearing (115) is to be installed. â&#x20AC;˘

Grease amount: approximately 80% of the empty capacity

7) Install the shaft (104) into the casing (101). â&#x20AC;˘

Take care that the oil seal lip is not damaged by the shaft.

8) Turn over the casing (101) and press-fit the inner race of the taper roller bearing (116).

33-117

33. SLEWING UPPER STRUCTURE 9) Install two semicircular preload collars (114). â&#x20AC;˘

The thickness of the preload collar shall be plus 0 to 0.05 mm (0.0019 in) against actual value: L between the end face of the taper roller bearing and the end face of the groove on the shaft side. P(114 T (116) S O(128)

L. Grove width O. Oil seal P. Preload collar S. Shaft T. Taper roller bearing 10) Install the thrust washer (119) on the pin 1 (110) of the carrier 1 (102).

11) Install the spur gear (106) and insert the roller (117). â&#x20AC;˘

Number of rollers: 17 rollers by one spur gear (106)

12) Install the thrust washer (119), then fix the snap ring (123).

33-118

33. SLEWING UPPER STRUCTURE 13) Install the sun gear 1 (108) to back side of the carrier 2 (103) and fix it with the snap ring (123).

14) Install the thrust washer (119) on the pin 2 (111) of the carrier 2 (103).

15) Install the spur gear 2 (107) and insert the roller (118). â&#x20AC;˘

Number of rollers: 23 rollers by one spur gear (107).

16) Install the thrust washer (119), then fix the snap ring (124).

33-119

33. SLEWING UPPER STRUCTURE 17) Install ring (136) between the outside of semicircular preload collar (114) and casing (101).

18) Install the carrier 1 assy (102) in the casing (101).

19) Remove the thrust collar (113) installed back side of the carrier 2 assy (103).

20) Install the carrier 2 assy (103) in the casing (101). â&#x20AC;˘

On that occasion, take care so the thrust collar on the rear face does not fall.

33-120

33. SLEWING UPPER STRUCTURE 21) Install the sun gear 2 (109) in the center of the carrier 2 assy (103).

22) Fill hydraulic oil into the casing (101). •

Oil level: above the center of the tooth width of spur gear 2 (107) and below the upper end face of it.

•

Oil type: ISO VG46

107

23) Fit O-ring (129) to the spigot joint of the hydraulic motor housing. •

Apply a thin film of grease to the O-ring.

24) Install the hydraulic motor in the casing (101), then tighten the socket bolt (130). : 6mm Tightening torque: 29.4 ± 2.9 Nm •

In this case, install the hydraulic motor shaft into the splined part of sun gear 2 (109).

•

Apply Three-Bond #1305 to the socket bolts.

33-121

33. SLEWING UPPER STRUCTURE (7) Troubleshooting Failure Not slewing (Pressure rises)

Location Cause Remedy Pressure relief valve Oil pressure is low Replace valve assy. Malfunction of motion Hydraulic motor Seizure of sliding surface Replace motor assy Internal leakage Reduction unit Damaged gear Replace reduction unit assy Overload Reduce overload Insufficient torque Pressure relief valve Pressure setting is low Replace valve assy. (Pressure rises) Malfunction of motion Hydraulic motor Wear of sliding surface Replace motor assy Internal leakage Reduction unit Damaged gear Replace pinion kit or carrier kit Damaged bearing Abnormal sound Noise in piping Insufficient flow-rate Correct piping generation (Cavitation sound) Hydraulic motor Damage of sliding Replace motor assy surface Reduction unit Damaged gear Replace pinion kit or carrier kit Damaged bearing Pinion Damaged gear Replace pinion kit Oil leaking Mating surface of Damaged O-ring O-ring replacement valve Loose bolt Retighten bolt Mating surface of Damaged O-ring O-ring replacement motor Loose bolt Retighten bolt Mating surface of Damaged O-ring O-ring replacement reduction unit Loose bolt Retighten bolt Pinion Damaged oil seal Replace pinion kit Time-lag of starting and Pressure relief valve Malfunction of motion Replace valve assy. stopping Check valve Internal leakage Abnormal heat Hydraulic motor Damaged or seized Replace motor assy sliding surface Reduction unit Abnormal gear teeth Replace pinion kit or carrier kit Abnormal bearing

33-122

33. SLEWING UPPER STRUCTURE (8) Maintenance standards 1) Slewing motor Items

Judgment Service limit Shaft Abnormal wear of output shaft splines. Wear depth 25µm or more Cylinder Contact surface with valve plate. Wear depth 20µm or more Valve plate Sliding surface of cylinder. Wear depth 20µm or more Caulked part of shoe. Sliding surface Piston and shoe Play 0.3 mm (0.01 in) or more of shoe. Swash plate Wear of sliding surface of shoe. Wear depth 0.1 mm or more Inside of the body Damage, rust

Remedy Replace Replace Replace Replace Replace Replace

2) Reduction Unit Items Judgment Gears in the casing Abnormal wear of gear.

Service limit Remedy Pitting extending Ratio of pitted area to tooth Replace it as over 5% or more surface. a pinion kit. of tooth surface. PITTING

Carrier 1, 2

Deformed or damaged splined part. Play of pin 1 (carrier 1) Play of pin 2 (carrier 2) Abnormal wear of tooth surface. Damaged tooth.

Visible damage

Wear of rolling surface of needle bearing roller (spur gear 1, 2).

Visible flaking or pitting.

Replace

Pin 1 Pin 2

Wear of rolling surface of needle bearing roller.

Visible flaking or pitting.

Replace it as a carrier kit.

Each bearing.

Pitting on roller needle. Pitting on rolling surface of inner and outer race.

Visible flaking or pitting.

Replace

Other parts (Socket bolt and thrust washer and so on)

Anomalous damage, rust.

Sun gear 1 Sun gear 2 Spur gear 1 Spur gear 2

Eccentric wear of More than 0.005 mm play pin bore. when checked by hand. Pitting extending PITTING over 5% or more of tooth surface.

Replace the planetary gear carrier assy Replace

Replace

33-123

33. SLEWING UPPER STRUCTURE 33.2.6

ROTARY CONTROL VALVE

33.2.6.1

CONSTRUCTION COMPONENTS

1 11 10

8 6

P F E D C B A G

15 13 7, 17 4 12 9 Fig. 33-119

No.

NAME

Q.TY

No.

NAME

Q.TY

STEM

SEAL RING

2 3 4 5 6 7 8 9

BODY FLANGE SPACER PIN SEAL NAME PLATE O-RING O-RING

1 1 1 1 7 1 1 1

11 12 13 14 15 16 17

SEAL RING SNAP RING SCREW M10 x 30 PLUG 1/4 SPRING WASHER BACK-UP RING CLEVIS

1 1 4 3 4 1 2

33-124

33. SLEWING UPPER STRUCTURE 33.2.6.2

DISASSEMBLY AND ASSEMBLY

33.2.6.2.1

General precautions

•

For disassembly and assembly, select the clean area and prepare clean containers to put the removed parts.

•

Clean around the port and remove the paints of the joint with wire brush.

•

Clean the removed parts with cleaning solvent, like light oil, etc.

•

Replace seals with new ones every disassembly, and apply grease lightly.

•

Check every part for severe wear and seizure, and remove burr, etc. with emery paper.

•

Check that seal groove is free from foreign substances, dust, etc.

33.2.6.2.2 (1)

Disassembly

Loosen bolt and remove flange (3). Fix the body (2) with vise. : 17 mm

: 17 mm

(2)

Take out O-ring (9), snap ring (12) and spacer (4) from the body (2).

2 4

9 12

(3)

Remove shaft (1) from the body (2). •

Apply the knock pin (K) to the end face of the shaft, and strike it with hammer.

•

Choose the knock pin (K) made of copper, plastic, etc.

K. Knock pin

K 2 1

33-125

33. SLEWING UPPER STRUCTURE (4)

Remove the dust seal ring (11) from the rod (1).

(5)

Remove the seal ring, etc. from the inside the body. •

Be sure of the position of seal, etc. referring to the construction drawing.

•

Take out O-ring with the pointed tool like a gimlet.

33.2.6.2.3 (1)

(2)

Assembly

Insert the seal rings into the body. •

Check the seal position referring to the construction drawing.

•

Ensure that O-rings are free from twisting.

•

Do not deform nor bend the seal ring.

Assemble the dust seal ring (11) onto the shaft (1). •

Apply enough grease to the lip section of the dust seal.

33-126

33. SLEWING UPPER STRUCTURE (3)

Install shaft (1) to body (2). •

Apply hydraulic oil or grease around the shaft lightly.

•

Strike the shaft with a plastic hammer carefully not to damage seal.

(4)

Assemble the spacer (4) and the snap ring (12). •

Fit the snap ring in the groove correctly.

(5)

Fit O-ring (9) and install flange (3).

(6)

Install spring washer (15) and bolt (13). : 17 mm

or : 17 mm •

Tightening torque: 46.5 Nm

•

Put pipe through the locking pin of the shaft, and check that the shaft rotates smoothly at a torque of approximately 78 ÷ 108 Nm

33-127

33. SLEWING UPPER STRUCTURE 33.2.6.3

MAINTENANCE STANDARD

33.2.6.3.1

Check Procedures and Remedy

Check interval 2000 h

Place checked Check procedure Remedy Seals which prevent Check if oil is leaking out. Replace the O-rings if there is external leakage of leakage. hydraulic oil. 4000 h All seal parts. – Replace all the seal parts Disassemble and All sliding portion. Check for abnormal wear, defects, Recondition in accordance with check whether there corrosion, etc. due to seizing, foreign the service limit. is leakage or not material being caught, etc. When disassembling All parts. Check for abnormal wear, defects, Recondition in accordance with due to trouble corrosion, etc. due to seizing, foreign the service limit. Regarding the seal kit, replace material being caught, etc. 33.2.6.3.2

Parts service limit

(1) Body and shaft Part Seal parts and sliding portion

Judgment criteria • Wearing of surface treated with induction hardening, and coming off of surface due to seizing, foreign material getting caught, etc. Body and shaft sliding • Abnormal wear or defects by 0.1 mm eep or deeper due portion other than seals. to seizing or foreign material getting caught, etc. • Defects less than 0.1 mm deep. Portions which slide against • Wearing by 0.5 mm or more, or abnormal wear. the thrust ring. • Wear less than 0.5 mm. • Defects due to seizing or foreign material getting caught, etc. which are within the wear limit of 0.5 mm and within repairable level.

Remedy Replace

Replace Repair with an oil stone. Replace. Repair so that is smooth. Repair so that is smooth.

(2) Flange and thrust ring Part Judgment criteria • Portions of flange which • Wearing by 0.5 mm or more, or abnormal wear. slide against the shaft end. • Wear less than 0.5 mm. • Thrust metal • Defects due to seizing or foreign material getting caught, etc. which are within the wear limit of 0.5 mm and within repairable level.

33-128

Remedy Replace Repair so that is smooth. Repair so that is smooth.

33. SLEWING UPPER STRUCTURE (3) Slipper seal

1.5mm

Judgment criteria

Remedy

• O-ring is excessively extruded from groove.

Replace

• Slipper seal width is 1.5 mm or more smaller than the Replace width of the seal groove.

• Unequal wear of 0.5 mm or more.

Replace

Judgment criteria

Remedy

• O-ring is excessively extruded from groove.

Replace

• Unequal wear of 0.5 mm or more.

Replace

Judgment criteria

Remedy

0.5mm

(4) O-ring

(0.02")

(5) Backup ring

• Thickness of 1.5 mm or less. Width of 4 mm or less. Replace

4mm 1.5mm

33-129

33. SLEWING UPPER STRUCTURE 33.2.6.3.3

Inspection after assembly

After assembly is completed, check for leakage of oil in each circuit using the equipment shown below.

(1) Connect a pipe (3) between the hydraulic pump (4) and the shaft (1) side port. (2) Connect a pressure gauge (5) to the body (2) side. (3) Increase the pressure gradually to 22.6 MPa adjusting the relief valve (6), then perform 1 minute leak test. •

Open the neighboring ports on both sides and check visually for leakage from the ports.

•

Check the body for crack, which may cause oil leakage, by a dye check.

33.2.6.4

TROUBLESHOOTING

Defect External oil leakage: Internal oil leakage

Shaft sticks Flange looseness

Cause • O-ring is defective. • Thrust ring is defective. • Excessive wear on sliding surfaces. • Shaft and body are stuck together. • Capscrew tightening is insufficient.

Corrective action • Replace all the seal parts • Replace all the seal parts • Replace the assembly. • Carry out grinding and honing. If excessive looseness cause oil leakage, replace the assembly. • Retighten to the specified torque.

33-130

34. TRAVEL SYSTEM TABLE OF CONTENTS 34.1 REMOVING AND INSTALLING .......................................................................34-1 34.1.1 TRAVEL SYSTEM COMPONENTS .........................................................34-1 34.1.2 CRAWLER ................................................................................................34-1 34.1.3 UPPER ROLLER ....................................................................................34-10 34.1.4 MAINTENANCE STANDARD .................................................................34-15 34.1.5 TOOLS AND JIGS ..................................................................................34-16 34.1.6 LOWER ROLLER ...................................................................................34-17 34.1.7 IDLE WHEEL ..........................................................................................34-25 34.1.8 IDLER ADJUSTER .................................................................................34-31 34.1.9 SPROCKET ............................................................................................34-35 34.1.10TRANSLATION MOTOR ........................................................................34-36 34.1.11SLEWING BEARING ..............................................................................34-38 34.2 DISASSEMBLY AND ASSEMBLY ................................................................34-41 34.2.1 TRANSLATION MOTOR ........................................................................34-41

34. TRAVEL SYSTEM

31.1

REMOVING AND INSTALLING

31.1.1

TRAVEL SYSTEM COMPONENTS

9 5 2

6 3 4 8

Fig. 34-1 Name and location of parts 2. 3. 4. 5.

Crawler Upper roller Lower roller Idle wheel

31.1.2 31.1.2.1 31.1.2.1.1

6. 7. 8. 9.

Idler adjust Sprocket Translation motor Slewing bearing

CRAWLER REMOVAL AND INSTALLATION PROCEDURES Removing rubber crawler

(1) Lift the one side of machine with attachment, as shown in Fig. 34-2, and place support under lower frame to support machine (S). ÷ S

Fig. 34-2 Crawler removing posture (2) Loosen grease nipple for crawler adjuster, discharging grease in cylinder, and release tension of crawler. : 17 mm • When loosening the grease nipple (G) of the adjuster, do not loosen it more than one turn. G

• Where grease does not come out well, drive the crawler forward / reverse. The over loosening of grease nipple will cause it to jump out incurring danger of injury. So be careful not to over loosen the grease nipple. Keep body and face away from the grease nipple for safety.

Fig. 34-3 Releasing crawler tension

34-1

34. TRAVEL SYSTEM (3) Put steel pipes (P) in the rubber crawler, turn the sprocket in the reverse direction slowly and when the rubber crawler has floated off the idler stop the rotating. (4) Slide the rubber crawler sideways, and remove it.

Fig. 34-4 Removing rubber crawler 31.1.2.1.2

Installing rubber crawler

Installation is done in the reverse order of removal. (1) Engage the track with the sprocket, and insert it on the idler adjuster. (2) Put steel pipes (P) in the rubber crawler, turn the sprocket in the reverse direction slowly and when the rubber crawler has floated off the idler stop the rotating. (3) Slide the rubber crawler to the position to be set on idler exactly.

(4) Confirm that the rubber crawler is engaged securely with the sprocket, idler and lower roller.

Fig. 34-5 Installing rubber crawler

(5) Tighten the grease nipple for the crawler adjuster, and adjust tension by feeding grease. : 17 mm, Tightening torque = 73.5 Nm Rubber crawler Appropriate tension A: 85 รท 95 mm Steel crawler Appropriate tension B: 130 รท 150 mm

Fig. 34-6 Feeding grease

Fig. 34-7 Crawler tension

34-2

34. TRAVEL SYSTEM 31.1.2.2

REMOVAL AND INSTALLATION PROCEDURES

(1) Removing 1) The crawler track link includes a set of master pin (6), which should be placed at the position front of the front idler.

Fig. 34-8 Position of master pin 2) Put square timbers A and B under the shoe at the top end of the crawler and between the crawler and the link over the track frame to reduce the load on the master pins.

Fig. 34-9 Removing master pin 3) Loosen grease nipple (G) for track spring adjustment, discharge grease in the cylinder and slack the tension of the shoe.

: 17 mm

WARNING When loosening grease nipple for adjustment, donâ&#x20AC;&#x2122;t turn it more than one turn to loosen. When grease is remained, move the machine forward and backward slightly. Be careful that the grease nipple may be popped out.

G A

Fig. 34-10 Loosening grease nipple for adjustment

34-3

34. TRAVEL SYSTEM 4) Straighten the curve of lock pin, and draw out it striking by hammer.

â&#x20AC;˘ Remove lock pin (8) with shoe plate. 5) Apply master pin drawing out jig (a) to the small diameter section of master pin (6), and draw it out striking by hammer. 6

WARNING

Especially Pay attention to the front idler which may spring out due to the force of spring when drawing out master pin (6) to repair broken parts relating to the front idler. Be careful not to be injured by scattering materials, when large hammer is used.

Fig. 34-11 Removing lock pin a

Fig. 34-12 Removing master pin

WARNING Donâ&#x20AC;&#x2122;t approach the machine because the end of the crawler may drop just before extending the track link assembly to the ground while rotating the sprocket. Put wooden block just in case.

6) Move the machine back slowly, and remove the crawler extending it to the ground. Weight of steel crawler (one side):

Fig. 34-13 Removing crawler

E45B SR: 260 kg E50B SR - E55B: 275 kg (2) Assembly 1) Install the crawler to the position where the end of the track link engages with the sprocket placing the track link narrowing toward the end toward the front idler side as shown in the figure. Fig. 34-14 Direction of crawler

34-4

34. TRAVEL SYSTEM 2) Move the machine forward slowly by inserting the bar in the master pin hole on the end of the crawler and assisting so that the sprocket engages with the track link, and also assist so that the crawler catches the normal position and engages with the front idler using pry-bar.

Fig. 34-15 Installing crawler 3) Hook chain block to the upper and lower parts of the shoe plate, and align the master pin hole pulling by the chain block.

Fig. 34-16 Alignment of pin holes 4) Align master link holes on the both ends of the crawler link with the link holes inserting pry-bar, apply master pin drawing out jig (a) used when removed and press fit master pin by hammer.

6 a

WARNING Be careful not to be injured by scattering materials, when large hammer is used. Apply molybdenum grease to the master pin before press fitting. Fig. 34-17 Press fitting master pin 5) After press fitting master pin (6), insert lock pin (8) and bend the top end in advance. 6) After completion of installation, adjust the tension of crawler by the same procedure of the rubber crawler. : 17 mm G

Fig. 34-18 Extension of track link (Example for rubber crawler)

34-5

34. TRAVEL SYSTEM 31.1.2.3

CONSTRUCTION COMPONENTS

(1) Construction of rubber crawler No. 1

Quantity per machine 2

NAME RUBBER CRAWLER ASSY

Fig. 34-19 Rubber crawler assy •

This standard machine provides rubber crawler.

(2) Construction components of steel crawler

No.

NAME

Q’ty (for each side) E50B SR E45B SR E55B 35 37

Track link (RH)

Track link (LH)

Master link (RH)

Master link (LH)

Master pin

Safety pin

Track pin

Bushing

Collar

Edge bolt

144

152

Nut

144

152

Shoe

28 Fig. 34-20 Construction components of steel crawler

34-6

34. TRAVEL SYSTEM 31.1.2.4

MAINTENANCE STANDARD

(1) Rubber crawler C

B B

M B-B

Fig. 34-21 Rubber crawler L. Distance between the bottom of frame and top of rub- R. Rubber cover ber crawler M. Centre line of steel frame C. Core Unit: mm ITEM Sag of rubber crawler L. Cracks and notch on rubber crawler. Breakage of steel cord. Contact surface of rubber crawler and lower roller. Height (H). Lug projection (h).

SERVICEABILITY STANDARD VALUE REPAIRABLE LEVEL LIMIT 85 ÷ 95 — — Where the depth of Where the depth of None. them does not reach to them reaches to the the steel cords. steel cords. None. None. Exist. Where 10 percent of Where half of cores are None. cores are visible from visible from outside. outside. 94 — 70 25 — 0

34-7

REMEDY Adjustment. Replace. Replace. Replace. Replace. Replace.

34. TRAVEL SYSTEM (2) Steel crawler (Track link)

A. Link pitch C. Collar D. Bushing F. Track pin H. Shoe screw I.

Master pin

L. Distance between the bottom of frame and top of steel crawler M. Master link P. Pin T. Track bushing

34-8

34. TRAVEL SYSTEM

Symbol Item A Link pitch Bushing outer diameB ter C Link height D

F G H L

Reference value 135

ø32

ø35 67 Basic dimension

Interference between Shaft bushing and link Hole

ø34.85

Interference of track pin and link

Shaft

ø22.3

Hole

ø22.16

Fitting of master pin and link

Shaft

ø22.16

Hole

ø22.16

Clearance gap of link Tightening torque of shoe screw Slackening of steel crawler

Repairable level 139

63 Fit

ø35

0.5 (One side)

Fit

Interference 0,11 ÷ 0,35

Interference 0

Interference 0,1 ÷ 0,18

Interference

Play 0,0 ÷ 0,07

—

5 (both side)

7 (both side)

216 Nm 130 ÷ 150 mm

Replace

Replace link. Replace Repair weld.

—

34-9

Unit: mm Service limit Remedy 143 Parts over the critical value in use should ø31 be replaced with link assembly. 62

Adjust tension.

34. TRAVEL SYSTEM 31.1.3 31.1.3.1 31.1.3.1.1

UPPER ROLLER REMOVAL AND INSTALLATION PROCEDURES Removing

(1) Loosen the grease nipple (G) for crawler adjustment by one only turn to discharge grease and release tension on the crawler. : 17 mm

WARNING Turn the grease nipple slowly paying attention not to turn more than one turn, and be careful for the spouting out grease.

Fig. 34-22 Releasing crawler tension

(2) Push up the crawler with a hydraulic jack, and place suitable wooden block (A) to keep a clearance between the crawler and lower frame. (3) Remove the fixing capscrews and nuts, and remove the upper roller from the lower frame. : 17 mm Weight of upper roller assembly: 5 kg)

Fig. 34-23 Supporting with wooden blocks

34-10

34. TRAVEL SYSTEM 31.1.3.1.2

Assembly

WARNING Before installing the upper roller (A), make sure that sufficient oil is filled in and that the upper roller rotates smoothly by hand. If the oil volume is insufficient, refill oil, or if the upper roller does not rotate smoothly or oil is leaking, check the bearing and the seals and replace them where necessary. Oil: HYPOIDE 90 Volume: 20 cc

Fig. 34-24 Removing/Installing upper roller

(1) Insert the shaft of the upper roller (A) assembly into the lower frame. (2) Coat mounting capscrews with Loctite #262 and tighten it to the torque. : 17 mm, Tightening torque: 66 Nm • Install it so that the nut is located on the crawler idler side (B). • At installation, support the crawler with wooden blocks the same way as it was dismantled so it does not disturb the work. (3) After installing upper roller (A), tighten grease nipple for crawler adjuster, grease it, and adjust crawler tension. : 17 mm Tightening torque: 73.5 Nm 31.1.3.2

CONSTRUCTION COMPONENTS

No. 1 ROLLER

NAME

Q.TY 1

SHAFT

PLATE

COVER

BUSHING

SEAL

O-RING

SCREW M8x22

SNAP RING

10 PLUG

11 COLLAR

6 2

Fig. 34-25 Construction of upper roller

34-11

34. TRAVEL SYSTEM 31.1.3.3 31.1.3.3.1

DISASSEMBLY AND ASSEMBLY Disassembling

(1) Remove plug (10), and drain out oil.

8 3

: 5 mm

9 10 7 4

(2) Place the end face inside upper roller (1) on stand jig (f) and remove snap ring (9).

(3) Remove cover (4) upwards, using the threaded hole for the plug. (4) Remove O-ring (7) from cover (4).

(5) Loosen two socket bolts (8) and remove plate (3). : 6 mm

Fig. 34-26 Preparation for disassembly (6) Put the extusion jig (g) against the end face of shaft (2) and extrude shaft (2) with retainer for floating seal (6), using a press or hammer (D).

g 2

Fig. 34-27 Extruding shaft (7) Remove floating seal (6) from upper roller (1).

Fig. 34-28 Removing out floating seal

34-12

34. TRAVEL SYSTEM (8) Remove the floating seal (6) from collar (11). D

WARNING Collar is press fitted into shaft (2). Therefore do not disassemble it.

33.9 (1.34")

2 5

(9) When extruding bushing (5), place upper roller (1) on the stand jig (f), put the extrusion jig (j) against the end face of bushing (5) and extrude it by means of a press (D).

6 1

11 f

Fig. 34-29 Extruding bushing 31.1.3.3.2

Installing

Installing of the upper roller is performed in the reverse order of removing.

D h

(1) Place the upper roller (1) on the stand jig (f), and press the jig (D) against the end face of the bushing, and press it in a specified position.

5 1

WARNING

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. (2) Two floating seals (6) make a pair. Attach one floating seal to retainer fixed in shaft (2), and another to the inside of upper roller (1). â&#x20AC;˘ Prior to placing floating seal (6) in, apply engine oil lightly to seal surface.

2 6

(3) Put shaft (2) in upper roller (1), and press-fit it.

Fig. 34-30 Fixing floating seal D

Fig. 34-31 Pressing shaft

34-13

34. TRAVEL SYSTEM (4) Place upper roller (1) on the stand jig (f) and attach plate (3) to the end face of the shaft with socket bolts (8). In that case, coat the threaded part of socket bolts (8) with Loctite #242 beforehand.

9 7

4 3 1

: 6 mm Tightening torque: 34 Nm (5) Fix O-ring (7) in the groove of cover (4). â&#x20AC;˘ Coat grease to O-ring. (6) Install cover (4) to upper roller (1). Use a press in this operation as a press fit is used.

Fig. 34-32 Installing cover (7) Fix snap ring (9) into upper roller (1). (8) Fill in 20cc of engine oil API grade CD #30 through the plug hole of cover (4).

(9) Place seal tape around plug (10) and tighten it into the plug hole of cover (4). 1

: 5 mm Tightening torque: 23 Nm â&#x20AC;˘ After assembling the upper roller, confirm that oil is not leaking from it and that it rotates smoothly by hand.

Fig. 34-33 Filling oil

34-14

34. TRAVEL SYSTEM 31.1.4

MAINTENANCE STANDARD

Fig. 34-34 Sectional view of upper roller Unit: mm CODE

ITEM

A B

Tread diameter Tread width

Clearance between shaft and bushing

D E — —

Interference between roller and bushing Tightening torque of socket bolt Oil Roller rotation

STANDARD VALUE ø82 102 Basic dimension

Tolerance

ø32

Shaft

ø36

Hole

+0.025 +0.050 +0.03 0

REPAIRABLE LEVEL ø73 95

SERVICE LIMIT ø70 92

Fit

Play 0.7 Interference 0

Play 1.0 Play 0.01

34 Nm API engine oil grade HYPOIDE 90, 20cc Roller rotates smoothly by hand

34-15

REMEDY Replace

Replace bushing

Apply Loctite #242 Replenish Reassemble

34. TRAVEL SYSTEM 31.1.5

TOOLS AND JIGS

31.1.5.1

Tightening tools Unit: mm Tools

Opposing flats 17

Socket

5.6

Allen wrench 31.1.5.2 MARK

Mask TOOLS

SKETCH

MARK

TOOLS

Fixing jig

Fastening tool (Extraction tool)

Stand jig

34-16

SKETCH

34. TRAVEL SYSTEM 31.1.6 31.1.6.1

LOWER ROLLER REMOVAL AND INSTALLATION PROCEDURES

Q.ty on one side: 4 pc. 31.1.6.1.1

Removing

(1) Slightly loosen capscrews (M16x35) (2) fastening lower roller assembly (1) to the lower frame.

1 2

: 24 mm (2) As same as the case for removal of the crawler, loosen the grease nipple for crawler adjusting within one turn to discharge the grease, and release the tension on the crawler. : 17 mm (3) Lift the lower frame good enough to remove the lower roller, using the attachment.

Fig. 34-35 Lower roller assembly

(4) After lifting the lower frame to a proper height, place square lumber under the lower frame to stabilize the machine. (5) Remove the capscrews (2) fastening the lower roller, and remove the lower roller assembly. : 24 mm Weight of lower roller assembly: 8.7 kg Fig. 34-36 Crawler removing posture 31.1.6.1.2

Installing

(1) Installing position of lower roller Install the lower roller assembly so that the plug (3) directs outward from the machine. (2) Coat the mounting capscrews (2) with Loctite #262 in advance. Place the roller assembly (1) between the crawler and lower frame (4). Fasten the capscrews (2) temporarily. : 24 mm (3) Lower the machine in full contact with the ground and tighten the capscrews (2) as specified. : 24 mm, Tightening torque = 208 Nm (4) Tighten the grease nipple of the crawler adjuster. Lift the machine, and adjust the crawler tension by feeding grease. : 17 mm, Tightening torque = 73.5 Nm

34-17

1 4 3 2

Fig. 34-37 Installing lower roller

34. TRAVEL SYSTEM 31.1.6.2

CONSTRUCTION COMPONENTS

No.

NAME

Q.TY

Roller

Shaft

Bushing

Snap ring

Seal

O-ring

Plug: PT 1/8

12 Collar

13 Collar

13 8

Fig. 34-38 Lower roller construction 31.1.6.3 31.1.6.3.1

DISASSEMBLY AND ASSEMBLY Disassembling

(1) Loosen the plug (9) to drain oil.

: 5 mm (2) Remove snap ring (6). (3) Removing collar (12) and O-ring (8). Place the lower roller on the jig (A) so that the shaft (4) stands vertically. Apply the extruding jig (P) to the upper shaft end. Push the shaft (4) with a press or a hammer until the O-ring comes out from the collar (12) to remove the upper collar (with seal) and O-ring (8).

(4) Removing shaft. Push the shaft further to remove the shaft (4), the lower collar (with seal) (13), and O-ring (8) in one piece.

8 6

WARNING Prior to extruding the shaft, prepare a drain oil container to receive lubricating oil remaining in the lower roller. Otherwise the lubricating oil flows out to contaminate the work floor.

Fig. 34-39 Removing shaft (4), collar (12) and O-ring (8) P

(5) Removing collar (13) and O-ring (8). Place the shaft (4) with the collar (13) and O-ring (8) pulled out according to the above procedure on the jig (O). Apply the extruding jig (P) to the shaft to push it out using a press.

4 O

Fig. 34-40 Removing collar (13)

34-18

34. TRAVEL SYSTEM (6) Removing the seal (7). Remove the seal (7) from the collars (12) and (13).

Fig. 34-41 Removing the seal (7) (7) Removing the seal (7). Take out the seal (7) from the roller (1).

7 1

Fig. 34-42 Removing the seal (7) (8) Removing bushing (5). Cut off the bushing (5) having very small thickness with a lathe or tear it off without damaging the bore. When an amount of wear of the bushing is small, place the roller (1) on the jig (m) and apply the tip of the extruding jig (D) to the end surface of the bushing (n) to hammer out the bushing.

WARNING In order to avoid damage to the bore of the roller (1), hammer the bushing (5) lightly and change the jig applying position circumferentially little by little to push out the bushing slowly.

Fig. 34-43 Removing bush (5)

34-19

34. TRAVEL SYSTEM 31.1.6.3.2

Assembly

(1) Attach O-ring (8) to one side. Install O-ring (8) to shaft groove (4). • Grease O-ring. • Replace O-ring with new one without fail at reassembling.

Fig. 34-44 Attach O-ring (8) to one side (2) Press fitting bushing (5) Align the center of the bushing (5) with that of the bore of the roller (1) with the bushing press fit jig (q) inserted to the bushing (5) to push the bushing in with a press vertically. (Press load: 35.300N) Press fit the opposite side bushing (5) too.

q 5

• Apply molybdenum disulfide grease to the press fit section of the bushing to press fit the bushing at a normal temperature. • If the press fit failed due to eccentric pushing and so on, always replace the bushing with new one.

Fig. 34-45 Press fitting bushing (5)

(3) Press fitting collar (13) Fit O-ring to the one side of shaft (4) mating pin hole of collar (3) on which floating seal (7) is fit with pin hole of shaft (4) in advance. • Care should be taken not to damage O-ring (8) while press-fitting collar (13) to shaft (4).

Fig. 34-46 Press fitting collar (13)

34-20

34. TRAVEL SYSTEM (4) Installing snap ring (6) (5) Attach floating seal (7) of roller side. Fit floating seal (7) 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.

(6) Inserting roller (1). Insert roller (1) from the side where collar (13), Oring (8) is not press-fitted to the shaft (4).

Fig. 34-47 Installing roller (1) (7) Installing O-ring (8). Install the O-ring (8) to the shaft groove (4). •

Coat grease to O-ring.

•

Always replace the O-ring with new one prior to reassembling.

(8) Installing collar (12). Insert the collar (12), into which the seal (7) is built in advance, into the shaft (4). •

Insert it until the snap ring groove of the shaft (4) is in alignment with the end surface of the collar (12).

(9) Installing snap ring (6) Fit the snap ring (6) in the snap ring groove of the shaft (4).

Fig. 34-48 Installing the collar (12)

34-21

34. TRAVEL SYSTEM 10) Oil supply. Supply 70 cc of HYPOIDE 90 class engine oil through the plug (9) hole.

(11) Leakage test. Perform leakage test at an air pressure of 2.0 kgf/ cm2 (14 psi) prior to tightening the plug (9). (12) Installing plug (9). Apply oil resistant sealing agent to the plug (9), and screw it in the plug hole in the end surface of the collar (13). : 5mm Tightening torque: 16.7 Nm Fig. 34-48 Installing oil supply plug (9)

WARNING After assembling the lower roller as a single unit, ensure that it shows no oil leakage and can be manually rotated.

34-22

34. TRAVEL SYSTEM 31.1.6.4

MAINTENANCE STANDARD C

20 (0.787")

Fig. 34-50 Lower roller Unit: mm Code A B C

E — —

ITEM

STANDARD VALUE

Flange outer diameter Tread outer diameter Flange width Clearance between shaft and bushing Interference between roller and bushing Oil Roller rotation

REPAIRABLE SERVICE LEVEL LIMIT

Basic dimension

ø130

—

ø100

ø94

ø92

Fit

Tolerance

Fit

Welding repair or replacement

Shaft

ø35

ø39

0 (0) –0,025 Play Play +0,25 0.10 ÷ 0.275 0,5 (0.02) Bushing +0,10 +0,16 Bushing +0,12 Interference Interference 0,095 ÷ 0,16 0 +0,025 Roller 0 Engine oil HYPOIDE 90 class 70 cc

REMEDY

Rollers rotate smoothly by hand

34-23

—

Replace bushing

— Replenish Reassemble

34. TRAVEL SYSTEM Unit: mm MARK

TOOLS

SKETCH

MARK

TOOLS

Bushing extrusion rod

Shaft extrusion jig

Stand jig

Bushing fixing jig

34-24

SKETCH

34. TRAVEL SYSTEM 31.1.7 31.1.7.1 31.1.7.1.1

IDLE WHEEL REMOVAL AND INSTALLATION PROCEDURES Removing

(1) Remove the crawler assembly. (2) Remove idler together with idler adjuster assembly, rolling it, using a pry-bar or equivalent. (3) Loosen capscrews (M10x50) (c), and separate idler assembly (a) from idler adjuster assembly (b). : 17 mm Weight of idler assembly: 37 kg (one side) Weight of idler adjuster assembly: 33 kg (one side)

Fig. 34-51 Removing idler assembly

WARNING The separated idler assembly (a) is easy to fall down. Lay it down so it does not fall down on your feet, utilizing wooden blocks. Fig. 34-52 Disassembling idler assembly 31.1.7.1.2

Installing

(1) Install idler assembly (a) to the idler adjuster assembly (b) by means of capscrews (c) in the reverse order of removing the idler assembly. Coat the threaded part of capscrews (c) with Loctite #262 beforehand. : 17 mm, Tightening torque = 66 Nm (2) The assembly of the idler and idler adjuster is to be installed to the lower frame so that the grease feeding plug (1) is positioned to upside, and the grease nipple (2) is facing to outside. (3) Following procedures of section (2), install the crawler assembly, and adjust the crawler tension. â&#x20AC;˘ On that occasion, confirm the lubrication through the grease nipple is proper and that grease is not leaking from the grease cylinder.

34-25

Fig. 34-53 Installing idler assembly

34. TRAVEL SYSTEM 31.1.7.2

CONSTRUCTION COMPONENTS 8

7 5

Fig. 34-54 Idler assembly construction No.

NAME

Q.TY

No.

NAME

Q.TY

Idler adjust

Bushing

Shaft

Collar

O-ring

Seal

Plug 1/8â&#x20AC;?

31.1.7.3 31.1.7.3.1

DISASSEMBLY AND ASSEMBLY Disassembling

(1) Remove plug (8) on the side of collar (3) and drain oil. 5 mm (2) Apply pin push bar (jig R) to the top of pin, and take out striking lightly by hammer. (3) Put idler (1) on repair stand (U), apply pushout jig (S) on shaft (6), push out shaft (6) with collar (3), then remove collar (3). Fig. 34-55 Extruding pin

Fig. 34-56 Extruding shaft

34-26

34. TRAVEL SYSTEM (4) With idler (1) placed on the stand, tap bushing (2) lightly by hammer, while placing the bushing extruding rod (V) against the end face of bushing (2) evenly all round, till it comes out. (5) 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 thick paper between the sealing faces. (6) Remove O-ring (7) from shaft (6).

Fig. 34-57 Removing bushing 31.1.7.3.2

Assembly

(1) Align inner hole of idler (1) and bushing (2) and press fit it vertically with press.

Fig. 34-58 Press fitting bushing (2) (2) Fit O-ring (7) to O-ring groove on shaft (2). â&#x20AC;˘ Coat grease to O-ring. (3) Installation of collar (3) (See 32.2.1.3) Press fit the O-ring installed side of shaft into collar (3), and drive pin (5). (4) Fit one piece of two (2) pieces type floating seal (4) on each side of collar (3) and idler (1).

Fig. 34-59 Pressing in shaft (6) (5) Insert shaft (6) into idler (1). â&#x20AC;˘ Apply gear oil to shaft. (6) Fit floating seal (4) on the other side of idler (1).

Fig. 34-60 Installing floating seal (4)

34-27

34. TRAVEL SYSTEM (7) Fit floating seal (4) on the other collar (3), press fit it in shaft, and insert the drive pin (5) in with mallet. (8) Filling oil / Inspection Fill in 70 รท 80 cc of gear oil HYPOIDE 90 through the plug hole of collar, place the screwed part of plug (8) with seal tape and put in plug (8). : 5 mm โ ข

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.

Fig. 34-61 Press fitting collar (3)

Fig. 34-62 Driving pin (5)

34-28

34. TRAVEL SYSTEM 31.1.7.4

MAINTENANCE STANDARD

Fig. 34-52 Idler assembly Unit: mm Code A B C

ITEM

STANDARD VALUE

REPAIRABLE LEVEL

SERVICE LIMIT

ø364

—

ø320 40

ø312 36

ø310 34

Fit

Play 0.278 ÷ 0.183

Play 1.5

Play 2.0

Interference 0.093 ÷ 0.015

Interference 0

Play 0.01

Crawler idler projection diameter Tread diameter Flange width Basic Clearance between dimension

shaft and bushing Interference between idler and bushing Oil Idler rotation

ø45 ø50

Gear oil HYPOIDE 90 70 ÷ 80 cc Idler rotates smoothly by hand

34-29

REMEDY

Replace

Replace bushing

Replenish Reassemble

34. TRAVEL SYSTEM 34.1.7.5

TOOLS AND JIGS

(1) Tools Unit: mm Tools

Opposing flats

Socket hexagon

19. 24

Allen wrench

5. 6

(2) Attachment Unit: mm Symbol

Tool

Illustration

Symbol

Tool

Pin extruding jig

Bracket repair

Shaft extruding jig

Bushing press fitting jig (2 piece)

Bushing striking rod

Collar press fitting jig

34-30

Illustration

34. TRAVEL SYSTEM 31.1.8

IDLER ADJUSTER

31.1.8.1

REMOVAL AND INSTALLATION PROCEDURES

31.1.8.1.1

Removing

(1) Idler adjuster assembly assembled with idler assembly (a) is removed from the lower frame. Do this work by referring to 34.1.7.1.1 Removing front idler. (2) Loosen capscrews (c) and separate idler assembly (a) from idler adjuster assembly (b). Fig. 34-53 Disassembling idler assembly

: 17 mm Weight of idler assembly: 37 kg (one side) Weight of idler adjuster assembly: 33 kg (one side)

WARNING The separated idler assembly is easy to fall down. Lay it down so it does not fall down on your feet, utilizing wooden blocks. 31.1.8.1.2

Installing

(1) Installation is done in the reverse order of removal. First of all, assemble idler assembly (a) to idler adjuster assembly (b), and tighten them together with capscrews (c). In that case, coat the threaded part of capscrews (c) with Loctite #262 beforehand. : 17 mm, Tightening torque = 66 Nm (2) Before installing the idler adjuster to the crawler frame, assemble it with the idler assembly. For the procedure, refer to 34.1.7.1.2 Installing front idler. 31.1.8.2

CONSTRUCTION COMPONENTS

No. NAME 1 Piston

Q.TY 1

Grease cylinder

Rod

Spring

Plate

Nut

Oil seal

O-ring

10 Split pin

11 Spring pin

12 Grease cup

Fig. 34-54 Idler assembly

34-31

34. TRAVEL SYSTEM 31.1.8.3

DISASSEMBLY AND ASSEMBLY

(1) Disassembling H

1) Before disassembling and assembling the idler adjuster assembly, prepare spring setting jig (V). Capacity of hydraulic jack: more than 5 tons

WARNING Large power is needed to set the spring. Prepare a special jig before disassembly and assembly.

S (V) J

2) Place a hydraulic jack between the jig base and the stand. 3) Loosen the holding-down nuts of the jig and draw out the retainer upward. 4) Draw out piston (1) from grease cylinder (2) of the idler adjuster assembly.

Fig. 34-66 Special jig (V) for spring adjustment

5) Extract the oil seal (8) and the O-ring (9) from the grease cylinder (2). 6) Set the idler adjuster assembly on the stand of the jig (V), with its plate (5) side facing up. 7) Fit retainer plate (R) to plate (5) tighten holdingdown nuts alternately, and secure idler adjuster assembly. B. Base H. Holding-Down nut R. Retainer plate S. Spring setting jig V

Fig. 34-67 Slinging work of idler adjuster

J. Hydraulic jack

Fig. 34-68 Fixing Holding-down nut (H) 8) Remove split pin (10), press spring (4) lifting it with jack so that nut (6) can be turned freely, and remove nut (6).

Fig. 34-69 Compression of spring

34-32

34. TRAVEL SYSTEM 9) Allow the hydraulic jack to retract slowly till the spring is extended to its free length. Remove the retainer plate (R) and take off plate (5). The free length of the spring: Approximately 412 mm

10) Hook lifting eye nut (W) to screw M30xP3 on grease cylinder (2) top end and hoist it. Lifting nut: M30xP3

11) Remove the grease cylinder (2) and from the spring (4).

Fig. 34-70 Removing retainer plate (2) Assembly Perform assembly in the reverse order of disassembly. 1) Insert grease cylinder (2) into spring (4) and erect it in the centre of the jig stand upright. 2) Install the plate (5) on top of spring (3). Center the rod of grease cylinder (2) and the holes in bracket (4). Attach the retainer plate (R) and four holding-down nuts (H). Fasten the nuts evenly all round fix the idler adjuster assembly to the jig body. 3) Extend the hydraulic jack, compress spring (4) to a set length and screw in nut (6) to the screwed part at the tip of grease cylinder (2). Set length of the spring: 335 mm 4) Tighten nut (6) till the holes for locking split pins (9) are aligned, then fit split pin (10).

Fig. 34-71 Removing and installing of idler adjuster assembly

: 46 mm 5) Remove the idler adjuster assembly from the jig.

6) Extract the oil seal (8) and the O-ring (9) from the grease cylinder (2).

â&#x20AC;˘ Apply grease on oil seal (8) and O-ring (9). 7) Fill up grease in grease cylinder (2), remove the grease nipple from piston (1) and press the piston by hand to discharge the inside air. â&#x20AC;˘ Push the piston in while directing the grease nipple hole downward to make it easier to release air.

Fig. 34-72 Attach idler adjuster assembly to the jig

8) Tighten grease nipple to piston (1). : 17 mm Tightening torque: 73.5 Nm

34-33

34. TRAVEL SYSTEM 31.1.8.4

MAINTENANCE STANDARD

Code ITEM A Installed length of spring B Free length of spring C Stroke D

Set length

E F

Outside view of piston Tightening torque of grease nipple

D/R Rubber crawler 335 412 28 E45B SR: 661 E50B SR - E55B: 674 No scoring and rusting 73.5 Nm

Unit: mm D/S Steel shoe ← ← ← 631 ← ←

D/S D/R A, B

Fig. 34-73 Adjuster assy

34-34

34. TRAVEL SYSTEM 31.1.9

SPROCKET

31.1.9.1

REMOVAL AND INSTALLATION PROCEDURES

31.1.9.1.1

Removing

(1) Remove the crawler assembly.

(2) Place wooden block (3) under the lower frame (1) so the sprocket (2) is off the ground. (3) Loosen capscrew (M12) for the mounting of the sprocket by means of an Allen wrench and remove the sprocket (2). : 22 mm Single weight of sprocket (2): 14 kg

Fig. 34-74 Making sprocket free 31.1.9.1.2

Installing

(1) Check the fixing parts of the travel motor (5) and the sprocket (2), eliminate burrs and dirt thoroughly, and install the sprocket (2).

(2) Apply Loctite #262 to the threaded portion of capscrew to mount the capscrews (4) and fasten then temporarily. (3) Remove the wooden block (3) under the lower frame (1) and tighten capscrews (4) to specified torque to fix sprocket (2) and travel motor (5).

Fig. 34-75 Removing sprocket

: 22 mm, Tightening torque = 181 Nm (4) Install crawler.

Fig. 34-76 Tightening capscrew 31.1.9.2

MAINTENANCE STANDARD A

P, C, D37 6.6

Fig. 34-77 Sprocket Unit: mm

Width of sprocket teeth

STANDARD VALUE 32

Sprocket outer diameter

ø435.8

Code

ITEM

REPAIRABLE LEVEL 29 ø429

34-35

SERVICE LIMIT 27 ø427

REMEDY Replace Welding repair or replacement

34. TRAVEL SYSTEM 31.1.10

TRANSLATION MOTOR

31.1.10.1

REMOVAL AND INSTALLATION PROCEDURES

31.1.10.1.1

Removing

(1) Remove the crawler assembly.

(2) Place wooden block (3) under the lower frame (1) so the sprocket (2) is off the ground. (3) Remove the capscrews (A4) located inside the lower frame and remove the covers (A1). : 17 mm (4) Push the air bleeding cap with boots on hydraulic oil tank to release air in the tank. (5) Disconnect the joint of hydraulic piping connected with the travel motor, and plug the joints in order to prevent outflow of oil and entering of dust.

Fig. 34-78 Making sprocket free

)

: 19 mm, 22 mm and 32 mm

(6) Loosen the capscrew M14x35 (B2) that fasten the travel motor to the lower frame. On that occasion, put a matching mark between the lower frame and the travel motor.

: 22 mm (7) Apply a wire rope to a part near the sprocket of the travel motor for balancing, and remove the unit out of the lower frame. Weight of travel motor (5) (with sprocket (2): 79 kg

Fig. 34-79 Removing cover and travel motor

Fig. 34-80 Removing and installing travel motor 31.1.10.1.2

Installing

(1) If there are burrs and dirt on fitting part with which the travel motor are fastened, eliminate it beforehand. Place a wire sling in the travel unit with the same way as in the removing, and install it to the lower frame.

(2) Coat the threaded part of the mounting capscrews (4, B3) with Loctite #262 and tighten them. : 22 mm, Tightening torque = 181 Nm B3

Fig. 34-81 Installing travel motor

34-36

34. TRAVEL SYSTEM (3) Reconnect the hydraulic pipings as before, and tighten the joints to the specified torque. •

Fill the casing with hydraulic oil prior to perform drain piping. Tightening torque Nm Port Thread size Spanner O-ring 30° flare (PF) used mm type fitting type fitting 78.5 108 27 1/2 A,B 29.4 36.3 17 1/4 P 49.0 73.5 22 3/8 DR

(4) Install the covers (A1) located inside the lower frame, and tighten capscrews (A4). (see Fig. 3479).

DR P A B

Fig. 34-82 Installing hydraulic pipings (Left-travel motor)

: 17 mm (5) Remove the wooden block (3) supporting the lower frame and install the crawler. (6) Check the oil level in the reduction unit of travel motor [See Item (7) below] and replace or replenish oil as required. Oil: GEAR OIL HYPOIDE 90 Volume of oil: 900 cc

7 6

: 8 mm (7) Checking oil level in reduction unit a. Stop the machine so that the drain plug (8) of the reduction unit is located in the lowest position. b. Remove the level plug (7) and check the oil level and contamination. The oil level is proper if it is close to the plug bore. Replenish oil if necessary.

GL 90

Fig. 34-83 Checking oil level

• When starting operation, operate motor in low idling and at low speed for several minutes, and check it for possible oil leakage and noise. 31.1.10.2

MAINTENANCE STANDARD

OIL

TIGHTENING TORQUE

ITEM

SPECIFICATIONS

Sprocket fixing Capscrew M14 Apply Loctite #262 181 Nm

Travel motor fixing Capscrew M14

Specifications and grade Volume

Gear oil HYPOIDE 90 900 cc

34-37

34. TRAVEL SYSTEM 31.1.11

SLEWING BEARING

31.1.11.1

REMOVAL AND INSTALLATION PROCEDURES

31.1.11.1.1

Removing

(1) Remove the upper slewing structure. (See details in “Slewing upper structure”)

(2) Remove capscrews (B) that fix the inner race of slewing bearing (A). : 22 mm (3) Remove the grease in the inner race of slewing bearing. (4) Screw lifting-bolts in the slewing bearing (A), and lift it by crane. Weight of slewing bearing assembly: 76 kg

Fig. 34-84 Slewing bearing

Fig. 34-85 Lifting slewing bearing 31.1.11.1.2

Installing

(1) Before installing the slewing bearing, clean thoroughly the bearing and the mating surface of the lower frame to be free from dirt, oil and other foreign materials. (2) Lift up the bearing and place it on the lower frame, aligning the (S) mark engraved on the inner race as shown in Fig. 34-86.

A L

A-A

(3) Coat the threads of the capscrews (B) with Loctite #262 and tighten all capscrews temporarily. (4) Tighten the capscrews at 180° intervals alternately, and tighten them up to the specified torque. : 22 mm, Tightening torque = 181 Nm (5) Replenish 4.8 kg of “HYPOIDE 90” to the grease bath. (6) After installing the slewing bearing on the lower frame, install upper slewing structure. L. Lower frame S. Reference inside slewing bearing (S) (REFERENCE S).

Fig. 34-86 Location of reference (S) for slewing bearing installation

34-38

34. TRAVEL SYSTEM 31.1.11.2 No. 1

CONSTRUCTION COMPONENTS NAME Inner race

Q.TY 1

Outer race

Ball

Spacer

Spacer (adjusting)

Cap

Taper pin

Seal ring A

Seal ring B

Grease cup

31.1.11.3 31.1.11.3.1

3, 4, 5

6 10 7

Fig. 34-87 Cross-section of slewing bearing

DISASSEMBLY AND ASSEMBLY Disassembling

(1) Take off seal A (8) fitted in the groove on lower circumference of inner race (2), and place the bearing in level on a wooden block (W). (2) Remove taper pin (7), using a hammer and a push rod. (3) Remove plug (6) with an puller bolt making use of the threaded bore in the centre of the plug (6). (4) After removing plug (6), take out balls (3) and spacers (4), (5) from the bore in order, while rotating outer race (2) slightly.

34-39

2 W

6 9

Fig. 34-88 Disassembling slewing bearing

34. TRAVEL SYSTEM 31.1.11.3.2

Assembly

(1) Degrease thoroughly the groove for seal A (8) located in the inner circumference of outer race (2) and the groove for seal B (9) located in the outer circumference of inner race (1). Coat the grooves with adhesive (Cyanoacrylate instant glue), fit seal B (9), and place inner race (1) on a surface plate. (2) Lift and lower outer race (2) slowly till the top surface of inner race (1) matches the bottom of the sealing groove of outer race (2). Place an adjusting washer under outer race (2) in order to support the outer race so the track surface of ball (3) is aligned.

1 4 5 3

Fig. 34-89 Removing balls / spacers

(3) Insert balls (3) and spacers (4) (5) coating with grease (HYPOIDE 90) alternately through the hole for plug (6) on outer race (2).

WARNING

When inserting balls (3) and spacers (4) (5), the ball tracks must be aligned completely. To achieve it, outer race (2) should be adjusted. It is very dangerous to put your finger into the plug bore directly; always use a push rod (P) or a hooked rod (H).

Fig. 34-90 Installing balls (4) Install plug (6) to outer race (2), confirming the direction and the position of the bore for taper pin (7). (5) Push taper pin (7) into bore, and caulk the head of the taper pin with a punch. (6) Confirm that grease nipple (10) is useful. Apply grease (HYPOIDE 90) and confirm that the outer race rotates smoothly and that the lip of the seal is not scored. Grease amount: approximately 90 g (7) Confirm that grease nipple (10) is useful. Apply grease (NLGI-2 MoS2) and confirm that the outer race rotates smoothly and that the lip of the seal is not scored. Grease amount: 180 g 31.1.11.4

Fig. 34-91 Installing spacer

MAINTENANCE STANDARD

Regarding the maintenance standards for the wear of the slewing bearing, refer to the Article Measuring Slewing Performances in Maintenance Standards and Test Procedures.

34-40

34. TRAVEL SYSTEM

31.2

DISASSEMBLY AND ASSEMBLY

31.2.1

TRANSLATION MOTOR

31.2.1.1

TECHNICAL FEATURES

OF. Oil filling port OL.Oil level check port DP. Drain port Rotating direction Clockwise Counterclockwise No. A B

NAME Oil inlet port Outlet port

D1 Discharge port D2 P P2 Pressure detecting port P3 HS. High speed LS. Low speed

Oil inlet port A B SIZE PF1/2 PF1/4 PF1/8 PT1/8

34-41

Oil outlet port B A

34. TRAVEL SYSTEM (3) EXPLODED VIEW OF TRAVEL MOTOR AND REDUCTION UNIT

Travel motor

Reduction unit

34-42

34. TRAVEL SYSTEM No.

NAME

Q.TY

No. 102 103 107 108 109 110 112 113 114 115 116 132 135 139 145 149 150 151 167 177 190

1 2 3 4 5 6 7 9 11 12 13 14 22 24 27 28 29 30

Hub Mandrel Carrier Sun gear (1) Planetary gear (1) Sun gear (2) Planetary gear (2) Thrust washer (1) Thrust collar (4) Thrust washer (3) Cover Coupling Ring nut Ball bearing Needle roller bearing with retainer Needle roller bearing with retainer Inner race Inner race

1 1 1 1 3 1 4 2 4 7 1 1 1 2 3 4 3 4

Floating seal kit Floating seal

1 2

33 35 37 39 40 41 42 43 44 45 47

Plug with flange O-ring O-ring Cap Hexagon head screw Steel ball Parallel pin O-ring O-ring Ring Hexagon head screw

1 1 3 2 7 1 2 2 1 1 2

104

Cylinder and piston kit Cylinder block

1 1

105 106

Piston kit Piston assy Piston Shoe

1 9 1 1

161 162 163

Piston kit Piston assy Piston Shoe Seal ring

1 1 1 1 1

NAME

Q.TY

Shaft Swash plate Retainer plate Thrust washer Timing plate Washer Piston Spring Spring Friction plate Separator plate Oil seal O-ring O-ring Snap ring Ball bearing Ball bearing Roller Pivot Parallel pin Spring

1 1 1 1 1 2 1 8 1 2 3 1 1 1 1 1 1 3 2 2 1

263 264 221 224 225 226 227 228 230 236

Rear flange assembly Rear flange kit Rear flange Spool Spool kit Spool Oil stopper Cap Cap Stop Cap Valve Spring Spring O-ring

1 1 1 1 1 1 1 2 2 2 2 2 2 2 2

237 252 254 266 268 273 275 276 279 280 299 241 243

O-ring Hexagon socket plug Hexagon socket plug Spring Steel ball O-ring Orifice Orifice Filter Plug with flange Name plate Parallel pin Edge bolt

2 4 6 1 1 2 5 1 1 1 1 2 6

201 223

34-43

34. TRAVEL SYSTEM 31.2.1.2

TOOLS AND JIGS

(1) Standard tools No. NAME 1 Allen wrench 2 Socket wrench (Ratchet handle) 3 Torque wrench

Torque wrench adaptor

5 6 7 8 9 10

Hexagon socket Extension bar Hammer Plastic hammer Minus driver Snap ring pliers

11 12

Cutting pliers Lifting tool

13 14

Container Leather gloves

SIZE 3 (For M6), 6 (For M8 and PF1/4), 8 (For PF3/8) Barrel type

Q.TY 1 each 1

Dial type, about 12 Nm Dial type, about 90 Nm Dial type, about 560 Nm Nominal socket size 13 and 30 Nominal rod size 3, 6 and 8 For width across flats of 3 mm 150 mm Nominal size 12 L= about 300 mm about 150 mm, 50 mm For shaft For hole 200 mm Lifting capacity: 300 kg or more Lifting eye (for M14) Lifting eye (for PF 3/8) Wire with hooks For general use: W450 x D300 x H120

1 each

1 each 1 1 1 1 1 1 1 2 1 set (2) (2) (1) 2 1 pair

(2) Screws No. 1

Name Hexagon socket head cap screw (JIS B1176)

APPLICATION ITEM (Item in cross-sectional or exploded view) Disassembly and assembly Cleaning parts 104 and 149 149 Drying after cleaning

Outline Approx. M6x50 Approx. M16x40 Approx. M16x40

NAME

SIZE

General workbench Cleaning bath For rough and finish cleaning Workbench for press Pressing capacity: 1.96 kN or more Heating capacity: 100 °C or more Heating bath Volume 500 x 500 x 500 mm Compressed air Pressure 294 ÷ 490 kPa

34-44

Q.ty 1 2 3 NOTES Q.TY 1 set 1 set 1 set 1 set

34. TRAVEL SYSTEM (3) Attachment No. NAME 1 Working bench for travel motor (WB) No.

No. NAME 2 Fixing metal (FM) No.

This is used to carry out the work for assembly and disassembly of travel motor easy and safe. Retainer metal (RM1) (RM) No.

This is used to insert spring (114), washer (110), snap ring (145) into cylinder block (104), and also used to remove spring (114) from cylinder block (104). Oil seal press fit tool (RM3) No.

For press fitting the oil seal (132) in the oil seal hole of the spindle (2). Jig for adjusting the preload to the bearing (JB) No.

This is used to connect the spindle (2) and hub (1). 4

Retainer metal (RM2) (RM) No.

This is used to pull out bearing (149) from drive shaft (102). 6

Bearing press fit tool (BB) No.

For press fitting the ball bearing (24) in the hub (1). 8

For installing the ring nut (22) to the spindle (2).

34-45

Steel rod (1) (SR) No.

This is used to remove the ring (45) from the hub (1).

34. TRAVEL SYSTEM No. NAME 9 Long lifting eye (LE) No.

Application Hub Mandrel Travel motor

No. 10 Spatula (SP) No.

NAME

â&#x20AC;&#x153;Aâ&#x20AC;? M12 M12 M12

"A"

This is used to remove the timing plate (109) from rear flange (201). Jig for cover removal (JC) No.

This is used to remove the cover (13) from the hub (1). Floating seal (F/S) inserting jig (II) (FS2)

This lifting eye is used to sling up travel motor, the spindle (2) and the hub (1). 11

Pin punch (PP) No.

This is used to remove the outer race of floating seal (31). Floating seal (FS1) inserting jig (F/S) No.

For building the floating seal (31) into the hub (1). 15

Floating seal (F/S) inserting jig (FS3) No.

For building the floating seal (31) into the spindle (2).

34-46

For building the floating seal (31) into the hub (1) and spindle (2).

34. TRAVEL SYSTEM 31.2.1.3 31.2.1.3.1

DISASSEMBLY PREPARATIONS FOR DISASSEMBLY

Prior to disassembling, carry out the following preparations: (1) Workbench preparation •

Prepare workbench for travel motor.

•

Prepare workbench which is rigid enough to disassemble or assemble internal parts of travel motor and has a wide area for placing them to prevent them from moving or dropping during the work.

•

Cover workbench with rubber, vinyl, etc.

(2) Preparations of tools and materials Prepare materials shown in 34.2.1.2. 31.2.1.3.2

GENERAL PRECAUTIONS FOR WORKING

WARNING Internal parts during disassembly are slippery as they are smeared by hydraulic oil. Handle them with extreme care not to drop them. Otherwise, you may be injured or they may be damaged. Combustible material such as kerosene is used to clean the parts. Handle it with extreme care not to cause fire or burns, as it catch fire easily. (1) Prior to disassembly, make a good judgment on the features etc. of the generated abnormalities to work according to the disassembling procedure. (2) All parts are manufactured in high precision. Therefore handle them with care not to bump them each other or drop them. (3) Work patiently not to forcibly strike or pry the sticking parts during disassembly. Otherwise it may result in generating burrs, damages, and performance deterioration. (4) Be careful not to leave the disassembled parts without appropriate protection. Otherwise they may be rusted by moisture and or contaminated by dust. (5) Put a match mark on each mating surface of part during disassembly. (6) Carry out the work putting every removed part in order, and taking care not to cause damage or loss. (7) Sealing parts shall be replaced in principle, even though no damage is found on them. Keep them on hand prior to disassembly. (8) Photos and figures of typical models are shown. Any partial difference between them and the product in use does not affect the disassembling procedure.

34-47

34. TRAVEL SYSTEM 31.2.1.3.3

DISASSEMBLY

(1) Cleaning travel motor LE

1) Tighten the lifting eyes (LE) into the tapped holes of the spindle (2).

WARNING Screw two lifting eyes into the tapped holes of the spindle diagonally located with each other. 2) Pass a wire sling through the lifting eyes, lift up the travel motor by hoist, and carry into the cleaning bath.

Fig. 34-92 Mounting lifting eye

3) Clean the travel motor with a car brush.

WARNING Since soil and sand are accumulated in the clearance (where the floating seal is fixed) between the hub (1) and the spindle (2), clean it with particular care.

Fig. 34-93 Cleaning travel motor (2) Installing travel motor 1) Place travel motor on a workbench.

WARNING While aligning the threaded holes of the hub (1) and the workbench, place the travel motor in fixing holes of the workbench slowly. 2) Fix the travel motor with two socket bolts (F) on the workbench (WB). Fig. 34-94 Placing travel motor on workbench

WARNING Tighten the hexagon socket screws securely. Failure to do so could result in injury cased by the travel motor falling when it is inverted.

Fig. 34-95 Fixing travel motor on workbench

34-48

34. TRAVEL SYSTEM (3) Draining lubricating oil 1) Turn over the travel motor. 2) Loosen a plug (33) and two socket plugs (39). • If the plug (33) and the socket plugs (39) are removed and the travel motor is reversed, oil spills. Loosen them to such an extent that they can be turned by hand. 3) Turn over the travel motor and extract the lubricating oil. (Turn up the side of motor) 4) Remove the O-rings (37) from the plug (33) and two socket plugs (39). • Do not reuse O-ring (37) which have been removed.

Fig. 34-96 Removing plug (33)

Fig. 34-97 Draining oil (4) Remove cover (13). 1) Turn over the travel motor. (The reduction gear side is directed upwards). SR

2) Remove the ring (45) with tool (SR). 3) Loosen two capscrews in the middle of the cover removal jig in the thread holes from which the plugs (33) and (39). (Two points) 4) Apply a block to two capscrews in the middle of the cover removal jig and tighten the screws to remove the cover (13) with tool (JC). • If it is difficult to remove the cover (13) due to resistance of the O-ring (35), lift the cover while lightly tapping the external periphery of the cover with a plastic hammer. 5) Remove the O-ring (35) from the hub (1).

Fig. 34-98 Removing ring (45)

• Do not reuse the removed O-ring (35).

Fig. 34-99 Removing cover (13)

34-49

34. TRAVEL SYSTEM (5) Removal of drive gear 1 (4) 1) Pull out the drive gear 1 (4) by hand. 2) Remove the steel balls (41) from the shaft (1) (4). â&#x20AC;˘ The coupling (14) may come off at the same time.

Fig. 34-100 Removing sun gear 1 (4) (6) Removing carrier assembly 1) Take out the carrier assembly from the hub (1). 2) Pull out the drive gear 2 (6) from the hub. 3) Remove the coupling (14) from the shaft (102).

Fig. 34-101 Removing carrier assembly 4) Disassembling carrier assembly 1. Loosen the hexagonal head screws (40) to remove them from carrier (3). 2. Remove three thrust washers (12), three planetary gears 1 (5), three needle roller bearings with retainers (27) and three bearing inner races (29) from the carrier (3).

Fig. 34-102 Disassembling carrier assembly 5) Remove the thrust washer 1 (9) from the carrier (3).

Fig. 34-103 Removing thrust washer (9)

34-50

34. TRAVEL SYSTEM (7) Removing planetary gear 2 (7) 1) Loosen four hexagonal head screws (40) and remove them from spindle (2).

Fig. 34-104 Unscrewing hexagonal head screw (40) 2) Remove four planetary gears 2 (7), four needle roller bearings with cages (28) and four inner races (30). 3) Remove four thrust collars 4 (11) from the spindle (2). 4) Remove the thrust washer 1 (9) from the spindle (2).

Fig. 34-105 Removing planetary gear 2 (7) (8) Removing rear flange 1) Turn over the travel motor, so rear flange (201) is on the top. â&#x20AC;˘ Follow the procedures below to make it easy to remove the plug when disassembling the interior of the rear flange (201). â&#x20AC;˘ Do not loosen the plugs unless disassembling the interior of the rear flange. 2) Loosen two plugs (224).

Fig. 34-106 Tightening plug (224) 3) Loosen two plugs (226).

Fig. 34-107 Tightening plug (226)

34-51

34. TRAVEL SYSTEM 4) Loosen six socket bolts (243) and remove them from the rear flange (201).

Fig. 34-108 Removing socket bolt (243) 5) Remove the rear flange (201) from the spindle (2). â&#x20AC;˘ Hold the rear flange by both hands, hold it up gently upright to remove it. Perform the work with care not to forcibly pry or strike the flange. Otherwise it may cause the timing plate (109) to drop and be damaged.

Fig. 34-109 Removing rear flange (201) 6) Remove the parallel pins (42) from the spindle (2).

Fig. 34-110 Removing parallel pin (42) 7) Remove the O-rings (43) and (44) from the spindle (2). â&#x20AC;˘ Do not reuse the removed O-rings (43) and (44).

Fig. 34-111 Removing O-rings (43) and (44)

34-52

34. TRAVEL SYSTEM (9) Removing rear flange fittings 1) Place the rear flange (201) on the workbench, with the mating surface for the spindle (2) facing up. 2) Remove the timing plate (109) from the rear flange (201). â&#x20AC;˘ It may be hard to remove the rear flange as the mating surface of it is stuck with oil. Insert a spatula (SP) into the draft groove of the mating surface on the rear flange side and hold the timing plate up. Then the rear flange comes off. If a sharp tool like a screwdriver is put into the mating surface, the mating surface may be damaged to cause an oil leakage. Do not use sharp tools.

Fig. 34-112 Removing timing plate (109)

3) Remove the parallel pins (241) from the rear flange (201).

Fig. 34-113 Removing parallel pin (241) 4) Remove bearing (150) from the rear flange (201).

Fig. 34-114 Removing bearing (150) (10) Removing brake valve parts from rear flange. 1) Remove two plugs (224) from the rear flange (201).

Fig. 34-115 Removing plug (224)

34-53

34. TRAVEL SYSTEM 2) Remove two stoppers (225) and two springs (228) from the rear flange (201). 3) Remove the spool (223) from the rear flange (201). â&#x20AC;˘ To remove the spool (223), place your hand on one part of the plug port of the rear flange (201) and tilt it down. Then the spool (223) falls down. Hold the tip and remove it.

Fig. 34-116 Removing stopper (225), spring (228) and spool (223) 4) Remove two plugs (226) from the rear flange (201).

Fig. 34-117 Remove the plug (226) 5) Remove two springs (230) and two valves (227) from the rear flange (201).

Fig. 34-118 Removing spring (230) and valve (227) 6) Remove O-ring (236) from plug (224). â&#x20AC;˘ Do not reuse the removed O-ring (236).

Fig. 34-119 Removing O-ring (236)

34-54

34. TRAVEL SYSTEM 7) Remove O-ring (237) from plug (226). â&#x20AC;˘ Do not reuse the removed O-ring (237).

Fig. 34-120 Removing O-ring (237) (11)Removing two-speed switching spool 1) Remove the plug (221) from the rear flange (201). 2) Remove O-ring (273) from plug (221). â&#x20AC;˘ Do not reuse the removed O-ring (273).

Fig. 34-121 Removing plug (221) 3) Remove the spool (263) from the rear flange (201).

Fig. 34-122 Removing spool (263)

34-55

34. TRAVEL SYSTEM (12) Removing the parking brake section

WARNING

Install a protection cover (PC) on the piston (112). Otherwise the piston may fly out suddenly from the spindle (2) due to compressed air to cause injury.

1) Blow compressed air (AH) into the passage hole for the parking brake spindle (2) and take out the piston (112) from the spindle (2). 2) Remove the O-rings (135) and (139) from the piston (112). • Do not reuse the removed O-rings (135) and (139).

Fig. 34-123 Removing piston (112)

Fig. 34-124 Removing piston (112) (13)Disassembling hydraulic motor section • When placing the travel motor on its side, place an oil pan under the travel motor to receive oil flowing out from the travel motor. 1) Incline travel motor 90 degrees. 2) Drain oil out of the travel motor. 3) Remove two separator plates (116) and, one friction plate (115). 4) Hold the cylinder block (104) by hand and turn it 2 or 3 times alternatively to separate the shoe (106) adhered on the swash plate (103).

Fig. 34-125 Lifting cylinder block (104)

• Note that, if the cylinder block (104) is pulled out without separating the shoe (106), the shoe (106) left on the swash plate (103) may allow the parts (piston, shoe, etc.) on the cylinder block (104) to come off and drop into the spindle (2).

Fig. 34-126 Removing cylinder block (104)

34-56

34. TRAVEL SYSTEM 5) Remove the cylinder block (104) from the drive shaft (102). 6) Remove piston assembly [piston (105) and shoe (106)] and the retainer plate (107) from the cylinder block (104). â&#x20AC;˘ When removing the cylinder block, hold the retainer plate (107) by both hands to remove it with the piston assembly. â&#x20AC;˘ The piston (105) and the shoe (106) are squeezed at the spherical portion of the piston to make them one piece. It is not possible to remove the piston from the shoe without damaging the shoe. When replacement is required, replace the piston and bottom together (hereafter referred to as the piston assembly).

Fig. 34-127 Removing retainer plate (107)

7) Remove the retainer plate (107) from piston assembly (105) and (106) [seven sets].

Fig. 34-128 Removing piston assembly (105) and (106) 8) Remove the thrust ball (108) from the cylinder block (104).

Fig. 34-129 Removing thrust washer (105) 9) Remove three rollers (151) from the cylinder block (104).

Fig. 34-130 Removing roller (104)

34-57

34. TRAVEL SYSTEM (14)Removing spring inside cylinder block 1) Place the cylinder block (104) on the press bench. • Remove the spring, only when its replacement is necessary. • When removing the spring, align the centre of the retainer bushing (RM1) with the washer centre in order to prevent the cylinder block from being damaged by contact. • Put a vinyl sheet (VS) over the cylinder block so as not to damage the surface of the cylinder block.

RM1

Fig. 34-131 Removing spring (114) 2) Place the retainer metal ( I ) against the washer (110), remove the snap ring (145) from the snap ring groove of the cylinder block (104) with a snap ring plier.

WARNING

RM1 110 145

114

Release pressing force slowly. Otherwise the spring may fly out to cause injury.

104

Fig. 34-132 Removing spring (114) 3) Remove the snap ring (145), washer (110), spring (114), and washer (110) out of the cylinder block.

Fig. 34-133 Removing internals of cylinder block (104) (15)Removing swash plate 1) Remove the swash plate (103) from the drive shaft (102). • When removing the swash plate (103), ensure that pivot (167) is not adhered on the swash plate (103).

Fig. 34-134 Removing swash plate (103)

34-58

34. TRAVEL SYSTEM 2) Pull the drive shaft (102) out of the spindle (2). Then the ball bearing (149) is removed together. • Be careful to lightly strike the tip of the shaft on the reduction side using a plastic hammer to allow the shaft to come off easily. Otherwise the shaft may pop out. 3) Remove two pivots (167) and two the parallel pins (177) from the spindle (2). 4) Take out the 2-speed switching piston kit (piston assembly and seal ring) and the spring (190) from the spindle (2). Fig. 34-135 Removing drive shaft (102)

Piston assembly: Piston (161), Shoe (162) Seal ring (163) (16)Removing ball bearing • Remove the ball bearing, only when its replacement is necessary. 1) Place the retainer metal (RM2) on the press bench and put the drive shaft (102) into it. 2) Hold down the tip of the drive shaft (102) by a press and remove the bearing (149) from the shaft. • Do not reuse the ball bearing.

CA. Compressed air (Air gun)

Fig. 34-136 Removing 2-speed switching piston kit

149 102 RM2

Fig. 34-137 Removing ball bearing (149) (17)Removing spindle 1) Apply the clamp plates (FM) to the spindle (2) in the equally spaced positions, and fasten three M16 x 2.0 x 150 (approximately) to the workbench.

2) Turn over the travel motor. (Direct the reduction unit side upward.)

Fig. 34-138 Fixing spindle (2)

34-59

34. TRAVEL SYSTEM 3) Remove two hexagon set screws (47).

Fig. 34-139 Removing hexagon set screw (47) 4) Loosen the ring nut (22) using a tightening jig (JB). â&#x20AC;˘ Do not reuse the removed ring nut (22) of which tooth flank may be damaged.

Fig. 34-140 Loosen ring nut (22) JB

1 22

Fig. 34-141 Installing jig 5) Remove the ring nut (22) from the spindle (2).

Fig. 34-142 Removing ring nut (22)

34-60

34. TRAVEL SYSTEM (18) Removal of the ring nut 1) Turn over the travel motor. (Direct the motor side upward.) 2) Remove the clamp plates from the workbench. 3) Tighten two M16 eyebolts in the mounting thread holes of the spindle (2) in the diagonal position. 4) Hook a wire rope with hook to M16 eyebolts, and lift by a crane to remove the spindle (2) from the hub (1). At this time, the floating seal (31) and oil seal (132) will be removed together with the spindle (2).

Fig. 34-143 Removing spindle (2)

(19) Removing main bearing 1) Remove the floating seal (31) from the hub (1). • Do not reuse the removed floating seal (31). 2) Apply a punch between the inside periphery of the hub (1) and the main bearing (24) to remove the main bearing using a hammer. • When the fit section of the outer race of ball bearing (24) comes out of hub (1), the ball bearing drop from the hub. Therefore place a receptacle under the workbench and spread a rubber mat on the receptacle so as not to damage the parts.

Fig. 34-144 Removing floating seal (31)

3) Turn over the travel motor. 4) Tapping the end face of outer race of ball bearing (24) with aluminum rod (pin punch) (PP) and hammer, remove the ball bearing from hub (1).

• Remove ball bearing (24) little by little, tapping evenly the end face of outer race of the ball bearing at 3 or 4 points of the from the hub so that the ball bearing is not suck.

Fig. 34-145 Removing ball bearing (24) (20)Removing spindle fittings 1) Remove the floating seal (31) from the spindle (2).

Fig. 34-146 Removing floating seal (31)

34-61

34. TRAVEL SYSTEM 2) Remove the oil seal (132) from the spindle (2). • Never reuse the removed oil seal (132).

132

Fig. 34-147 Removing oil seal (132) (21)Rough washing of parts 1) Separate the four parts, namely the hub (1), the spindle (2), the cover (13) and the rear flange (201) from the other parts (hereafter referred to as built-in parts). 2) Put the hub, spindle, cover, and rear flange in a cleaning bath and clean them. • Carefully remove dust accumulated on the surfaces of parts to make them completely clean.

WARNING Kerosene is combustible. Be careful not to cause fire, burns, and injury.

Fig. 34-148 Cleaning each part

• Before cleaning stained parts, immerse them in kerosene until dust and stain become soft and are floated so as to prevent damage when cleaning. 3) Put the built-in parts in a rough cleaning bath containing kerosene and clean them.

Fig. 34-149 Cleaning each section

34-62

34. TRAVEL SYSTEM (22)Finish cleaning 1) Put parts in a finish cleaning bath containing kerosene and clean them well, turning them slowly. 2) Wipe off kerosene adhered to the parts using a clean waste cloth. â&#x20AC;˘ Dry the inner surfaces of the hub (1) and the spindle (2) in the dust-free and dry conditions by blowing compressed air on them. After drying, apply hydraulic oil to every part. â&#x20AC;˘ Dry the inner surface of the rear flange (201) and the hydraulic motor components in the dustfree and dry conditions by blowing compressed air on them. After drying, apply hydraulic oil to every part.

Fig. 34-150 Finish cleaning

Fig. 34-151 Finish cleaning

34-63

34. TRAVEL SYSTEM 31.2.1.4

ASSEMBLY

Perform assembly basically in reverse order of disassembly. 31.2.1.4.1

PREPARATION

Prepare a workbench, tools and jigs as in the case of Section 34.2.1.3; DISASSEMBLY. 31.2.1.4.2

GENERAL PRECAUTIONS FOR ASSEMBLY

(1) For assembly also, take the general precautions described in Section 34.2.1.3; DISASSEMBLY. (2) For assembly, remove any metallic dust or foreign material from all parts and make sure that the parts are free of burrs and dents which should be ground off using an oilstone. (3) Replace the O-rings, oil seals, and floating seals with new ones. (4) Bonding adhesive is applied to the threaded portions and tapped holes of spindle (2) and carrier (3) when assembling. Remove their grease by using the tap (M8 1.25), and wash with solvent. After that, degrease solvent of the holes by spraying with compressed air. Replace hexagon head bolt (40) with new ones. (5) Be careful not to damage the O-rings, oil seals, and floating seals at installation (Lightly apply grease to them for smooth installation). (6) Prior to assembly, apply clean hydraulic oil (HYPOIDE 90) to movable and sliding portions of hydraulic motor components and valves. (7) Use no cloth gloves during assembly to prevent malfunctions due to textile lint. (8) On completion of assembly, plug every opening to prevent the entry of dirt. (9) Photos and figures of typical models are shown. Any partial difference between them and the product in use does not affect the assembling procedure. 31.2.1.4.3

ASSEMBLING PROCEDURE

NOTE: after replacing any of the following parts with new ones, adjust the preload of the ball bearing and thickness of the snap ring without fail: (1) Parts requiring preload adjustment of the ball bearing after their replacement: hub (1), the spindle (2) and ball bearing (21) NOTE: when replacing any of the above parts, use the parts previously adjusted. Otherwise, the travel motor may malfunction resulting in premature breakage.

34-64

34. TRAVEL SYSTEM (1) Assembling hub section 1) Place the hub (1) on the press workbench on a support (S). 2) Insert the main bearing (24) in the hub (1). Place the main bearing press fit jig (BB) on the outer race of the main bearing (24). Push down the jig by a press to press fit the bearing into the hub (1).

1 BB

3) Turn over the hub (1). 4) Press fit the main bearing (24) into the hub (1) in the same way as the above item 2). • Be careful not to mistake orientation of the main bearing (24) when press fitting.

Fig. 34-152 Inserting bearing (24) FS2

5) Apply grease to the O-ring of the floating seal (31). Build the floating seal into the floating seal groove of the hub (1). • Apply a small amount of grease to the entire surface of the O-ring after removing it from the floating seal. • Place the FS inserting tool (FS1), the floating seal and the FS inserting tool (FS2) in this order, and press in until the FS inserting tool (FS2) contacts with the FS inserting tool (FS1). Remove the FS inserting tools and ensure that the end surface of the hub is in alignment with the face of the floating seal at an accuracy of 1 mm or less.

FS1

31 1

Fig. 34-153 Installing floating seal (31)

6) Attach two lifting eyes (LE) to the tapped holes of the hub (1) in diagonal position. 7) Attach a wire with hooks to the lifting eyes, lift the hub (1) by a crane and then install the hub (1) on the workbench. • While aligning the tapped hole in the hub (1) with the fixing hole (F) in the workbench (WB), carefully insert the hub (1) into the fixing hole (F) in the workbench.

Fig. 34-154 Lifting hub (1)

8) Attach the hub (1) to the workbench (WB) by tightening the socket bolts in diagonal position.

WARNING Fully tighten the socket bolts. Otherwise, the travel motor may fall down to cause injury when it is turned over.

Fig. 34-155 Installing hub (1) to the workbench

34-65

34. TRAVEL SYSTEM (2) Assembling spindle section

FS2

1) Apply grease to the O-ring of the floating seal (31), and fit the floating seal in the groove of the spindle (2). • Place the FS inserting tool (FS3), the floating seal and the FS inserting tool (FS2) in this order, and press in until the FS inserting tool (FS2) contacts with the FS inserting tool (FS3). Remove the FS inserting tools and ensure that the end surface of the hub is in alignment with the face of the floating seal at an accuracy of 1 mm or less.

FS3

31 2

Fig. 34-156 Installing floating seal (31)

2) Attach two lifting eyes to the spindle (2) in diagonal position. 3) Attach a wire with hooks to lifting eyes, lift the spindle (2) by crane and then insert the spindle (2) in the hub (1) slowly. 4) Fix the hub (1) and the spindle (2) with fixing plate in diagonal position. Tightening torque: 59 ± 20 Nm 5) Turn over the travel motor. 6) Apply Loctite #638 to the spindle with the bearing preload adjuster. Tightening torque: 392 ± 39 Nm

Fig. 34-157 Inserting spindle (2)

JB 1

Fig. 34-158 Installing ring nut (22) 7) Tighten two hexagon socket set screws (47). Tightening torque: 4.9 ± 1.0 Nm 8) After tightening up the screw, deform the entrance of the threaded holes for avoiding loosening screw

Fig. 34-159 Attaching hexagon set screw (47)

34-66

34. TRAVEL SYSTEM 9) Turn over the travel motor. (Direct the motor side upward). 10) Remove the clamp plates from the workbench. FM

Fig. 34-160 Removing fixing plate (3) Assembling motor parts inside spindle 1) Press fit the oil seal (132) into the spindle (2) using the oil seal press fit tool (RM3) and a hammer.

RM3

• Apply MG2 grease to the lip of the oil seal before installing.

132

• Be careful not to mistake the orientation of the oil seal.

2) Insert two parallel pins (177) into the pin holes of the spindle (2). 3) Apply Moly NLGI 2 grease to the semi-spherical surface of two pivots (167) and fit them to the parallel pins (177) installed to the spindle (2).

Fig. 34-161 Installing Oil seal (132)

4) Apply grease to the spring pin (190) to install to the piston kit consisting of piston (161), shoe (162) and seal ring (163). 5) Apply grease to the sliding surface of the piston assembly to install to the piston hole of the spindle (2).

Fig. 34-162 Installing piston kit (4) Inserting shaft

WARNING Carefully carry out the insertion work using leather gloves to prevent possible burns. 1) Put the ball bearing (149) in a heating bath to heat it at 100 ± 10 °C for 10 minutes and then insert it onto the drive shaft (102).

Fig. 34-163 Inserting bearing (149)

34-67

34. TRAVEL SYSTEM 2) Incline travel motor 90 degrees. 3) Insert the shaft (102) into the spindle (2). • Insert the shaft (102) into the spindle (2) slowly and carefully. Otherwise the lip of the oil seal (132) fitted inside the spindle (2) may be damaged. Damage to the lip may cause oil leakage, leading to premature failure of the travel motor. 4) Install the swash plate (103) into the spindle (2). • Apply grease to an interface between the swash plate (103) and the spindle (2).

Fig. 34-164 Inserting shaft

• Align two pivots (167) installed in the spindle (2) with the pivot mounting holes of the swash plate to fit the swash plate (103) into the spindle (2). (5) Installing cylinder block 1) Place the washer (110), spring (114), washer (110), and snap ring (145) in this order, into the cylinder block (104). • Direct the sharp edge side of the snap ring (145) toward the inlet side. • Direct the sharp edge side of the washer (110) contacting the snap ring (145) towards the snap ring side.

Fig. 34-165 Installing swash plate (103)

2) Place the cylinder block (104) on the press bench.

CAUTION When mounting the snap ring, if the tip of the pliers slips out of the hole of the snap ring, the snap ring could jump out 3) Place the retainer metal (RM1) against the washer (110). While holding down the retainer metal (RM1) by press, fit the snap ring (145) into the snap ring groove of the cylinder block (104) with a snap ring plier.

Fig. 34-166 Assembling cylinder block

• Pressing force of the spring (114) is more than 1180 Nm. • Cover the cylinder block (104) with a vinyl sheet (VS) to prevent damage to the contact plane between the cylinder block (104) and the timing plate (109).

104 VS RM1 110

145

Fig. 34-167 Installing snap ring (145)

34-68

34. TRAVEL SYSTEM (6) Assembling hydraulic motor section 1) Put three rollers (151) into the holes of the cylinder block (104). 2) Place the thrust ball (108) on the cylinder block (104).

Fig. 34-168 Installing rollers (151) 3) Fit seven piston assemblies to the retainer plate (107). • After assembling, immerse the whole unit in hydraulic oil. 4) Fit the retainer plate (107) and the seven piston assemblies to the cylinder block (104). • Carefully match the retainer plate (107) with the spherical part of the thrust ball (108) for installation. 5) Insert the cylinder block (104) onto the drive shaft (102). • For installation, align the spline hole in the cylinder block (104) with the spline shaft of the drive shaft (102).

Fig. 34-169 Assembling piston assembly into retainer plate

• After installing the cylinder block, turn it by hand to make sure that it fits properly. If not, inspect it. • Do not take up the cylinder block (104). Otherwise the thrust balls (108) may come off, leading to abnormality in rotation.

Fig. 34-170 Inserting cylinder block (104)

34-69

34. TRAVEL SYSTEM (7) Installing parking brake • Prior to installing, immerse the friction plate (115) in hydraulic oil. 1) Incline the workbench by 90 degrees. 2) Assemble one friction plate (115) and two separator plates (116) into the cylinder block (104) alternately one by one. 3) Lightly coat the O-rings (135) and (139) with grease and install them into the O-ring grooves of the piston (112). 4) Install the piston (112) into the spindle (2). • If it is hard to fit the piston (112) into the spindle (2) due to the resistance of the O-rings (135) and (139), lightly tap the end face of the piston (112) with a plastic hammer.

Fig. 34-171 Installing friction plates (115) and separator plates (116)

• Take care not to damage the O-rings when installing the piston (112). (8) Assembling brake valve parts inside rear flange. 1) Fit two O-rings (237) to two plugs (226). • Coat the O-rings (237) with grease. 2) Install the valve (227) and spring (230) onto the plug (226), applying grease to them so as to connect all of them by adhesion of grease. 3) Insert the plug (226) with the valve (227) and spring (230) assembled in one piece, into the rear flange (201).

Fig. 34-172 Installing piston (112)

• For insertion of the plug (226), place the rear flange (201) on the workbench, facing the tapped hole for plug mounting of the rear flange (201) upward and align the centre of tapped hole with the plug centre. This is intended to prevent the O-ring from being damaged and spring (230) from coming out of valve (227) due to contact between the bore of the rear flange and the valve. 4) After installing two plugs (226) to the rear flange (201), temporarily tighten them using an Allen wrench.

Fig. 34-173 Inserting plug (226)

Fig. 34-174 Temporarily tightening plug (226)

34-70

34. TRAVEL SYSTEM 5) Insert the spool (223) into the rear flange (201). • Apply hydraulic oil to the spool and insert the spool into the rear flange. • To install the spool, align the hole of the rear flange with the spool shaft centre so as to prevent the inner surface of the rear flange and the outer surface of the spool from being damaged due to interference. • Otherwise internal leaks will occur after reassembly, resulting in performance deterioration of the travel motor. Fig. 34-175 Assembling spool (223)

6) Fix the O-ring (236) to the plug (224). 7) Install the spring retainer (225) and spring (228) into the plug (224). 8) Remove two plugs (224) from the rear flange (201). 9) Temporarily tighten two plugs (224) to the rear flange (201) with a wrench.

Fig. 34-176 Installing O-ring (236) (9) Assembling rear flange fittings 1) Installing two-speed switching spool inside rear flange. 1. Insert the spring (266) and the spool (263) into the rear flange (201). 2. Fix the O-ring (273) to the plug (221). • Apply grease to the O-ring (273). 3. Tighten the plug (221) onto the rear flange (201). 4. Tighten the plug (221) in the rear flange (201) at the specified torque with an Allen wrench key. Tightening torque: 59 ± 9.8 Nm

Fig. 34-177 Temporarily tightening plug (224)

Fig. 34-178 Assembling spool (263)

34-71

34. TRAVEL SYSTEM 2) Coat the ball bearing (150) with hydraulic oil and fit it to the rear flange (201). 3) Put two the parallel pins (241) into the pin holes in the rear flange (201). 4) Apply grease to the mating face of the timing plate (109) in contact with the rear flange (201).

Fig. 34-179 Inserting bearing (150) 5) Install the timing plate (109) into the rear flange (201), using the parallel pin (241) as a guide. • Install the timing plate (109) until it comes in close contact with the rear flange (201). This close contact prevents the timing plate (109) from falling out of the rear flange (201) when the rear flange is installed into the spindle (2). 6) Install eight springs (113) into the rear flange (201). • Sufficiently coat the springs (113) with grease and fix them so as not to allow them to drop from the rear flange (201).

Fig. 34-180 Installing timing plate (109)

(10)Connecting rear flange with the spindle 1) Insert the O-rings (43) and (44) into the O-ring groove of the spindle (2). • Fit the O-rings (43) without applying grease. Otherwise grease may ooze out of the contact surface between the rear flange (201) and the spindle (2) if an oil leakage occurred.

Fig. 34-181 Installing O-rings (43) and (44) 2) Fix two the parallel pins (42) to the spindle (2). 3) Fill 0.3 l (0.08 gal) of hydraulic oil into the spindle (2).

Fig. 34-182 Installing parallel pin (42)

34-72

34. TRAVEL SYSTEM 4) Align two parallel pins (42) set in the spindle (2) with the pin holes of the rear flange and install the rear flange (201) into the spindle (2).

Fig. 34-183 Installing rear flange (201) 5) Screw six hexagonal bolts (243) into the spindle (2) and tighten them at the specified torque. Tightening torque: 29.4 ± 4.9 Nm

Fig. 34-184 Tightening socket bolts (243) 6) Tighten the plug (226) at the specified torque. Tightening torque: 78.5 ± 9.8 Nm

Fig. 34-185 Tightening plug (226) 7) Tighten the plug (224) at the specified torque. Tightening torque: 196 ± 14.7 Nm

Fig. 34-186 Tightening plug (224)

34-73

34. TRAVEL SYSTEM (11)Installing carrier assembly 1) Insert three thrust washers (9), three bearing inner races (29), three needle roller bearings with cage (27) and three planetary gears 1 (5) in this order into the column section of the carrier (3). NOTE: if the tapped hole of carrier (3) is smeared oil or grease, degrease it by using the tap (M8 1.25). Thereafter, clean it with solvent and dry the solvent from the holes by means of compressed air. Otherwise axial-force dose not occur enough, and it may cause bole to loosen.

Fig. 34-187 Installing planetary gear 1 (5)

2) Tighten three hexagon head screws (40) with three thrust washers 3 (12) to fasten the carrier assembly to the column section of the carrier to the specified torque. Tightening torque: 33.3 Âą 4.9 Nm [Carrier assembly finished]

Fig. 34-188 Tightening hexagon head screw (40) (12)Tightening planetary gear 2 1) Turn over the travel motor. (Direct the reduction unit side upward.) 2) Install the thrust washer 1 (9) to the spindle (2). 3) Insert four thrust collars (11) and four inner races (30) into the column section of the spindle (2). 4) Insert four needle roller bearings with retainer (28) into the column section of the spindle (2). 5) Make four planetary gears 2 (7) intermesh with the internal teeth of the hub (1) to insert them into the column section of the spindle (2). â&#x20AC;˘ If the tapped hole of carrier (2) is smeared oil or grease, degrease it by using the tap (M8 1.25). Thereafter, clean it with solvent and dry the solvent from the holes by means of compressed air. Otherwise axial-force does not occur enough, and it may cause bolt to loosen.

34-74

Fig. 34-189 Installing planetary gear 2

34. TRAVEL SYSTEM 6) Tighten four thrust washers 3 (12) into the column sections of the spindle (2) with four hexagon screws (40) at the specified torque. Tightening torque: 33.3 Âą 4.9 Nm

Fig. 34-190 Tightening hexagon head screw (40) (13)Installing sun gear 2 1) Install the coupling (14) to the shaft (102). 2) Make the sun gear 2 (6) mesh with the planetary gear 2 (7) to install.

Fig. 34-191 Installing sun gear (102) (14)Installing carrier assembly 1) Install the planetary gear carrier assembly mounted in item (11) while making it mesh with the drive gear 2 (6) and the internal teeth of the hub (1). (15)Installing sun gear 1 1) Insert the sun gear 1 (4) into the coupling (14). Preassemble the steel balls (41) into the drive gear 1 (4). â&#x20AC;˘ Apply grease to the steel balls (41) to prevent them from dropping before assembling them onto the drive gear 1 (4).

Fig. 34-192 Installing carrier assembly

2) Install the drive gear 1 (4) while making it mesh with the teeth of the three planetary gears 1 (5).

Fig. 34-193 Installing the drive gear 1 (4)

34-75

34. TRAVEL SYSTEM (16)Installing cover 1) Supply 0.6 litres of lubricating oil to the hub (1). • Apply grease to the O-ring (35) 2) Fit the O-ring (35) into the O-ring groove of the hub (1). 3) Install the cover (13) to the hub (1). • When it is difficult to fit the cover (139) into the hub (1), tap the periphery of the cover (13) lightly and uniformly with a plastic hammer. Otherwise the O-ring (35) may be damaged to cause oil leakage. Lubricating oil may also gush out through the thread hole.

Fig. 34-194 Supplying lubricating oil

4) Fit the O-ring (45) into the O-ring groove of the hub (1). • Avoid the position in which the mating port of the ring (45) faces the notch of the hub (1). 5) Install the O-rings (37) to two plugs (33) and (39). • Apply grease to the O-ring (37) lightly. 6) Tighten the plugs (33) and (39) into the cover (13) to the specified torque. Tightening torque: 58.8 ± 9.8 Nm (17) Removal of travel motor

Fig. 34-195 Inserting plug (13)

1) Turn over the travel motor. (Direct the motor side upward). 2) Remove the travel motor mounting screws from the workbench. 3) Screw two eyebolts into the thread holes of the spindle (2). • Arrange the two eyebolts in the diagonal position. 4) Hook the wire rope with hook to the eyebolts to remove the travel motor from the workbench using a crane. Fig. 34-196 Removing travel motor

34-76

34. TRAVEL SYSTEM 31.2.1.5

MAINTENANCE STANDARD

After disassembling GM motor, follow these standards to perform maintenance. Handle every part with care and, in particular, avoid damaging the moving and sliding portions. (1) Replace any seal (O-ring, oil seal, and floating seal) once used even if no damage is found. (2) Wear parts maintenance standard. 1) Replace any part heavily damaged visually. 2) Replace a part that shows the following abnormalities. Item no.

Part name

Defect

Standard value (Standard dimension)

Allowable value (Criteria)

–

Play 0.05 mm

Play 0.15 mm

–

• Severe visual damage (1)

(2) (3) etc. (4) (6) (5) (7) (9) (11) (12)

Hub

Mandrel

• Pitting recognized on ring gear tooth flank • Abnormal wear such as galling • Severe visual damage • Abnormal wear such as galling.

Carrier assembly

• Abnormal wear such as galling

Sun gear 1 Sun gear 2 Planetary gear 1 Planetary gear 2 Thrust washer 1 Thrust collar 4 Thrust washer 3

• Pitting recognized on tooth flank • Flaking recognized on bearing rolling surface • Sliding surface abnormally worn

discoloured

and/or

• Dent recognized (24)

Main bearing

(27) (28)

Needle bearing

(29) (30)

Inner bearing cup

(201)

Rear flange

(102)

Shaft

(103)

Swash plate

(104)

Cylinder block

(105) (106)

Piston assy Piston Shoe

(107)

Retainer plate

• Flaking recognized • Uneven wear recognized • Pitting recognized on roller • Abnormal wear on cage end surface • Flaking recognized on bearing rolling surface • Scratch recognized on valve (263) sliding surface • Oil seal (132) contacting surface worn • Spline worn • Seizure is recognized • Spline worn • Bore severely worn • Scratch and uneven wear recognized on timing plate (109) sliding surface • Clearance exists between piston (105) and bottom (106) • Abnormal and uneven wear recognized on shoe surface • Uneven wear recognized on shoe (106) sliding surface • Scratch and uneven wear recognized on thrust ball (108) sliding surface

34-77

34. TRAVEL SYSTEM

Item no.

Part name

(108)

Thrust washer

(109)

Timing plate

(115)

Friction plate

(116)

Mating plate

Defect

• Uneven wear recognized on retainer – plate (107) sliding spherical surface • Seizure and uneven wear recognized on sliding surface • Uneven wear recognized on both end surfaces Braking torque • Specified torque cannot be obtained 32.4 Nm

(105)

Piston

(149) (150)

• Seizure is recognized • Scratch recognized on periphery • Dent recognized

Ball bearing

• Flaking recognized

(161) (162) (163) (223) (263)

Two-speed piston kit Piston Shoe Seal ring Spool

Standard value (Standard dimension)

Allowable value (Criteria) –

Braking torque 32.4 Nm

–

• Wear recognized • Uneven wear recognized on periphery • Abnormal and/or uneven wear recognized on shoe surface • Abnormal wear recognized on seal ring • Uneven wear recognized on periphery • Scratch recognized on periphery

34-78

34. TRAVEL SYSTEM 31.2.1.6 •

Performance verification test

After finishing maintenance of the GM motor, carry out performance verification tests according to the procedures below:

(1) Measuring instruments to be used 1 2 3

Pressure gauge for 35 kgf/cm2 Measuring cylinder (for 5 litres) Stop watch

2 1 1

(2) Test procedure

Mount the GM motor on the body (frame section) and connecting piping. However, do not install the crawlers. (Because the performance test (no-load run)

Mounting and piping of GM motor

Note: 1. Connecting piping so that a pressure gauge can be installed (in the main circuit) and an amount of drain of the hydraulic motor can be measured. 2. Mount the GM motor carefully using bolt holes without hammering.

GM motor speed

Running-in of GM motor 1

10 rpm

20 rpm

Pressure

Rotating direction

Working time

No-load

Right and left

One minute or more each

Performance verification test of GM motor Preparation operation before testing 1

Verification test Acceptance criteria-

Run the machine for preparation until the following temperatures are approximately achieved. • Hydraulic oil temperature 45-55 °C • External temperature of reduction unit hub 40-80 °C

Measure the following values to decide acceptance or rejection. GM motor drive pressure 1.57 MPa or lower at 10 rpm Drain amount of hydraulic motor 0.5 l/min or less at 10 rpm

Reject

Install crawlers

Disassemble and adjust again

34-79

34. TRAVEL SYSTEM

[NOTES]

34-80

42. TROUBLESHOOTING (HYDRAULIC SYSTEM) TABLE OF CONTENTS 42.1 GENERAL PRECAUTIONS ............................................................................ 42-1 42.1.1 CONFIRM ACTUAL TROUBLED CONDITIONS AT SITE ....................... 42-1 42.2 TROUBLE DIAGNOSIS: HYDRAULIC SYSTEM ............................................ 42-2 42.3 TROUBLESHOOTING .................................................................................... 42-3 42.3.1 TOOL ....................................................................................................... 42-3 42.3.2 TRAVEL OPERATION ............................................................................. 42-5 42.3.3 SLEWING OPERATION ........................................................................... 42-7 42.3.4 PUMP ....................................................................................................... 42-9

42. TROUBLESHOOTING (HYDRAULIC SYESTEM)

42.1

GENERAL PRECAUTIONS

Troubleshooting provides the procedure to investigate the cause of trouble when a problem occurs. This manual describes how to systematically solve a specific problem as quickly as possible. For the troubleshooting concerning the inside of equipment, refer to the troubleshooting for each manual of the equipment. 42.1.1

CONFIRM ACTUAL TROUBLED CONDITIONS AT SITE

(1) Get to the site as quickly as possible. Verify the machine model, serial number, situation of trouble and field, and notify possible arrival time to the user.

Fig. 42-1 Make field investigation (2) Verify background of trouble occurred. 1) Model name and serial number. 2) Type of attachment. Check that the combination of attachments was proper and that the operating manner was not unreasonable. 3) Operating time on the hourmeter. 4) Record of troubles. First trouble or repeated trouble. 5) History of the trouble and additional modifications. Reoccurrence of the same trouble in the past or trouble due to additional modification.

Fig. 42-2 Verifying the causes of the trouble occurred

(3) How to diagnose trouble 1) Verify defective part. 2) Reproduce the fault conditions. 3) Where the defective part can not be verified, surmise the possible causes systematically. 4) Check the assumed cause. 5) Report the repairing method, the procedures used and the repairing modes to the user. (4) Explanation of the cause of trouble 1) Explain the cause of trouble to the user. For example, explain the oil leakage through the piston is caused by defect on the piston rod. And the proper operating manner of the machine should be explained to the user to prevent recurrence of the same kind of trouble. 2) Handling of damaged parts. The damaged parts to be claimed and returned are the evidence, so they should be handled with care. For example, protect them from invasion of water, soil, etc., into ports on a hydraulic equipment, etc., at the returning them. And also use care not to give any damages and breakage for transport.

42-1

Fig. 42-3 Diagnosing the trouble by means of the troubleshooting

42. TROUBLESHOOTING (HYDRAULIC SYESTEM)

TROUBLE DIAGNOSIS: HYDRAULIC SYSTEM

Tool

(2) Travel speed is slow. (3) Attachment operating power is low.

Pump Slewing operation Travel operation

(4) Malfunction of attachment. (1) Travel operational failure. 2

(2) Travel speed is slow. (3) Attachment operating power is low. (4) It deviates in travel independent operation. (1) Slewing operational failure. (2) Slewing speed is slow.

(3) Slewing operating power is low. (4) Malfunction of slewing operation.

(1) Engine speed is reduced due to pump load. (2) Malfunction of pump.

Abbreviations E/G: SOL: SW: ATT: C/V: R/V: V:

engine solenoid switch attachment control valve pressure relief valve valve

42-2

Hydraulic cylinder

Travel motor

Slewing motor

Shuttle valve

Check valve

Actuator Attachment spool

Travel spool

Travel straight valve

Each overload R/V

Main gear pump R/V

Valve Travel and ATT main R/V

Defect Attachment operational failure (1) (excluding swing operation).

Gear pump

Reference No.

Classification

Pump Main pump

Causes

Trochoid pump

42.2

42. TROUBLESHOOTING (HYDRAULIC SYESTEM)

42.3

TROUBLESHOOTING

42.3.1

TOOL

42.3.1.1

Attachment operational failure (excluding swing operations)

Boom arm, bucket, YES dozer and travel can be operated?

One or more of them can not be operated?

YES

Primary pilot pressure normal?

YES

Spool stick of control valve exists?

Check control valve spool.

Secondary pressure normally generated by pilot valve?

Check pilot valve.

Check lever lock solenoid or lever lock switch. (To troubleshooting of the electric system).

Failed lock lever solenoid or switch.

NO YES

Pump delivers oil?

Failure of pilot relief valve.

NO Failure of pilot pump.

42.3.1.2 (1)

Attachment speed is slow

Attachment operating speed is slow. Is each operating speed NO of boom, arm and bucket within the reference value?

YES

Is the speed of travel sprocket within the reference value?

Failure of cylinder.

NO YES

Failure of pump.

Does control valve spool NO out of reference function? YES Set cylinder to stroke end, disconnect hose NO on the return side, apply pressure, and check that leaking inside of piston is within reference value. (2)

Failure of control valve spool.

Failure of cylinder.

Arm actuated slowly. Swing actuation speed normal?

Travel sprocket speed within reference value? NO

YES Dozer actuation speed normal?

YES

Failure of P2 pump.

YES When pressurised with return side hose disconnected and with cylinder at stroke end, leakage inside piston normal?

Failure of cylinder.

Failure of P3 pump. NO Failure of cylinder.

YES

Arm conflux valve defective.

42-3

42. TROUBLESHOOTING (HYDRAULIC SYESTEM) 42.3.1.3

Attachment operating power is low

Is main relief pressure within reference value?

Failure of pilot relief valve.

YES Is overload relief pressure within reference value?

Failure of overload relief valve.

YES Set cylinder to stroke end, disconnect hose on the NO return side, apply pressure, and check that leaking inside of piston is within reference value.

42.3.1.4 (1)

Failed cylinder or failed cylinder side valve.

Malfunction of attachment

Natural drop of attachment is large.

YES

Is oil tightness of each cylinder is within reference value?

YES

Is leaking inside of NO cylinder within reference value? YES YES Port relief pressure normal? NO

(2)

(3)

Travel normal, but boom, arm, bucket or swing impossible to actuate together with travel.

Failure of cylinder.

Failure of control valve spool or failure of lock valve (only for boom). Failure of port relief valve.

YES

The conflux valve does not switch.

Failure of swing cylinder.

Operational failure.

YES Does swing spool in control valve move?

Adjust wire.

YES NO

Swing cylinder pressurised? YES

YES Impossible to hold.

Leakage in pressurised cylinder section within reference value? NO

42-4

Failure of control valve swing spool. Failure of swing cylinder.

YES

Check the check valve in control valve for dust, etc. Failure of swing cylinder.

42. TROUBLESHOOTING (HYDRAULIC SYESTEM) 42.3.2 42.3.2.1

TRAVEL OPERATION Travel operational failure

Is travel pilot pressure normal?

Is pilot pump delivery pressure is approx. 35.5 kgf/cm2 or higher.

Failure of pilot pump.

YES YES

Failure of travel pilot valve. NO

Does travel spool move? YES Is much wear metal powder accumulated on hydraulic oil return filter? NO

Failure of control valve travel spool.

YES Failure of travel motor.

Is much wear metal powder mixed in YES lubricating oil for travel reduction unit?

42.3.2.2

Failure of travel reduction unit.

Travel speed is slow

Travel sprocket speed within reference value?

YES

Travel sprocket speed changes between 1st and 2nd speed. NO

YES

Does 2-speed change spool of travel motor move? NO

YES

Failure of travel motor spool.

Is much wear metal YES powder accumulated on hydraulic oil return filter? NO YES Is much wear metal powder mixed in lubricating oil for travel reduction unit? NO Is amount of travel motor NO drain within reference value?

Failure of travel motor.

Failure of travel reduction unit.

Failure of travel motor.

Check the 2nd travel speed solenoid valve (see troubleshooting for the electric system). Is ATT operating speed other than travel speed within reference value? NO

YES

Is travel pilot pressure normal?

YES

Does control valve spool move?

Failure of control valve travel spool.

NO YES

Primary pressure of travel pilot normal?

Failure of pilot pump. Failure of pilot relief valve.

YES Failure of pump. Failure of travel pilot valve. Is engine speed within reference value?

YES

Failure of pump.

NO Engine speed error.

YES

Adjust accel wire.

42-5

Adjust engine speed.

42. TROUBLESHOOTING (HYDRAULIC SYESTEM) 42.3.2.3

Travel power is low

NO Is the power of boom, arm and bucket normal? YES

42.3.2.4

Is main relief pressure normal?

YES Control valve travel spool YES shows abnormality such as stick? NO Is much wear metal YES powder accumulated on hydraulic oil return filter? NO YES Is much wear metal powder mixed in lubricating oil for travel reduction unit?

Failure of pilot relief valve.

Failure of control valve travel spool.

Failure of travel motor.

Failure of travel reduction unit.

It deviates in travel independent operation

There is a big different NO between right and left sprocket speed at travel idling. YES

Is tension of shoe within reference value?

NO Adjust shoe tension.

YES It may be caused by deflection of construction like lower frame, etc.

Is it free from bent of YES hose of travel line and oil leakage? NO NO Travel pilot normal? YES Does the flow change in YES reverse by changing the connection of pump delivery hose? NO YES Does the deviation change in reverse by changing the connection of right and left hoses between control valve and travel motor? NO

Replace hose.

Check or replace travel pilot valve.

Check on pump or replace it.

YES There is flaw on the outer surface of the travel spool.

Replace travel spool assembly.

NO Replace control valve.

Is much wear metal pow- YES der accumulated on hydraulic oil return filter? NO Is amount of travel motor YES drain within reference value? NO

Check travel motor or travel reduction unit, or replace it. Replace travel spool assembly. Check travel motor or travel reduction unit, or replace it.

42-6

42. TROUBLESHOOTING (HYDRAULIC SYESTEM) 42.3.3 42.3.3.1

SLEWING OPERATION Slewing operational failure

Dozer operable?

Failure of P3 pump.

YES Failure of P3 relief valve. Slewing relief valve normal?

Replace slewing relief valve.

Failure of control valve slewing spool.

YES Does slewing spool for control valve move?

YES Is much wear metal YES powder accumulated on hydraulic oil return filter?

Failure of slewing motor when it is gun metal. Failure of slewing reduction unit when it is steel powder.

42.3.3.2

Slewing speed is slow

Is slewing speed within reference value at no load? NO

YES

Is slewing relief pressure within reference value? YES Is amount of slewing motor drain within reference value?

Is dozer operating speed YES within reference value?

Failure of slewing relief valve.

NO Failure of slewing motor.

Failure of control valve slewing spool.

NO Is engine speed within reference value?

YES

Failure of gear pump.

NO Adjust engine speed.

42-7

42. TROUBLESHOOTING (HYDRAULIC SYESTEM) 42.3.3.3

Slewing power is low

It is difficult to perform NO slewing motion and boom load operation. It is impossible to carry out diagonal pulling operation of swing and arm. It is impossible to slewing because of poor slewing power at slope. YES

Is gear pump main relief pressure within reference value?

Improper gear pump main relief pressure.

YES

Is slewing relief pressure NO within reference value?

Failure of slewing relief valve.

YES

Is much wear metal YES powder accumulated on hydraulic oil return filter?

Failure of slewing motor when it is gun metal. Failure of slewing reduction unit when it is steel powder.

42.3.3.4

Malfunction of slewing operation

(1)

It is impossible to stop slewing operation at slope.

(2)

Slewing drift after slewing inertia exerted on it is large.

YES

Parking brake spring failure in slewing motor, or friction plate failure for parking brake.

Failure of slewing relief valve.

Is slewing brake power within reference value?

YES

Is slewing brake power within reference value? NO Is swing relief pressure within reference value?

42-8

42. TROUBLESHOOTING (HYDRAULIC SYESTEM) 42.3.4 42.3.4.1

PUMP Engine speed is reduced due to pump load

Engine speed lowers by YES performing slewing, boom and arm operations simultaneously, or dozer, travel and boom operations simultaneously.

YES Malfunction of control unit of pump.

Is engine speed lowered and finally is it stopped? NO

42.3.4.2

(1)

Malfunction of pump

Oil leaks between engine YES and pump installing flange.

Is coupling worn severely? NO Is pump internal pressure within reference value? YES

YES

Replace seal for pump shaft. YES (2)

Noise from pump.

Is the hydraulic oil in hydraulic tank cloudy white? NO

Replace coupling and seal for pump shaft. NO Is return filter normal?

Change return filter.

Does hydraulic oil in tank NO satisfy NAS 9 class?

Flush hydraulic oil, or replace return filter.

YES

YES Shortage of hydraulic oil.

Replenish hydraulic oil.

NO Check for air intake through piping on the suction side.

YES Is much wear metal powder on return filter in hydraulic tank? NO

Replace parts inside of pump. Check coupling for severe wear (See article mentioned before).

42-9

42. TROUBLESHOOTING (HYDRAULIC SYESTEM)

[NOTES]

42-10

43. TROUBLESHOOTING (ELECTRICAL SYSTEM) TABLE OF CONTENTS 43.1 TROUBLE DIAGNOSIS: ELECTRICAL SYSTEM .......................................... 43-1 43.2 TROUBLESHOOTING .................................................................................... 43-2 43.2.1 GENERAL ................................................................................................ 43-2 43.2.2 ATTACHMENT OPERATION ................................................................... 43-6 43.2.3 TRAVEL OPERATION ............................................................................. 43-7 43.2.4 DECELERATION ..................................................................................... 43-8

43. TROUBLESHOOTING (ELECTRICAL SYSTEM)

Defect (1) Engine does not start.

General

(2) Horn does not sound. (3) 1

Working light does not light up.

(4) Hourmeter does not actuate.

Deceleration Travel operation Attachment operation

(5) Fuel gauge does not actuate. (6)

Water temperature meter does not actuate.

(1)

All controls does not function. (Excluding swing operations)

(1)

Travel 1 and 2 speed can not be changed.

(1)

Deceleration switching can not be carried out.

Abbreviations Decel: Deceleration SOL:

Solenoid

43-1

Travel holding circuit control unit

Timer

Safety relay

Charge indicator relay

Deceleration switch

Relay Engine stop solenoid relay

Lever lock switch/limit switch

Travel 1, 2 speed switch

Horn switch

Switch Working light switch

For engine stop solenoid

Lever lock solenoid

Solenoid Travel 1, 2 speed solenoid

Fuel level sensor

Horn

Sens ors Coolant temp sensor

Deceleration motor

Gauge cluster

Reference No.

Classification

Generator

Electrical equipment

Causes

Fuse, disconnect, short circuit, looseness Others

TROUBLE DIAGNOSIS: ELECTRICAL SYSTEM

Working light

43.1

43. TROUBLESHOOTING (ELECTRICAL SYSTEM)

43.2

TROUBLESHOOTING

43.2.1

GENERAL

43.2.1.1

Engine does not start

(1) Starter does not rotate.

Check voltage of battery.

Check battery fluid and specific gravity.

Charge or replace battery.

OK Check the starter motor on the inside.

The voltage of B terminal NO of starter motor (M-1) is 12 V.

Replace starter cable.

OK The voltage of B terminal of key switch is 12 V.

Replace fusible link 45A.

OK Voltage of C terminal of key switch is 12 V.

Replace key switch.

OK Check safety relay on the inside.

NO Voltage of black-white harness (C terminal) at connector (CN-7F) of safety relay (R-2) is 12 V.

Check the harness.

OK Check the safety relay from the outside.

NO Voltage of white-red harness (S terminal) at connector (CN-7F) of safety relay (R-2) is 12 V.

Check the starter motor on the inside.

OK Malfunction of safety relay

The voltage of S terminal NO of starter motor (M-1) is 12 V.

Breakage of harness between safety relay (R2) and starter motor

Replace safety relay.

Check generator.

Check the harness.

Replace the starter motor.

43-2

43. TROUBLESHOOTING (ELECTRICAL SYSTEM) (2) Starter turns but engine does not start.

(When key is ON position)

YES The voltage between green-red and black harness of connector (CN-303) of engine stop solenoid valve (SV-3) is 12 V with the start key in the ON position. NO Voltage between yellowgreen and red-white harness of connector (CN-9F) of engine stop relay (R-7) is 12 V for 1 second after keying on.

Voltage of white-black line of connector (CN22F) of timer unit (R-6) is 12 V.

Failure of engine stop solenoid valve (SV-3).

Replace the engine stop solenoid valve.

Breakage of harness between engine stop relays and engine stop solenoid valve (SV-3).

Check the harness.

NO Failure of timer unit (R6).

Replace timer unit.

YES

Breakage of harness between engine stop relay (R-7) and timer unit (R-6).

Check the harness.

NO Breakage of harness between timer unit (R-6) and fuse box.

Check the harness.

YES The voltage between white and black harness of connector (CN-303) of engine stop solenoid (SV-3) is 12 V.

Engine stop solenoid (SV-3) error.

Replace the engine stop solenoid valve.

Breakage of harness between engine stop solenoid valve (SV-3) and fuse box.

Check the harness.

NO YES Voltage of white harness of fuse box is 12 V. NO YES No. 5 fuse box is blown.

Check harness placed on the short-circuited sections.

Harness is shortcircuited to frame.

Check that harness in fuse box is free from breakage.

The voltage of the accumulator power switch is of 12 V.

YES

Harness is broken between key switch and fuse box.

Check the harness.

NO Check switch.

43-3

43. TROUBLESHOOTING (ELECTRICAL SYSTEM) 43.2.1.2

Horn does not sound

When horn switch is pressed, The voltage between pink-black and black harness is 12 V.

YES

Failure of horn.

Replace horn.

Breakage of harness between horn (E-3) and horn switch (SW-7).

Check the harness.

Failure of horn switch (SW-7).

Replace horn switch.

Breakage of harness between horn switch (SW-7) and fuse box.

Check the harness.

Harness is short-circuited to frame.

Check harness of short-circuited section.

NO Voltage of red-green harness of horn switch (SW-7) is 12 V.

YES

Voltage between red-green harness of fuse box is 12 V.

YES

NO No. 4 fuse box is blown.

YES

Check that harness in fuse box is free from breakage.

Check diode (D-1) for short circuiting.

43.2.1.3

Working light does not light up

When key is switched ON, Voltage between light green-red and black harness of working light (L-2) is 12 V.

YES Working light error.

Replace working light.

Breakage of harness between working light switch (SW-2) and working light (L-2).

Check the harness.

Failure of working light switch (SW-2).

Replace working light switch.

Breakage of harness between working light switch (SW-2) and fuse box.

Check the harness.

Harness is short-circuited to frame.

Check harness of short-circuited section.

NO Voltage between yellow and green harness of working light switch (SW-2) is 12 V.

YES

Voltage of yellow-green harness of fuse box is 12 V.

YES

NO No. 3 fuse box is blown.

YES

Check that line in fuse box is free from disconnection.

43-4

43. TROUBLESHOOTING (ELECTRICAL SYSTEM) 43.2.1.4

Hourmeter does not actuate

While engine is starting, YES Is voltage between the white and pink cables of the hourmeter (E-26) 12 V? NO

Defective hourmeter.

Is voltage between white and black harness of connector (CN-16F) of charge indicator relay (R-8) 12 V?

YES Check generator (E-2).

NO Voltage of yellow-green harness of fuse box is 12 V.

YES

Check charge indicator relay Breakage of harness between hourmeter (E-26) and charge indicator relay (R-8).

Breakage of harness between hourmeter (E26) and fuse box.

43.2.1.5

YES

Check the harness.

Check harness of the short-circuited sections.

NO No. 6 fuse box is blown.

Replace hourmeter.

Harness is shortcircuited to frame.

Check that harness in fuse box is free from breakage.

Fuel gauge does not actuate

When key is switched ON, The voltage between the white-green and black harness of connector (CN-27F) of the instrument panel (E-6) is 12 V.

YES

NO Voltage of white-green harness of fuse box is 12 V.

YES

YES When sensor moves, resistance between yellow and black harness of connector (CN-27F) of gauge cluster (E-6) changes (approx.10 ď &#x2014; at NO full load and approx. 90 ď &#x2014; at no load).

Breakage of harness between gauge cluster (E-6) and fuel sensor (SE-1).

Check the harness.

Breakage of harness between gauge cluster (E-6) and fuse box. Check harness placed on the short-circuited sections.

NO No. 6 fuse box is blown.

Check and replace the gauge cluster.

YES

Harness is shortcircuited to frame.

Check that harness in fuse box is free from breakage.

43-5

43. TROUBLESHOOTING (ELECTRICAL SYSTEM) 43.2.1.6

Water temperature meter does not actuate

When key is switched ON, The voltage between the white-green and black harness of connector (CN-27F) of the instrument panel (E-6) is 12 V.

YES

NO Voltage of white-green harness of fuse box is 12 V.

YES

YES Resistance between yellow and red harness of connector (CN-27F) of gauge cluster (E-6) changes depending on water temperature (approx. 80  at 67 °C NO (152 °F) and approx.  24 at 105 °C (221 °F)).

Check and replace the gauge cluster.

Breakage of harness between gauge cluster (E-6) and fuel sensor (SE-1).

Breakage of harness between gauge cluster (E-6) and fuse box. Check harness placed on the short-circuited sections.

NO No. 6 fuse box is blown.

43.2.2 43.2.2.1

Check the harness.

YES

Harness is shortcircuited to frame.

Check that harness in fuse box is free from breakage.

ATTACHMENT OPERATION All controls do not function (excluding swing operations)

When key is switched ON, When lever stand was lowered, The voltage between green-white and black harness of connector (CN-108F) of lock lever solenoid (SV-1) is 12 V.

YES

YES NO Voltage of pink-blue harness of plug (F-2) of the left lock lever switch (SW9) is 12 V.

Check lock lever solenoid. (See troubleshooting for the hydraulic system). Breakage of harness between lock lever switch (SW-9) and lock lever solenoid valve (SV-1).

Check the harness.

Failure lock lever switch (SW-9).

Breakage of harness between lock lever switch (SW-9) and lock lever solenoid valve (SW-8).

Check the harness.

Failure lock lever switch (SW-8).

Replace lock lever switch (SW-8)

Breakage of harness between fuse box and lock lever switch (SW-8).

Check the harness.

Harness is short-circuited to frame.

Check harness of the short-circuited sections.

NO YES Voltage of yellow-black harness of plug (F-1) of the right lock lever switch (SW-8) is 12 V.

NO Voltage of yellow harness of fuse box is 12 V.

YES

NO No.2 fuse of fuse box is blown.

YES

Check that harness in fuse box is free from breakage.

43-6

43. TROUBLESHOOTING (ELECTRICAL SYSTEM) 43.2.3 43.2.3.1

TRAVEL OPERATION Travel 1 and 2 speed change can not be carried out

(1) When key is switched ON, The voltage of yellow-black harness of connector (CN-109F) of travel speed solenoid valve (SV-2) is 12 V.

(also without setting the travel speed) NO

Breakage of harness between fuse box and travel speed switching solenoid valve (SV-2).

Check the harness.

Breakage of harness between fuse box and holding circuit unit (E-14).

Check the harness.

YES Voltage of white-green harness of connector (CN-1F) of holding circuit unit (E-14) is 12 V.

YES

No. 6 fuse box is blown. YES Harness is short-circuited to frame.

To after selector switch was switched ON.

Check harness of short-circuited section. Check that line in fuse box is free from disconnection.

(2) After selector switch was switched ON, The voltage of light green harness of connector (CN-109F) of travel speed solenoid valve (SV-2) is 0 V.

YES Check the harness.

NO Voltage of light green line of connector (CN-1F) of holding circuit unit (E-14) is 0V.

YES

Breakage of harness between fuse box and holding circuit unit (E-14).

Check the harness.

NO The voltage of white-black harness of connector (CN-1F) of holding circuit unit (E-14) when travel speed selector switch is pressed.

Check harness of travel 1 and 2speed switch, and between travel 1 and 2-speed switch and holding circuit unit.

YES Check holding circuit unit.

43-7

43. TROUBLESHOOTING (ELECTRICAL SYSTEM) 43.2.4 43.2.4.1

DECELERATION Deceleration operation cannot be carried out

When key is switched ON, The voltage of yellow-green harness of connector (CN-113F) of deceleration motor (M-4) is 12 V.

Breakage of harness between fuse box (E-1) and deceleration motor (M4).

Check cables.

No.3 fuse of fuse box is blown.

Check harness of short-circuited section.

YES

Check that harness in fuse box is free from disconnection. The voltage of yellow-black line of connector (CN-6F) of deceleration relay (R-3) is 12 V.

Breakage of harness between fuse box (E-1) and deceleration relay (R-3).

Check harness of short-circuited section.

YES Check that line in fuse box is free from disconnection. When deceleration operation is off, The voltage between blue-white and green-yellow harness of connector NO (CN-113F) of deceleration motor (M-4) is 0V.

Failure of deceleration motor (M-4).

Adjust deceleration motor.

Breakage of harness between deceleration motor (M-4) and deceleration relay (R-3).

Adjust harness.

Failure of deceleration relay (R-3).

Replace deceleration relay.

Failure of holding circuit unit.

Replace holding circuit unit.

Failure of horn switch (SW-11).

Check deceleration switch.

Breakage of harness between deceleration switch (SW-11) and holding circuit unit (E-14).

Check the harness.

When deceleration operation is on, The voltage between black-yellow and green-yellow harness of connector (CN-113F) of deceleration motor (M-4) is 0V. NO When deceleration operation is on,

YES

The voltage of blue-black harness of connector (CN-6F) of deceleration relay (R-3) is 0V. NO When deceleration switch (SW-11) is YES pressed, Voltage of black-white harness of connector (CN-1F) of holding circuit (E-14) is 0V. NO

43-8

44. TROUBLESHOOTING (ENGINE) TABLE OF CONTENTS 44.1 TROUBLE DIAGNOSIS: ENGINE ................................................................... 44-1 44.2 TROUBLESHOOTING .................................................................................... 44-4 44.2.1 STARTING TROUBLE ............................................................................. 44-4 44.2.2 ENGINE ROTATION TROUBLE .............................................................. 44-6 44.2.3 OUTPUT DROPS DOWN ........................................................................ 44-7 44.2.4 OTHER TROUBLE ................................................................................... 44-8 44.3 ELECTRICAL EQUIPMENT .......................................................................... 44-11 44.3.1 ELECTRICAL EQUIPMENT LIST .......................................................... 44-11

44. TROUBLESHOOTING (ENGINE)

TROUBLE DIAGNOSIS: ENGINE Serviceman Inspection

Visual check

(1) Starter does not rotate Trouble start

(2)

The starter motor rotates but does not start

(1) Idling not smooth Rotation trouble

(2) Medium speed hunting (3)

Performance 3 drop

(1)

High speed not smooth Not reach max. speed Engine output not enough Overheating

(2) Knocking at high temperature Large amount of black exhaust (1) gas White exhaust gas (2) Excessive oil consumption Other trouble 4

(3)

Engine excessive fuel consumption

(4)

Engine not stop when key turned OFF

When key is turned OFF, power (5) supply disconnected but engine not stop

44-1

Improper battery electrolyte level

Excessive amount of engine oil

Gas/fluid

Poor quality fuel or heavy oil used

Improper viscosity or level of engine oil, or leakage

Improper specific gravity of battery electrolyte

Poor quality fuel or leakage

Coolant level

Breather hose clogged or depressed

Fan belt slip

Fluid

Fuel filter clogged

Primary fuel filter clogged

Air cleaner clogged

Oil filter clogged

Trouble

Air or water entered fuel system

No fuel or leakage

Group no.

Classification

Filters

Gas leakage through valve gasket

Cause

Large amount of blow-by gas

44.1

44. TROUBLESHOOTING (ENGINE)

(2)

The starter motor rotates but does not start

(1) Idling not smooth Rotation trouble

(2) Medium speed hunting (3)

Performanc 3 e drop

(1)

High speed not smooth Not reach max. speed Engine output not enough Overheating

(2) Knocking at high temperature Large amount of black exhaust (1) gas White exhaust gas (2) Excessive oil consumption Other trouble

(3)

Engine excessive fuel consumption

(4)

Engine not stop when key turned OFF

When key is turned OFF, power (5) supply disconnected but engine not stop

44-2

Air cleaner and muffler

Valve spring fatigue

Suction/ exhaust system

Valve clearance

Injection pump

Check nozzle

Check injection timing

Fuel system

Feed pump function

Generator current limiter

Starter

Stop solenoid valve

Glow plugs pre-heating

Glow relay

Connector and wiring

Electrical system

Safety relay

Electrical system

Start key switch

Engine

(1) Starter does not rotate 1

Engine dealer

Mechanism

Fuse

Trouble Starting trouble

Serviceman

Group no.

Classification

Cause

44. TROUBLESHOOTING (ENGINE) Engine dealer

(1) Starter does not rotate Trouble start 1

(2)

The starter motor rotates but does not start

(1) Idling not smooth Rotation trouble

(2) Medium speed hunting (3)

High speed not smooth Not reach max. speed

Engine output not enough (1) Performance 3 Overheating drop (2) Knocking at high temperature Large amount of black exhaust (1) gas White exhaust gas (2) Excessive oil consumption Other trouble 4 (3) (4)

Engine excessive fuel consumption Engine not stop when key turned OFF

When key is turned OFF, (5) power supply disconnected but engine not stop

44-3

Oil cooler element damaged

Cooling

Thermostat inspection

Fuel mixed

Check relief valve

Trouble

Oil gets into combustion chamber through piston / valve guide

Group no.

Classification

Lubrication system

Mechanical

Compression pressure low Control rack movement not smooth Governor spring fatigue Crank shaft oil seal defective Piston liner worn Piston ring worn Valve spring fatigue Internal part seizure Check fuel feed Defective head gasket Flywheel gear damaged

Cause

44. TROUBLESHOOTING (ENGINE)

44.2

TROUBLESHOOTING

44.2.1

STARTING TROUBLE

44.2.1.1

Starter does not rotate

Check voltage of battery.

Check battery fluid and specific gravity.

The voltage of B terminal of starter motor (M-1) is 12 V.

Charge or replace battery.

OK Check the starter motor on the inside.

OK Voltage of B terminal of key switch is 12 V. OK Voltage of C terminal of key switch is 12 V. OK (Hereafter when the key is in start position). Voltage of black-white harness (C terminal) at Check safety relay on the connector (CN-7F) of inside. safety relay (R-2) is 12 V. OK Voltage of white-red harness (S terminal) at Check safety relay on the connector (CN-7F) of inside. safety relay (R-2) is 12 V.

Replace starter cable.

Replace fusible link 45A.

Replace key switch.

NO Check the harness.

NO Malfunction of safety relay

Replace safety relay.

NO OK

Check the starter motor on the inside.

Check generator. The voltage of S terminal of starter motor (M-1) is 12 V.

Breakage of harness between safety relay (R2) and starter motor

Check the harness.

Replace the starter motor.

44-4

44. TROUBLESHOOTING (ENGINE) 44.2.1.2

The starter motor rotates but does not start

Check starter power

Less

Check battery fluid and specific gravity.

Charge or replace battery.

OK Check compression pressure Valve clearance Valve spring fatigue Piston liner worn

Check engine itself

Piston ring worn Defective head gasket Flywheel gear damaged Check radiator and thermostat

Check air suction system

Air cleaner clogged Check indicator

OK Check fuel meter Check fuel feed system

Check electrical system

Check engine oil viscosity

Feed pump performance

Check water separator

Check injection pump

Check fuel filter

Check injection nozzle

Check fuel quality

Check injection timing

12 V detected for glow plug NO

YES

Improper ground connection

Check if engine oil viscosity suitable for ambient temperature

Defective glow plug

Defective harness between key switch and glow

Change engine oil

NOTE: Check with the engine start key being in ON position.

44-5

44. TROUBLESHOOTING (ENGINE) 44.2.2

ENGINE ROTATION TROUBLE Check injection pipe Check injection nozzle. Idling not smooth.

Cylinder compression pressure not even. Check injection pump. Thermostat Inspection.

(1)

Minimum Idle speed is too high.

(2)

Medium speed

Adjust engine speed.

Check control rack.

Medium speed hunting.

Check governor spring. YES

Check if there is air mixed in fuel. (3)

High speed

Release air.

OK Check air suction system.

Check if air cleaner clogged.

OK Check fuel meter. Check water separator.

Check fuel feed system.

Check fuel filter. Check fuel quality.

OK Check injection nozzle. Check injection pump. Check the injection timing. Not reach maximum speed.

Adjust engine speed.

NOTE: check the above items at a coolant temperature above 50 Â°C.

44-6

44. TROUBLESHOOTING (ENGINE) 44.2.3 44.2.3.1 (1)

OUTPUT DROPS DOWN Engine output not enough

Overheating

Engine coolant temperature lamp lighted.

Check shovel work condition.

NO Check engine coolant temperature switch.

Check electrical system.

Check the instrument panel. Check wiring and connector.

OK Check coolant level. Check fan belt slip.

Check the cooling system.

Check radiator clogging. Thermostat Inspection.

OK Check fuel quality. Check fuel system.

Check the injection timing. Check fuel injection valve.

OK Check engine oil filter.

(2)

Check air suction system.

Air filter clogging Check indicator.

Check engine oil filter.

Check air cleaner filter.

OK Check fuel feed system. OK

Check if there is air mixed in fuel.

Release air.

OK Check water separator.

Check feed pump performance.

Check fuel filter.

Check injection pump.

Check fuel quality.

Check injection nozzle. Check the injection timing.

Check engine oil.

Check if engine oil viscosity suitable for ambient temperature.

Change engine oil.

Large amount of blow-by gas.

Check compression pressure.

Gas leakage through gasket.

Valve spring fatigue.

Check engine mechanical.

Check if engine oil gets into combustion chamber through piston / valve guide.

NOTE: check in the condition of operating at high speed.

44-7

Check valve clearance. Control rack not smooth. Piston ring worn. Failure of head gasket.

44. TROUBLESHOOTING (ENGINE) 44.2.3.2

Knocking at high temperature

Check fuel system.

Check fuel quality.

Change fuel.

Check engine mechanical.

Check if engine oil gets into combustion chamber. OK Large amount of blow-by gas.

Check oil adhering condition at exhaust port.

Gas leakage through gasket.

Check compression pressure. Check the injection timing. Check injection nozzle.

NOTE: check at an engine coolant temperature above 50 Â°C.

44.2.4 44.2.4.1

OTHER TROUBLE Exhaust trouble

Large amount of black exhaust gas.

Check air cleaner.

Replace air element.

OK Check engine oil viscosity. Check if engine oil too much. OK Check injection nozzle. Check the injection timing. Check gas leakage through head gasket.

Check injection pump. Check valve clearance. Valve spring fatigue. Check piston ring defect.

Large amount of white exhaust gas.

Check if there is air mixed in fuel. OK Check if engine oil gets into combustion chamber through piston / valve guide. Large amount of blow-by gas. Gas leakage through gasket.

NOTE: check at an engine coolant temperature above 50 Â°C.

44-8

Check water separator.

Check compression pressure. Check the injection timing.

44. TROUBLESHOOTING (ENGINE)

NOTE: a breather mechanism of blow-by gas reduction system is applied to the engine as shown in the right drawing. Remove and plug the suction manifold to check blow-by gas. 1. 2. 3. 4 5. 6. 7. 8. 9. 10. 11.

2 1

Diaphragm cover Spring Centre plate Diaphragm Remove this side Bonnet Breather baffle Breather pipe Baffle plate Plug Suction manifold

8 10

7 11

Construction of breather mechanism

44-9

44. TROUBLESHOOTING (ENGINE) 44.2.4.2

Excessive oil consumption

Check engine oil leakage. (Check if engine oil too much)

Check ground under engine and oil pan.

Tighten packing and seal or replace if necessary.

OK Check if breather hose depressed or clogged. OK

Replace breather hose.

Check fuel quality.

Instruct to feed proper fuel.

OK Instruct to feed proper engine oil.

Check engine oil viscosity. OK

Crank shaft oil seal defective.

Check if engine oil gets into combustion chamber through piston / valve guide.

Piston liner worn. Piston ring worn.

NOTE: check in the condition of no engine oil leakage. 44.2.4.3

Excessive fuel consumption

Check for fuel leaks.

Check fuel quality.

Instruct to feed proper fuel.

OK Large amount of blow-by gas.

Check nozzle function.

Check gas leakage through gasket.

OK Check the injection timing.

Check compression pressure.

NOTE: check in the condition the proper fuel is used. 44.2.4.4

Engine not stop when key turned OFF

Engine stop solenoid valve (SV-3) normally energised.

Engine stop solenoid valve incorrectly installed.

Correct engine stop solenoid valve installation.

YES Check resistance of starter key terminal (between terminals B and accumulator).

Resistance 0 â&#x201E;Ś detected between terminals B and accumulator.

YES Replace key switch.

NOTE: check with the engine start key being in OFF position.

44-10

Check the harness.

44. TROUBLESHOOTING (ENGINE)

44.3

ELECTRICAL EQUIPMENT

44.3.1

ELECTRICAL EQUIPMENT LIST Group

Diode

Electric fittings

Lights

Engine

Relay

Code

Part Name

D-1

DIODE

D-2

DIODE

D-3

DIODE

D-4

DIODE

D-12

DIODE

D-13

DIODE

D-14

DIODE

D-18

DIODE

E-1

FUSE BOX

E-2

GENERATOR (ALTERNATOR)

E-3

HORN

E-4

FUSIBLE LINK (45A)

E-6

GAUGE CLUSTER

E-7

POWER SOCKET

E-8

AIR HEATER

E-10

RADIO (OPT)

E-11

OVERLOAD BUZZER

E-12

HEATER (OPT)

E-13

BATTERY

E-14

SEQUENCE BOX

E-15

FUSE BOX (OPT) (FOR COOLER)

E-16

RADIATOR

E-17

ENGINE CONDENSER

E-18

COMPRESSOR

E-23

ANTENNA

E-26

HOUR COUNTER

L-1

ROOM LAMP

L-2

BOOM WORKING LIGHT (55 W)

L-5

CAB / CANOPY WORKING LIGHT

M-1

STARTER MOTOR

M-2

WIPER MOTOR (CAB)

M-3

WASHER MOTOR (CAB)

M-4

DECELERATION MOTOR

M-6

FUEL PUMP

R-1

BATTERY RELAY

R-2

SAFETY RELAY

R-3

DECELERATION RELAY

R-6

TIMER UNIT

R-7

ENGINE STOP RELAY

R-8

CHARGE INDICATOR RELAY

R-9

CAB / CANOPY WORKING LIGHT

R-14

SLEW / SWING SELECT RELAY

44-11

44. TROUBLESHOOTING (ENGINE) Group Sensors

Solenoid

Switch

Code

Part Name

SE-1

FUEL SENSOR

SE-2

ENGINE THERMO SENSOR

SV-1

LEVER LOCK SOLENOID

SV-2

2nd SPEED SELECTION SOLENOID

SV-3

ENGINE STOP SOLENOID

SV-5

POWER SHIFTING SOLENOID (Radiator specifications)

PSV-D

NIBBLER OPEN PROPORTIONAL SOLENOID (RIGHT SIDE)

PSV-E

NIBBLER CLOSE PROPORTIONAL SOLENOID (LEFT SIDE)

SW-1

KEY SWITCH

SW-2

WORKING LIGHTS SWITCH

SW-3

2nd SPEED SELECTOR SWITCH

SW-4

WIPER WASHER SWITCH

SW-5

ENGINE COOLANT TEMPERATURE SWITCH

SW-6

ENGINE OIL PRESSURE SWITCH

SW-7

HORN SWITCH

SW-9

LEVER LOCK SWITCH

SW-10

HEATER SWITCH (OPT)

SW-11

DECELERATION SWITCH

SW-15

HIGH AND LOW PRESSURE SWITCH

SW-16

CONDENSER SPEED SHIFT SWITCH

SW-35

HYDRAULIC BREAKER ACTIVATION SLIDER

SW-39

OVERLOAD PRESSURE SWITCH

SW-40

OVERLOAD SWITCH

44-12

51. ENGINE TABLE OF CONTENTS

51.1 GENERAL ...................................................................................................... 51-1 51.2 INSPECTION AND ADJUSTMENT.............................................................. 51-19 51.3 TROUBLESHOOTING ................................................................................. 51-54 51.4 DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES........... 51-62 51.5 LUBRICATION SYSTEM ........................................................................... 51-116 51.6 COOLING SYSTEM ................................................................................... 51-121 51.7 FUEL INJECTION PUMP/GOVERNOR..................................................... 51-123 51.8 TURBOCHAGER: DISASSEMBLY, INSPECTION AND REASSEMBLY .. 51-129 51.9 STARTER MOTOR .................................................................................... 51-153 51.10 ALTERNATOR ........................................................................................... 51-179 51.11 ELECTRIC WIRING ................................................................................... 51-183 51.12 MAINTENANCE STANDARD .................................................................... 51-193 51.13 TIGHTENING TORQUE FOR BOLTS AND NUTS .................................... 51-204

51. ENGINE

51.1

GENERAL

51.1.1

ENGINE NOMENCLATURE

Destination Nominal engine speed or output T: with turbocharger None: Natural aspirated engine The subdivision code of the model name Cylinder bore (in mm) Model series Number of cylinders

Engine specification class Classification

Load

Engine speed

CL VL

Constant load Variable load

Constant speed Variable speed

*The engine specification class (CL or VL) is described in the specifications table. 51.1.2

SPECIFICATIONS

1. The information described in the engine specifications tables (the next page and after) is for standard engine. To obtain the information about the engine installed in each machine, refer to the manual provided by the Manufacturer. 2. Engine rating conditions are as follows (SAE J 1349, ISO 3046/1) • Atmospheric condition: Ambient temperature 25°C (77 °F), atmospheric pressure 100 kPa (750 mm Hg), relative humidity 30% • Fuel temperature: 25 °C (77 °F) (Fuel injection pump inlet) • With cooling fan, air cleaner, exhaust silencer (Yanmar standard part) • After running-in hours. Output allowable deviation: ± 3%

51-1

Available engine speed (rpm) 1500/1800 2000-3000

51. ENGINE (1) 3TNV82A Engine name

Unit

3TNV82A

Engine specification class

Type

Vertical, in-line, 4-cycle, water-cooled diesel engine

Combustion chamber

Direct injection

Number of cylinders

Cylinder bore stroke

mm x mm

82 x 84

1.331

Displacement Rotation Continuous rating speed Output Rated output

rpm

1500

1800

9.9

12.0

Rotation speed

rpm

1500

1800

2000 2200 2400 2500 2600 2800 3000

Output

11.0

13.2

14.6 16.0 17.5 18.2 19.0 20.4 21.9

rpm

1600

1895

2180 2375 2570 2675 2780 2995 3180

Maximum no-load speed (Âą25) Order of ignition

1-3-2-1(No.1 cylinder on flywheel side)

Power take off

Flywheel

Rotating direction

Counterclockwise (viewed from flywheel)

Cooling system

Radiator

Lubrication system

Forced lubrication with trochoid pump

Starting system

Electrical system

Appropriate fuel

ASTM fuel No. 2-D type TT

Applicable lubricant

Lubricant capacity Total (oil pan)* Effective

3.6

5.5

1.2

2.2

Coolant volume (engine only) Engine Dimensions ** (with crankshaft Vpulley diameter and housing)

SUPER GOLD 15W-40

SUPER GOLD 10W-30

1.8 (0.50)

Overall length

Overall width

489

Overall height

565

Engine mass (dry) ** (with flywheel housing)

Fan (standard)

Fan V-belt diameter (standard)

553

138

528

128 335 mm O/D, 6 blades pusher type

120 x 90

110 x 110

* Engine oil capacity may differ from the above depending on an engine installed on a machine unit.

** Engine mass and dimensions without radiator.

51-2

51. ENGINE (2) 3TNV84 Engine name

Unit

3TNV84

Engine specification class

Type

Vertical, in-line, 4-cycle, water-cooled diesel engine

Combustion chamber

Direct injection

Number of cylinders

Cylinder bore stroke

mm x mm

84 x 90

1.496

Displacement Rotation Continuous rating speed Output Rated output

rpm

1500

1800

11.3

13.5

Rotation speed

rpm

1500

1800

2000 2200 2400 2500 2600 2800 3000

Output

12.4

14.8

16.4 18,1 19,7 20,5 21,3 23,0 24,6

rpm

1600

1895

2180 2400 2590 2690 2810 2995 3210

Maximum no-load speed (Âą25) Order of ignition

Power take off

Flywheel

Rotating direction

Counterclockwise (viewed from flywheel)

Cooling system

Radiator

Lubrication system

Forced lubrication with trochoid pump

Starting system

Electrical system

Appropriate fuel

ASTM fuel No. 2-D type TT

Applicable lubricant

Lubricant capacity Total (oil pan)* Effective

6.7

1.9

1.8

Coolant volume (engine only) Engine Dimensions ** (with flywheel housing)

1-3-2-1(No.1 cylinder on flywheel side)

SUPER GOLD 15W-40

SUPER GOLD 10W-30

Overall length

Overall width

486

Overall height

622

Engine mass (dry) ** (with flywheel housing)

Fan (standard)

Crankshaft V pulley diameter and fan V-belt diameter (standard)

589

161

564

155 335 mm O/D. 6 blades pusher type

120 x 90

110 x 110

* Engine oil capacity may differ from the above depending on an engine installed on a machine unit.

** Engine mass and dimensions without radiator.

51-3

51. ENGINE (3) 3TNV84T Engine name

Unit

3TNV84T

Engine specification class

Type

Vertical, in-line, 4-cycle, water-cooled diesel engine

Combustion chamber

Direct injection

Number of cylinders

Cylinder bore stroke

mm x mm

84 x 90

1.496

Displacement Rotation Continuous rating speed Output Rated output

rpm

1500

1800

14.0

16.5

Rotation speed

rpm

1500

1800

2000 2200 2400 2500 2600 2800 3000

Output

15.8

18.8

25.0

rpm

1600

1895

2590 2700 2810 2995 3210

Maximum no-load speed (Âą25) Order of ignition

25.9

26.8

1-3-2-1(No.1 cylinder on flywheel side)

Power take off

Flywheel

Rotating direction

Counterclockwise (viewed from flywheel)

Cooling system

Radiator

Lubrication system

Forced lubrication with trochoid pump

Starting system

Electrical system

Appropriate fuel

ASTM fuel No. 2-D type TT

Applicable lubricant

Lubricant capacity Total (oil pan)* Effective

6.7

1.9

2.0

Coolant volume (engine only) Engine Dimensions ** (with flywheel housing)

SUPER GOLD 15W-40

SUPER GOLD 10W-30

Overall length

Overall width

486

Overall height

622

Engine mass (dry) ** (with flywheel housing)

Fan (standard)

Crankshaft V pulley diameter and fan V-belt diameter (standard)

29.1

589

161

564

155 350 mm O/D. 6 blades pusher type

120 x 90

110 x 110

* Engine oil capacity may differ from the above depending on an engine installed on a machine unit.

** Engine mass and dimensions without radiator.

51-4

30.9

51. ENGINE (4) 3TNV88 Engine name

Unit

3TNV82A

Engine specification class

Type

Vertical, in-line, 4-cycle, water-cooled diesel engine

Combustion chamber

Direct injection

Number of cylinders

Cylinder bore stroke

mm x mm

88 x 90

1.642

Displacement Rotation Continuous rating speed Output Rated output

Rotation speed Output

Maximum no-load speed (Âą25)

rpm

1500

1800

12.3

14.8

rpm

1500

1800

2000 2200 2400 2500 2600 2800 3000

13.5

16.3

18.0

rpm

1600

1895

2180 2400 2590 2700 2810 2995 3210

19.9

21.6

22.6

23.5

Order of ignition

1-3-2-1(No.1 cylinder on flywheel side)

Power take off

Flywheel

Rotating direction

Counterclockwise (viewed from flywheel)

Cooling system

Radiator

Lubrication system

Forced lubrication with trochoid pump

Starting system

Electrical system

Appropriate fuel

25.2

27.1

ASTM fuel No. 2-D type TT SUPER GOLD 15W-40

Applicable lubricant

Lubricant capacity Total (oil pan)* Effective

4.7 (1.20)

7.2 (1.90)

1.8 (0.50)

3.5 (0.90)

Coolant volume (engine only)

SUPER GOLD 10W-30

2.0

Overall length

Overall width

486

Overall height

622

155

Fan (standard)

350 mm O/D. 6 blades pusher type

Crankshaft V pulley diameter and fan V-belt diameter (standard)

Engine Dimensions ** (with flywheel housing)

Engine mass (dry) ** (with flywheel housing)

589

120 x 90

* Engine oil capacity may differ from the above depend-

ing on an engine installed on a machine unit. ** Engine mass and dimensions without radiator.

51-5

564

120 x 90

51. ENGINE (5) 4TNV84 Engine name

Unit

4TNV84

Engine specification class

Type

Vertical, in-line, 4-cycle, water-cooled diesel engine

Combustion chamber

Direct injection

Number of x cylinders

mm x mm

84 x 90

1.995

Cylinder bore stroke Displacement Rotation Continuous rating speed Output Rated output

rpm

1500

1800

14.9

17.7

Rotation speed

rpm

1500

1800

2000 2200 2400 2500 2600 2800 3000

Output

16.4

19.5

21.9

rpm

1600

1895

2180 2400 2590 2700 2810 2995 3210

Maximum no-load speed (Âą25) Order of ignition

24.1

26.3

27.4

28.5

1-3-4-2-1(No.1 cylinder on flywheel side)

Power take off

Flywheel

Rotating direction

Counterclockwise (viewed from flywheel)

Cooling system

Radiator

Lubrication system

Forced lubrication with trochoid pump

Starting system

Electrical system

Appropriate fuel

ASTM fuel No. 2-D type TT

Applicable lubricant

Lubricant capacity Total (oil pan)* Effective

7.4

2.3

2.7

Coolant volume (engine only) Engine Dimensions ** (with flywheel housing)

SUPER GOLD 15W-40

SUPER GOLD 10W-30

Overall length

Overall width

498.5

Overall height

617

Engine mass (dry) ** (with flywheel housing)

Fan (standard)

Crankshaft V pulley diameter and fan V-belt diameter (standard)

30.7

683

183

658

170 370 mm O/D. 6 blades pusher type

120 x 90

110 x 110

* Engine oil capacity may differ from the above depending on an engine installed on a machine unit.

** Engine mass and dimensions without radiator.

51-6

32.9

51. ENGINE (6) 4TNV84T Engine name

Unit

4TNV84T

Engine specification class

Type

Vertical, in-line, 4-cycle, water-cooled diesel engine

Combustion chamber

Direct injection

Number of cylinders

Cylinder bore stroke

mm x mm

84 x 90

1.995

Displacement Rotation Continuous rating speed Output Rated output

Rotation speed Output

Maximum no-load speed (Âą25)

rpm

1500

1800

19.1

24.3

rpm

1500

1800

2000

2200

2400

2600

21.3

26.9

27.9

30.5

33.5

35.7

38.6

41.2

1600

1895

2180

2400

2590

2810

2995

3210

1-3-4-2-1(No.1 cylinder on flywheel side)

Power take off

Flywheel

Rotating direction

Counterclockwise (viewed from flywheel)

Cooling system

Radiator

Lubrication system

Forced lubrication with trochoid pump

Starting system

Electrical system

Appropriate fuel

ASTM fuel No. 2-D type TT SUPER GOLD 15W-40

Applicable lubricant

Lubricant capacity Total (oil pan)* Effective

7.4

3.4

2.7

Engine Dimensions ** (with flywheel housing)

SUPER GOLD 10W-30

Overall length

Overall width

498.5

Overall height

713

Engine mass (dry) ** (with flywheel housing)

3000

rpm

Order of ignition

Coolant volume (engine only)

2800

683

Fan (standard)

Crankshaft V pulley diameter and fan V-belt diameter (standard)

183

649

170 370 mm O/D. 6 blades pusher type

120 x 90

* Engine oil capacity may differ from the above depend-

ing on an engine installed on a machine unit. ** Engine mass and dimensions without radiator.

51-7

110 x 110

51. ENGINE (7) 4TNV88 Engine name

Unit

4TNV88

Engine specification class

Type

Vertical, in-line, 4-cycle, water-cooled diesel engine

Combustion chamber

Direct injection

Number of cylinders

Cylinder bore stroke

mm x mm

88 x 90

2.190

Displacement Rotation Continuous rating speed Output Rated output

rpm

1500

1800

16.4

19.6

Rotation speed

rpm

1500

1800

2000 2200 2400 2500 2600 2800 3000

Output

18.0

21.6

24.1

rpm

1600

1895

2180 2400 2590 2700 2810 2995 3210

Maximum no-load speed (Âą25) Order of ignition

26.5

28.8

30.1

31.3

33.7

35.4

1-3-4-2-1(No.1 cylinder on flywheel side)

Power take off

Flywheel

Rotating direction

Counterclockwise (viewed from flywheel)

Cooling system

Radiator

Lubrication system

Forced lubrication with trochoid pump

Starting system

Electrical system

Appropriate fuel

ASTM fuel No. 2-D type TT

Applicable lubricant

Lubricant capacity Total (oil pan)* Effective

5.8

8.6

2.3

4.2

Coolant volume (engine only) Engine Dimensions ** (with flywheel housing)

SUPER GOLD 15W-40

SUPER GOLD 10W-30

2.7

Overall length

Overall width

498.5

Overall height

618

Engine mass (dry) ** (with flywheel housing)

Fan (standard)

Crankshaft V pulley diameter and fan V-belt diameter (standard)

683

183

658

170 370 mm /D. 6 blades pusher type

120 x 90

110 x 110

* Engine oil capacity may differ from the above depending on an engine installed on a machine unit.

** Engine mass and dimensions without radiator.

51-8

51. ENGINE (8) 4TNV94L Engine name

Unit

4TNV94L

Engine specification class

Type

Vertical, in-line, 4-cycle, water-cooled diesel engine

Combustion chamber

Direct injection

Number of cylinders

Cylinder bore stroke

mm x mm

94 x 110

3.053

Displacement Rotation Continuous rating speed Output Rated output

rpm

1500

1800

26.1

31.3

Rotation speed

rpm

1500

1800

2000

2200

2400

2500

Output

29.1

34.6

35.3

38.2

41.6

43.0

rpm

1600

1895

2180

2400

2590

2700

Maximum no-load speed (Âą25) Order of ignition

1-3-4-2-1(No.1 cylinder on flywheel side)

Power take off

Flywheel

Rotating direction

Counterclockwise (viewed from flywheel)

Cooling system

Radiator

Lubrication system

Forced lubrication with trochoid pump

Starting system

Electrical system

Appropriate fuel

ASTM fuel No. 2-D type TT

Applicable lubricant

Lubricant capacity Total (oil pan)* Effective

10.2

4.5

4.2

Overall length

719

Overall width

498

Overall height

717

Coolant volume (engine only) Engine Dimensions ** (with flywheel housing)

Engine mass (dry) ** (with flywheel housing)

SUPER GOLD 10W-30

SUPER GOLD 15W-40

245

235

Fan (standard)

410 mm (16.41) O/D. 6 blades pusher type

Crankshaft V pulley diameter and fan V-belt diameter (standard)

130 x 130

* Engine oil capacity may differ from the above depending on an engine installed on a machine unit.

** Engine mass and dimensions without radiator.

51-9

51. ENGINE (9) 4TNV98 Engine name

Unit

4TNV98

Engine specification class

Type

Vertical, in-line, 4-cycle, water-cooled diesel engine

Combustion chamber

Direct injection

Number of cylinders

Cylinder bore stroke

mm x mm

98 x 110

3.318

Displacement Rotation Continuous rating speed Output Rated output

rpm

1500

1800

30.9

36.8

Rotation speed

rpm

1500

1800

2000

2200

2400

2500

Output

34.6

41.2

41.9

45.6

49.3

51.1

rpm

1600

1895

2180

2400

2590

2700

Maximum no-load speed (Âą25) Order of ignition

Power take off

Flywheel

Rotating direction

Counterclockwise (viewed from flywheel)

Cooling system

Radiator

Lubrication system

Forced lubrication with trochoid pump

Starting system

Electrical system

Appropriate fuel

ASTM fuel No. 2-D type TT

Applicable lubricant

Lubricant capacity Total (oil pan)* Effective

10.2

4.5

4.2

Overall length

719

Overall width

498

Overall height

717

Coolant volume (engine only) Engine Dimensions ** (with flywheel housing)

Engine mass (dry) ** (with flywheel housing)

1-3-4-2-1(No.1 cylinder on flywheel side)

SUPER GOLD 10W-30

SUPER GOLD 15W-40

248

235

Fan (standard)

410 mm O/D. 6 blades pusher type

Crankshaft V pulley diameter and fan V-belt diameter (standard)

130 x 130

* Engine oil capacity may differ from the above depending on an engine installed on a machine unit.

** Engine mass and dimensions without radiator.

51-10

51. ENGINE (10) 4TNV98T Engine name

Unit

4TNV98T

Engine specification class

Type

Vertical, in-line, 4-cycle, water-cooled diesel engine

Combustion chamber

Direct injection

Number of cylinders

Cylinder bore stroke

mm x mm

98 x 110

3.318

Displacement Rotation Continuous rating speed Output Rated output

rpm

1500

1800

37.9

45.6

Rotation speed

rpm

1500

1800

2000

2200

2400

2500

2600

Output

41.9

50.4

50.7

55.5

60.3

62.5

64.0

rpm

1600

1895

2180

2400

2590

2700

2810

Maximum no-load speed (Âą25) Order of ignition

Power take off

Flywheel

Rotating direction

Counterclockwise (viewed from flywheel)

Cooling system

Radiator

Lubrication system

Forced lubrication with trochoid pump

Starting system

Electrical system

Appropriate fuel

ASTM fuel No. 2-D type TT

Applicable lubricant

Lubricant capacity Total (oil pan)* Effective

10.2

4.5

4.2

Overall length

715

Overall width

575

Overall height

779

Coolant volume (engine only) Engine Dimensions ** (with flywheel housing)

Engine mass (dry) ** (with flywheel housing)

1-3-4-2-1(No.1 cylinder on flywheel side)

SUPER GOLD 10W-30

SUPER GOLD 15W-40

258

245

Fan (standard)

430 mm O/D. 8 blades suction type

Crankshaft V pulley diameter and fan V-belt diameter (standard)

130 x 130

* Engine oil capacity may differ from the above depending on an engine installed on a machine unit.

** Engine mass and dimensions without radiator.

51-11

51. ENGINE (11) 4TNV106 Engine name

Unit

4TNV106

Engine specification class

Type

Vertical, in-line, 4-cycle, water-cooled diesel engine

Combustion chamber

Direct injection

Number of cylinders

Cylinder bore stroke

mm x mm

106 x 125

4.412

Displacement Rotation Continuous rating speed Output Rated output

rpm

1500

1800

41.2

49.3

Rotation speed

rpm

1500

1800

2000

2200

2400

2500

Output

45.6

54.4

56.6

61.4

65.5

67.7

rpm

1600

1895

2180

2400

2590

2700

Maximum no-load speed (Âą25) Order of ignition

Power take off

Flywheel

Rotating direction

Counterclockwise (viewed from flywheel)

Cooling system

Radiator

Lubrication system

Forced lubrication with trochoid pump

Starting system

Electrical system

Appropriate fuel

ASTM fuel No. 2-D type TT

Applicable lubricant

Lubricant capacity Total (oil pan)* Effective

Coolant volume (engine only)

1-3-4-2-1(No.1 cylinder on flywheel side)

SUPER GOLD 10W-30

SUPER GOLD 15W-40 14.0

9.0

7.5 6.0

Overall length

808

776

Overall width

629

Overall height

803

345

330

Fan (standard)

500 mm O/D. 7 blades pusher type

500 mm O/D. 7 blades suction type

Crankshaft V pulley diameter and fan V-belt diameter (standard)

Engine Dimensions ** (with flywheel housing)

Engine mass (dry) **

150 x 150

* Engine oil capacity may differ from the above depending on an engine installed on a machine unit.

** Engine mass and dimensions without radiator.

51-12

51. ENGINE (12) 4TNV106T Engine name

Unit

4TNV106T

Engine specification class

Type

Vertical, in-line, 4-cycle, water-cooled diesel engine

Combustion chamber

Direct injection

Number of cylinders

Cylinder bore stroke

mm x mm

106 x 125

4.412

Displacement Rotation Continuous rating speed Output Rated output

rpm

1500

1800

51.5

61.8

Rotation speed

rpm

1500

1800

2000

2200

Output

56.8

68.0

69.9

72.0

rpm

1600

1895

2180

2400

Maximum no-load speed (Âą25) Order of ignition

1-3-4-2-1(No.1 cylinder on flywheel side)

Power take off

Flywheel

Rotating direction

Counterclockwise (viewed from flywheel)

Cooling system

Radiator

Lubrication system

Forced lubrication with trochoid pump

Starting system

Electrical system

Appropriate fuel

ASTM fuel No. 2-D type TT

Applicable lubricant

Lubricant capacity Total (oil pan)* Effective

Coolant volume (engine only)

SUPER GOLD 10W-30

SUPER GOLD 15W-40 14.0

9.0

7.5

6.0

Overall length

808

Overall width

629

628.6

Overall height

866

355

340

Fan (standard)

500 mm O/D. 7 blades pusher type

500 mm O/D. 7 blades suction type

Crankshaft V pulley diameter and fan V-belt diameter (standard)

Engine Dimensions ** (with flywheel housing)

Engine mass (dry) **

776

150 x 150

* Engine oil capacity may differ from the above depending on an engine installed on a machine unit.

** Engine mass and dimensions without radiator.

51-13

51. ENGINE 51.1.3

FUEL, LUBRICATING OIL AND COOLANT

51.1.3.1 Fuel

IMPORTANT: Only use recommended fuel to obtain the best engine performance and prevent damage of parts, as well as air pollution.

1. Fuel selection Use the following diesel fuels for best engine performance: ASTM fuel No. 2-D type TT 2. Handling fuel • Water and dust in fuel oil can cause operation failures. Use containers which are clean inside to store fuel. Store the containers away from rain water and dust. • Before supplying fuel, let the fuel container rest for several hours so that water and dust in the fuel are deposited on the bottom. Only pump clean fuel up to level (A) to leave dirt on the bottom. • Pump up only the fuel in the upper half (A) to leave dregs near the bottom. 3. Fuel tank • The fuel tank is equipped with a filler port (1), a fuel return connection (3) and an outlet (to engine) (4). Be sure to attach drain cock (5), precipitation trap and primary strainer (2) to the fuel tank.

51-14

51. ENGINE 51.1.3.2 Lubricating oil

IMPORTANT: Use of other than the specified engine oil may cause inner parts seizure or early wear, leading to shorten the engine service life.

1. Selection of engine lube oil Use the following engine oil • API classification..... 4/56 or CF (Standards of the American Petroleum Institute) • SAE viscosity..........10W-30 or 15W-40 (Standard of the Society of Automotive Engineering) Engine oil with 10W30 or 15W40 can be used throughout the year. (Refer to the right figure). 2. Handling of engine oil • Carefully store and handle the oil so as to prevent dust or dirt entrance. When supplying the oil, pay attention and clean around the filler port. • Do not mix different types of oil as it may adversely affect the lubricating performance.

CAUTION When touching engine oil by hand, the skin of the hand may become rough. Be careful not to touch oil with your hands without protective gloves. If touch, wash your hands with soap and water thoroughly.

51-15

Selection of viscosity (SAE Service grade)

Atmospheric temperature (°C) 15W-40/10W-30 can be used almost throughout the year.

51. ENGINE 51.1.3.3 Coolant Use clean soft water and be sure to add the Long Life Coolant Antifreeze (LLC) in order to prevent rust built up and freezing. If there is any doubt over the water quality, distilled water or pre-mixed coolant should be used. IMPORTANT: make sure to add Long Life Coolant Antifreeze (LLC) to soft water. In cold season, the LLC is especially important. Without LLC, cooling performance will decrease due to scale and rust in the coolant line. Without LLC, coolant will freeze and expand to break the coolant line. Be sure to use the mixing ratios specified by the LLC manufacturer for your temperature range. Do not mix different types (brand) of LLC, chemical reactions may make the LLC useless and engine trouble could result. Change coolant once a year.

CAUTION When handling Long Life Coolant Antifreeze, wear protective rubber gloves not to touch it. If LLC gets eyes or skin, wash with clean water at once.

51-16

51. ENGINE 51.1.4 ENGINE EXTERNAL VIEWS 1. Filler port (engine oil) 2. Turbocharger 3. Air intake port (from air cleaner, optional) 4. Lifting eye 5. Coolant pump 6. Fan 7. Crankshaft V-pulley 8. V-belt 9. Filler port (engine oil) 10. Drain plug (engine oil) 11. Engine oil cooler (4TNV98T, 4TNV106, 4TNV106T) 12. Engine oil filter 13. Dipstick (engine oil) 14. Fuel injection pump 15. Governor lever 16. Fuel filter 17. Fuel cock 18. Fuel filter mounting 19. Lifting eye 20. Engine name plate 21. Rocker arm cover 22. Flywheel 23. Starter motor 24. Exhaust manifold 25. Generator

NOTE: this illustration shows the 4TNV98T engine (with turbocharger). The drain plug (engine oil) location depends on the engine installed on the machine unit to be on the fuel injection pump side (above illustration) or starter motor side.

51-17

51. ENGINE 51.1.5

STRUCTURAL DESCRIPTION

1. Emission reduction New fuel injection pressure • Mono plunger • Higher injection pressure • Injection timing, speed timer, load timer, cold start timer control 2. Noise reduction Higher stiffness cylinder block Higher stiffness gear-case 3. Emission reduction Injection nozzle • Low suck volume • Multi injection holes 4. Emission reduction Cylinder head • Optimal nozzle angle • Optimal swirl ratio • Optional valve timing 5. Emission reduction Piston • New combustion chamber - Noise reduction New lube oil pan • Change rotor shape for low pulsation • Driven by crankshaft directly 6. Emission reduction Cylinder head • 4 valve / cylinder (intake-2, exhaust-2) • Optimal installation of the injection nozzle vertical installation and location of the centre of cylinder • Optimal valve timing 7. Emission reduction New fuel injection nozzle • Low suck volume • Multi injection holes 8. Emission reduction New fuel injection pump • Mono plunger • Higher injection pressure • Mechanical control of injection timing, speed timer, load timer, cold start timer 9. Emission reduction Piston • New combustion chamber - Noise reduction (only applied for 4TNV84T) New lube oil pan • Change rotor shape for low pulsation • Driven by crankshaft directly

51-18

2-valve cylinder head

4-valve cylinder head

4TNV84T, 4TNV94L, 4TNV98(T)

51. ENGINE

51.2

INSPECTION AND ADJUSTMENT

51.2.1

PERIODIC MAINTENANCE SCHEDULE

The engine periodic inspection timing is hard to determine as it varies with the application, load status, qualities of the fuel and lubricating oils used and handling status. General rules are described here. : User-maintenance : Parts replacement : Shop-inspection Maintenance period Inspection Every Every Every every Classification Piece Daily Every 50 2000 500 250 1000 hours or hours hours or hours or hours or two years 3 months 6 months one year Whole Visual check around the machine  Fuel tank level check and fuel supply  Fuel tank drain  Water separator (Option) draining  Fuel system Fuel system bleeding  Water separator cleaning  Fuel filter element replacement  Lube oil level check and replenishment  Lubricating oil Lube oil replacement   system 2nd time and 1st time Lube oil filter replacement thereafter Coolant level check and replenishment  Radiator fin cleaning    V-belt tension check 2nd time and 1st time Coolant pump thereafter Coolant change Coolant/water path flushing and maintenance Fuel pipe and coolant pipe inspection Rubber hose and maintenance Injection Inspection and adjustment of governor governor lever and accelerator Air cleaner cleaning and element replacement Air intake system Diaphragm assy inspection Turbocharger blower cleaning* Warning lamp and instruments function check Electrical system Battery electrolyte level check and battery recharging Intake/exhaust valve head clearance Cylinder head adjustment Intake/exhaust valve seat lapping Fuel injection nozzle pressure inspection Fuel injection Fuel injection timing adjustment pump and Fuel injection pump inspection and nozzle adjustment

  





 

  (2 years)

*  

*EPA allows servicing the emission related parts every 1500 or 3000 hours

51-19

  * *

51. ENGINE 51.2.2

PERIODIC INSPECTION AND MAINTENANCE PROCEDURE

51.2.2.1 Check before daily operation Be sure to check the following points before starting an engine every day. No. (1) (2) (3) (4) (5) (6) (7)

Inspection item Visual check around the machine Fuel tank level check and fuel supply Lube oil level check and replenishment Coolant level check and replenishment Fuel pipe and coolant pipe inspection and maintenance Inspection and adjustment of governor lever and accelerator Warning lamp and instruments function check

1. Visual check around the machine If any problem is found, do not use before the engine repairs have been completed. • Oil leak from the lubrication system • Fuel leak from the fuel system • Coolant leak from the water cooling system • Damaged parts • Loosened or lost screws • Fuel, radiator rubber hoses, cracked V-belt, loosened clamp 2. Fuel tank level check and fuel supply Check the remaining fuel oil level in the fuel tank and refuel the recommended fuel if necessary. 3. Lube oil level check and replenishment (a) Checking oil level Check the lubricating oil level with the dipstick (A), after adjusting the position of the machine so that the engine is horizontal. Insert the dipstick fully and check the oil level. The oil shall not be contaminated heavily and have appropriate viscosity. No coolant water or diesel fuel shall be mixed. When lube oil is supplied after the engine has been running, check the lube oil level after about 10 minutes after the engine shutdown so that the lube oil has filled the oil pan. Standard value The level shall be between the upper (AU) and lower (AL) limit lines on the dipstick (A).

51-20

51. ENGINE

Model 3TNV82A 3TNV84(T) 88 4TNV84(T) 88 4TNV94L98(T) 4TNV106(T) (CL class) 4TNV106(T) (VM class)

Total volume (L) 5.5 (1.40) 6.7 (1.80) 7.4 (1.90) 10.5 (2.80) 14.0 (3.70) 14.0 (3.70)

(Unit: litres) (gal) Effective volume (L) 1.9 (0.50) 2.8 (0.70) 3.4 (0.90) 4.5 (1.20) 9.0 (2.40) 7.5 (2)

Lube oil capacity may differ from the above volume depending on an engine installed on a machine unit. (b) Replenishing oil pan with lube oil If the remaining engine oil level is low, remove the filler port cap (B) and fill the oil pan with the specified engine oil to the specified level through the filler port (C). NOTE: the oil should not be overfilled to exceed the upper limit line. Otherwise a naturally-aspirated engine may intake lube oil in the combustion chamber during the operation, then white smoke, oil hummer or urgent rotation may occur, because the blow-by gas is reduced in the suction air flow. In case of turbo-charged engine oil may jet out from the breather or the engine may become faulty. 4. Coolant check Daily inspection of coolant water should be done only by coolant recovery tank.

WARNING â&#x20AC;˘ Never open the radiator filler cap (R) while the engine and radiator are still hot. Steam and hot water will spurt out and seriously burn you. Wait until the radiator is cooled down after the engine has stopped, wrap the filler cap with a rag piece and turn the cap slowly to gently release the pressure inside the radiator. â&#x20AC;˘ Securely tighten the filler port plug (R) after checking the radiator. Steam can spurt out during engine running, if tightening loose. (a) Checking coolant water volume Check the coolant level in the expansion tank (C). If the water level is close to the LOW mark, open the coolant expansion tank plug (H) and replenish the tank with soft clean water up to the FULL mark. Standard value The level shall be between the upper and lower limit lines on the dipstick.

51-21

51. ENGINE

(b) Replenishing radiator with water If the coolant recovery tank water level is lower than the LOW mark, open the radiator cap (R) and check the coolant water level in the radiator. Replenish the radiator with coolant, if the level is low. â&#x20AC;˘ Check the coolant level while the engine is cool. Checking when the engine is hot is dangerous. And the water volume is expanded due to the heat. â&#x20AC;˘ Daily coolant level check and replenishing shall be done only from the expansion tank. Usually do not open the radiator cap to check or replenish.

T. L.

Tighten Loosen

IMPORTANT: if the coolant water runs short quickly or when the radiator runs short of water with the coolant expansion tank level unchanged, water may be leaking or the air tightness may be lost. Increase in the coolant expansion tank water level during operation is not abnormal. The increased water in the coolant expansion tank returns to the radiator when the engine is cooled down. If the water level is normal in the coolant expansion tank but low in the radiator, check loosened clamping of the rubber hose between the radiator and coolant recovery tank or tear in the hose. Standard value Engine: the radiator shall be filled up. (Unit: litres)) Model 3TNV82A 3TNV84(T) 3TNV88 4TNV84(T) 4TNV88 4TNV94L 4TNV98(T) 4TNV106(T)

Coolant water volume In an engine 1.8 2.0 2.7 4.2 6.0

Engine coolant water capacity may differ from the above volume depending on an engine installed on a machine unit. 5. Fuel pipe and coolant pipe inspection and maintenance Check the rubber hoses for fuel and coolant water pipes cracked. If the cracked hose is found, replace it with new one. Check the loosened clamp. If found, tighten it.

51-22

51. ENGINE 6. Inspection and adjustment of governor lever and accelerator. Make sure the accelerator of the machine unit can be operated smoothly before starting the engine. If it feels heavy to manipulate, lubricate the accelerator cable joints and pivots. Adjust the accelerator cable if there is a dislocation or excessive play between the accelerator and the governor lever. Refer to 3.2.3. 7. Warning lamp and instruments function check Before and after starting the engine, check to see that the alarm function normally. Failure of alarm cannot warn the lack of the engine oil or the coolant water. Make it a rule to check the alarm operation before and after starting engine every day. Refer to each manual for machine units in details. 51.2.2.2 Inspection after initial 50 hours operation Be sure to check the following points after initial 50 hours operation, thereafter every 250 hours or 3 months operation. No.

Inspection item

Lube oil and filter replacement

V-belt tension check

1. Lubricating oil change and filter replacement (1st time)

CAUTION When an engine is still hot, be careful with a splash of engine oil which may cause burns. Replace engine oil after the engine oil becomes warm. It is most effective to drain the engine oil while the engine is still warm.

51-23

51. ENGINE In early period of use, the engine oil gets dirty rapidly because of the initial wear of internal parts. Replace the engine oil earlier. Lube oil filter should also be replaced when the engine oil is replaced. The procedure of lube oil and lube oil filter replacement is as follows. (a) Drain engine oil • Prepare a waste oil container collecting waste oil. • Remove the oil filler cap to drain easily while draining the lube oil. • Loosen the drain plug (DP) using a wrench (customer procured) to drain the lube oil. • Securely tighten the drain plug after draining the lube oil. NOTE: use a socket wrench or a closed wrench when removing or tightening a drain plug. Do not use a spanner because there is the possibility that the spanner slips and you get hurt.

DP. Drain plug. The location depends on the engine installed on the machine unit.

(b) Replacing oil filter • Turn the lube oil filter (E) counterclockwise using a filter wrench (customer procured) to remove it. • Clean the mounting face of the oil filter. • Moisten the new oil filter gasket with the engine oil and install the new engine oil filter manually turning it clockwise until it comes into contact with the mounting surface, and tighten it further to 3/4 of a turn with the filter wrench. Tightening torque: 20 ÷ 24 Nm (14.75 ÷ 17.70 lbf•ft) (c) Oil filling and inspection • Fill with new engine oil until it reaches the specified level. IMPORTANT: do not overfill the oil pan (O) with engine oil. Be sure to keep the specified level between upper and lower limit on the dipstick (D). • Warm up the engine by running for 5 minutes while checking any oil leakage • Stop the engine after warming up and leave it stopping for about 10 minute to recheck the engine oil level with dipstick and replenish the engine oil. If any oil is spilled, wipe it away with a clean cloth.

T. L.

51-24

Tighten Loosen

51. ENGINE

2. V-belt tension check When there is not enough tension in the V-belt (V), the V-belt will slip making it impossible for the alternator (A) to generate power and cooling water pump and cooling fan (R) will not work causing the engine to overheat. Check and adjust the V-belt tension (deflection) in the following manner. NOTE: be especially careful not to splash engine oil on the V-belt, because it will cause slipping, stretching and aging of the belt. 1. Press the V-belt with your thumb [approximately 98N] in the middle of the V-belt span to check the tension (deflection). Available positions to check and adjust the Vbelt tension (deflection) are at the A, B or C direction as shown in the illustration right. You may choose a position whichever you can easily carry out the check and adjustment on the machine unit. • “New V-belt” refers to a V-belt which has been used less than 5 minutes on a running engine. • “Used V-belt” refers to a V-belt which has been used on a running engine for 5 minutes or more. The specified deflection to be measured at each position should be as follows. (Unit: mm) Direction For used V-belt For new V-belt

A 10 ÷ 14 8 ÷ 12

2. If necessary, adjust the V-belt tension (deflection). To adjust the V-belt tension, loosen the setscrew (S) and move the alternator (A) to tighten the V-belt. (Adjust the V-belt tension inserting a bar (AV)). After replacing with a new V-belt and adjusting it, run the engine for 5 minutes and readjust the deflection to the value in the table above. 3. After replacing with a new V-belt and adjusting it, run the engine for 5 minutes and readjust the deflection to the value in the table above. 4. Visually check the V-belt for cracks, oiliness or wear. If any, replace the V-belt with new one.

51-25

B 7 ÷ 10 5÷8

C 9 ÷ 13 7 ÷ 11

51. ENGINE 51.2.2.3 Inspection every 50 hours Be sure to check the following points before starting an engine every day.

No. 1 2 3 4

Inspection item Fuel tank drain Water separator draining Fuel system bleeding Battery electrolyte level check and battery recharging

1. Fuel tank drain 1. Prepare a waste oil container collecting waste oil. 2. Remove the drain plug (D) of the fuel tank (F) to drain (water, dust, etc.) from the fuel tank bottom. 3. Drain until fuel with no water and dust flow out. Then tighten the drain plug firmly.

2. Water separator draining Drain off the water separator (W) whenever there is a lot of drain collected in the water separator at the bottom of the cup (C) even if the time for periodic inspection has not elapsed yet. The cup of the water separator (C) is made of semi-transparent material and, in the cup itself, the red coloured floating ring (FR) which rises on the surface of the drain is installed to visualize the amount of drain. A level sensor connected to a warning device on the gauge cluster is provided as optional device. Drain off the water separator in the following manner. 1. Prepare a waste oil container collecting waste oil. 2. Close the fuel cock (FC). 3. Loosen the drain cock (DC) at the bottom of the water separator, and drain off any water collected inside. 4. Tighten the drain cock (DC) manually. 5. Air bleeding from fuel system. NOTE: if no drain drips when the drain cock is opened, loosen the air bleeding bolt (A) on the top of the water separator by turning counterclockwise 2 รท 3 times using screwdriver. (This may occur in case of the water separator position is higher than the fuel oil level in the fuel tank). After draining, be sure to tighten the air bleeding bolt (A).

51-26

51. ENGINE

3. Fuel system bleeding Bleed the fuel system according to the following procedures. When there is air in the fuel system, the fuel injection pump (FI) will not be able to operate. 1. Check the fuel oil level in the fuel tank. Refuel if insufficient. 2. Open the cock (FC) of the water separator (W). 3. Loosen the air bleeding bolt (A) on the water separator by turning counterclockwise 2 ÷ 3 times using a screwdriver or a spanner. 4. When the fuel coming out is clear and not mixed with any bubble, tighten the air bleeding bolt (A). 5. Feed fuel with the fuel priming pump (FP) or electro-magnetic fuel feed pump. • In case the engine uses the electro-magnetic fuel feed pump. Turn the starter switch to the ON position and hold it in the position for 10 ÷ 15 seconds to operate the fuel feed pump. • In case the engine uses the electro-magnetic fuel feed pump (FP). The priming pump is on the top of the fuel filter mounting. Move the priming pump up and down to feed fuel until feel your hand slightly heavy. - Water separator (W) (Installed on the pipe line) - Fuel filter (FF) (Mounting with fuel priming pump) (Option)

51-27

51. ENGINE

4. Battery electrolyte level check and battery recharging

WARNING Fire due to electric short-circuit • Make sure to turn off the battery switch or disconnect the negative cable (-) before inspecting the electrical system. Failure to do so could cause short-circuiting and fires. • Always disconnect the (-) Negative battery cable first before disconnecting the battery cables from battery. An accidental “short circuit” may cause damage, fire and or personal injury. And remember to connect the (-) Negative battery cable (back onto the battery) LAST. Proper ventilation of the battery area Keep the area around the battery well ventilated, paying attention to keep away any fire source. During operation or charging, hydrogen gas is generated from the battery and can be easily ignited. Do not come in contact with battery electrolyte Pay sufficient attention to avoid your eyes or skin from being in contact with the fluid. The battery electrolyte is dilute sulfuric acid and causes burns. Wash it off immediately with a large amount of fresh water if you get any on you.

Battery structure AP. Anode plate BC. Battery case C. Cap CO. Cover CP. Cathode plate G. Glass mat S. Separator T. Terminal

51-28

51. ENGINE

1. Electrolyte level • Check the electrolyte level (EL) in the battery. When the amount of fluid nears the lower limit (LL), fill with battery fluid (available in the market) to the upper limit (UL). If operation continues with insufficient battery fluid, the battery life is shortened, and the battery may overheat and explode. • Battery fluid tends to evaporate more quickly in the summer, and the fluid level should be checked earlier than the specified times. • If the engine cranking speed is so slow that the engine does not start up, recharge the battery. • If the engine still will not start after charging, replace the battery. • Remove the battery from the battery mounting of the machine unit after daily use if letting the machine unit leave in the place that the ambient temperature could drop at -15°C or less. And store the battery in a warm place until the next use the unit to start the engine easily at low ambient temperature. 2. Battery charge Use a battery tester or hydrometer and check the battery condition. If the battery is discharged, recharge it. (a) Measurement with a battery tester (BT) When checking the battery with the batter tester, connect the red clip of the tester to the battery positive (+) terminal and black clip to the battery negative (-) terminal by pinching them securely, and judge the battery charge level from the indicator position. Green zone: Normal Yellow zone: Slightly discharged Red zone: Defective or much discharged

51-29

51. ENGINE

(b) Measurement with hydrometer When using a hydrometer, the measured specific gravity must be corrected according to the temperature at the time of measurement. The specific gravity of battery electrolyte is defined with 20 °C (68 °F) as the standard. Since the specific gravity increases or decreases by 0.0007 when the temperature varies by 1 °C (33.8 °F) correct the value according to the equation below.

Electrolyte temperature at measurement Specific gravity at measurement Converted specific gravity at 20 °C

(c) Specific gravity and remaining battery charge Discharged quantity of Specific gravity Remaining electricity (20°C) charge (%) (%) 1.28 0 100 1.26 10 90 1.24 20 80 1.23 25 75

F. Float GT. Glass tube 3. Terminals Clean if corroded or soiled. 4. Mounting bracket Repair or replace it if corroded. Retighten if loosened. 5. Battery appearance Replace the battery if cracked or deformed. Clean with fresh water if contaminated.

51-30

RB. Rubber bulb

51. ENGINE 51.2.2.4 Inspection every 250 hours or 3 months Be sure to check the following points every 250 hours or 3 months operation, whichever comes first.

No. 1 2 3 4 5

Inspection item Lube oil and filter replacement Radiator fin cleaning V-belt tension check Inspection and adjustment of governor lever and accelerator Air cleaner cleaning and element replacement

1. Lube oil and filter replacement (The second replacement and after) Replace the engine oil every 250 hours operation from 2nd time and on. Replace the engine oil filter at the same time. Refer to 51.2.2.1 (1). 2. Radiator fin cleaning

CAUTION Beware of dirt from air blowing. Wear protective equipment such as goggles to protect your eyes when blowing compressed air. Dust or flying debris can hurt eyes. Dirt and dust (DD) adhering on the radiator fins (RF) reduce the cooling performance, causing overheating. Make it a rule to check the radiator fins daily and clean as needed. â&#x20AC;˘ Blow off dirt and dust from fins and periphery with compressed air (0.19 MPa or less in order not to damage the fins). â&#x20AC;˘ If contaminated heavily, apply detergent, thoroughly clean and rinse with tap water shower. IMPORTANT: Never use high pressure water or air from close by fins or never attempt to clean using a wire brush. Radiator fins (RF) can be damaged.

3. V-belt tension check (The second time and after) Check and adjust the V-belt tension. Refer to 51.2.2.1 (2).

51-31

51. ENGINE 4. Inspection and adjustment of governor lever and accelerator The governor lever (GL) and accelerating devices (accelerating lever, pedal, etc.) of the machine unit are connected by an accelerating wire or rod. If the wire becomes stretched or the connections loose, the deviation in the position may result and make operation unsafe. Check the wire periodically and adjust if necessary. Do not strongly move the accelerating wire or accelerating pedal. It may deform the governor lever or stretch the wire to cause irregular engine speed control. Checking and adjusting procedure are as follows. • Check that the governor lever (GL) of the engine makes uniform contact with the high idling (H) and low idling (LI) limiting screws when the accelerating devices are in the high idling speed or low idling speed position. • If either the high or the low idling speed side does not make contact with the limiting screw, adjust the accelerating wire. Loosen the accelerating wire fastening screw (AF) and adjust the wire to contact with the limiting screw.

CAUTION Never loosen the limiting screws. It will impair the safety and performance of the product and functions and result in shorter engine life.

5. Air cleaner cleaning and element replacement

CAUTION Beware of dirt from air blowing Wear protective equipment such as goggles to protect your eyes when blowing compressed air. Dust or flying debris can hurt eyes. The engine performance is adversely affected when the air cleaner element (E) is clogged by dust. So periodical cleaning after disassembly is needed. • Undo the clamps (L) on the dust pan (DP) and remove the dust pan. • Loosen the wing nut on the element and pull out the element (E).

51-32

51. ENGINE • Blow air (0,29 ÷ 0,49 MPa) from inside the element to blow dust off as shown in the figure on the right. Apply the air blowing pressure as low as possible so as not to damage the element (OE). If having the air cleaner with double elements, never remove and clean the inner element (IE). The purpose of installing the inner element (IE) is of protecting the engine from the penetration of dust during engine operation when leaving the outer element (OE) non-reinstalled after removing it or when damaging the outer element unexpectedly during engine operation. • Replace the element with a new one, if the element is damaged, excessively dirty or oily. • Remove the inside dust cover of the dust pan (DP), and clean the inside of the dust pan. • Reinstall the element (OE) with a new wing screw (do not drop the gasket). Reattach the inside dust cover to the dust pan (DP) and install the dust pan to the air cleaner case (AC) directing the TOP mark (AM) upwards. IMPORTANT: when the engine is operated in dusty conditions, clean the element more frequently. Do not run the engine with removed air cleaner or element, as this may cause foreign material to enter and damage the engine.

51.2.2.5 Inspection every 500 hours or 6 months Be sure to check the following points every 500 hours or 6 months operation, whichever comes first. No. 1 2 3

Inspection item Water separator cleaning Fuel filter element replacement Air cleaner cleaning and element replacement

51-33

51. ENGINE

1. Water separator cleaning Periodically wash the water separator element (E) and inside cup (C) with clean fuel. • Prepare a waste oil container collecting waste oil. • Close the fuel cock (FC). • Loosen the drain cock (DC) and drain. Refer to 51.2.2.3 (2). • Turn the retaining ring (F) counterclockwise and remove the cover (C). (Disconnect the coupler of the lead wire for drain sensor before removing the cup if it is with drain sensor). • Wash the element (E) and inside cup (C) with clean fuel. Replace the element with new one if any damaged. • Insert the element to the bracket (O-ring) and after putting the float ring (FR) in the cup, install it to the bracket by tightening the retaining ring (F) clockwise. Tightening torque: 15 ÷ 20 Nm • Close the drain cock (DC) (connect the coupler if with drain sensor). • Be sure to bleed air in the fuel system. Refer to 51.2.2.3 (3).

2. Fuel filter element replacement Replace the fuel filter at specified intervals, before it is clogged with dust to adversely affect the fuel flow. Also, replace the fuel filter after the engine has fully been cooled. • Close the fuel cock of the water separator. • Remove the fuel filter using a filter wrench (customer procured). When removing the fuel filter, hold the bottom of the fuel filter with a piece of rag to prevent the fuel oil from dropping. If you spill fuel, wipe such spillage carefully. • Clean the filter mounting surface and slightly apply fuel oil to the gasket of the new fuel filter. • Install the new fuel filter manually turning until it comes into contact with the mounting surface, and tighten it further to 1/2 of a turn using a filter wrench. Tightening torque for 3TNV82A to 4TNV106(T): 20 ÷ 24 Nm • Be sure to bleed air in the fuel system. Refer to 51.2.2.3 (3).

IMPORTANT: be sure to use genuine Yanmar part (super fine mesh filter). Otherwise, it results in engine damage, uneven engine performance and shorten engine life.

51-34

Loosen

Tighten

51. ENGINE

3. Air cleaner cleaning and element replacement Replace the air cleaner element periodically even if it is not damaged or dirty. When replacing the element, clean inside of the dust pan at the time. If having the air cleaner with double elements, never remove and clean the inner element. If the engine output is still not recover (or the dust indicator still actuates if having the air cleaner with a dust indicator) even though the outer element has replaced with new one, replace the inner element with new one. 51.2.2.6 Inspection every 1000 hours or one year Be sure to check the following points every 1000 hours or one year operation, whichever comes first.

No. 1 2 3 4 5

Inspection item Coolant change Diaphragm assy inspection Turbocharger blower cleaning* Intake/exhaust valve head clearance adjustment Fuel injection nozzle pressure inspection

1. Coolant change Coolant water contaminated with rust or water scale reduces the cooling effect. Even when antifreeze agent (LLC) is mixed, the coolant water gets contaminated due to deteriorated ingredients. Replace the coolant water at least once a year. • Remove the radiator cap (R). • Loosen the drain plug (D) (drain plug selection depends on the machine) at the lower portion of the radiator and drain coolant. • After draining the coolant, tighten the drain plug (D). • Fill radiator and engine with coolant water.

CAUTION Beware of scalding by hot water Wait until the temperature goes down before draining the coolant water. Otherwise, hot water may splash to cause scalding.

51-35

51. ENGINE

2. Diaphragm assy inspection Inspect the diaphragm assy on the rocker arm (RA) cover every 1000 hours or 2 years. Refer to 51.4.2.4 point 6 for the function of the diaphragm. • Loosen the screws (T) and remove the diaphragm assy, and check whether oil penetrates between the diaphragm (DC) and the cover (RA). If oil or other enters the diaphragm assy, the diaphragm will not work properly. • Check the damages of the diaphragm (D) rubber and the spring (S). If necessary, replace with new ones. NOTES: • When a diaphragm (D) is damaged, pressure control inside the crankcase becomes insufficient, and troubles such as combustion defect and so on occur. • Upon lubricating oil replacement or lubricating oil supply, the amount of lubricating oil must not be beyond the standard upper limit. If the lubricating oil quantity is beyond the upper limit or the engine is operated beyond the maximum allowable angle, the amount of oil mist can penetrate the combustion chamber and oil may boil.

51-36

51. ENGINE 3. Turbocharger blower cleaning* When the engine speed seems too low or the exhaust gas colour is strange, the blades of the turbocharger-blower may be dirty. Wash the turbine blower in such a case. (a) General items • As for washing, use washing liquid and clear water. • Washing time is the time when about 10% of the boost pressure decreases more than that of usual operation state as a standard. • Disassemble and clean the turbocharger periodically because the whole of the turbocharger cannot cleaned with this method. (b) Washing point • A specified quantity of washing liquid/water is poured with a filler (e.g. oil sprayer) from the air inlet of the blower gradually (about then seconds) at the normal load (3/4-4/4) of an engine. And, perform this work at no-load after load running of the engine, if it is difficult to pour the liquid into the blower at load running. Specified quantity of washing liquid/water. Turbocharger model

RHB31, RHB51

Injection amount, one time

20 cc

CAUTION It causes an accident when large quantity of washing liquid is poured rapidly into a turbocharger. • Pour the same amount of clear water as washing liquid/water into the blower about 3-5 minutes later after the washing liquid/water injection and wash it.

CAUTION It causes an accident when large quantity of water is poured rapidly into a turbocharger. • Repeat the washing after then minutes when there is no change with the boost pressure or the exhaust gas temperature after washing. When there is no change at all even if it repeats 3-4 times, disassemble and maintain the turbocharger because of the cruel dirt of the blower or other causes. • Operate the engine at load for at least 15 minutes after washing, and dry.

51-37

51. ENGINE 4. Intake/exhaust valve clearance adjustment Make measurement and adjustment while the engine is cold. (a) Valve clearance measurement • Remove the rocker arm cover above cylinder head. • Set the No.1 cylinder (N) in the compression TDC (top dead centre) Turn the crankshaft to bring the piston of cylinder No.1 to its compression top dead centre while watching the rocker arm (RA) motion, timing scale and the top mark (T) position of the crankshaft (C) pulley. (Position where both the intake and exhaust valves are closed).

NOTES: • The crankshaft shall be turned clockwise as seen from the radiator side. • The no. 1 cylinder (N) position is on the opposite side of the radiator and the ignition order shall be 1-3-4-2-1 at 180° intervals. • Since the intake and exhaust valve rocker arms (RA) are operated the same and there is a clearance (V) between the arm and valve generally at the top dead centre, the position can be checked by means of the play when the arm head is held with hand. Also see that the crankshaft (T) pulley top mark is positioned at zero on the timing scale. If there is no valve (V) clearance, inspection in the disassembled state is necessary since the valve seat may be worn abnormally.

51-38

51. ENGINE • Valve clearance measurement In case of 2-valve cylinder head insert a thickness gauge between the rocker arm (RA) and valve cap, and record the measured valve (V) clearance. In case of 4-valve head insert a thickness gauge between the rocker arm (RA) and the valve bridge (VB), and record the measured valve (V) clearance. (Use it as the data for estimating the wear state). • Adjusting other cylinders In case of 4-cylinder engines, turn the crankshaft by 180° and make adjustment for the no. 3 cylinder. Then adjust the no. 4 and no. 2 cylinders in this order. The cylinder to be adjusted first does not have to be the no. 1 cylinder. Select and adjust the cylinder where the piston is the nearest to the top dead centre after turning, and make adjustment for other cylinders in the order of ignition by turning the crankshaft 180° each time. In case of 3-cylinder engines, turn the crankshaft by 240° and make adjustment for the no. 3 cylinder. Then adjust the no. 2 cylinder in this order. The cylinder to be adjusted first does not have to be the no. 1 cylinder. Select and adjust the cylinder where the piston is the nearest to the top dead centre after turning, and make adjustment for other cylinders in the order of ignition by turning the crankshaft 240° each time. The adjustment method of reducing the flywheel turning numbers (for reference): For 3 cylinder engines Set no.1 cylinder to the compression T.D.C.and adjust the clearance of the  mark of the below table. Next, turn the flywheel once (the suction / exhaust valve of no. 1 cylinder is in the position of the overlap TDC at this time), and adjust the clearance of the  mark. Ignition order of 3 cylinder engines: 13 2 Cylinder no. 1 1 Valve Inlet Drain No. 1 compression   T.D.C. No. 1 overlap T.D.C.

2 Inlet

3 Drain

Inlet

Drain



The first time

 

The second time



For 4 cylinder engines Set no.1 cylinder to the compression T.D.C.and adjust the clearance of the  mark of the below table. Next, turn the flywheel once, and adjust the clearance of the  mark. Ignition order of 3 cylinder engines: 13 4 2 Cylinder no. 1 1 2 Valve Inlet Drain Inlet No. 1 compression    T.D.C. No. 4 compression T.D.C.

3 Drain

Inlet

4 Drain

Inlet

Drain The first time

 

51-39



The second time

51. ENGINE (b) Valve clearance inspection and adjustment • Loosen the setscrews In case of 2-valve cylinder head loosen the lock nut and adjusting screw, and check the valve for any inclination of valve cap (VC), entrance of dirt or wear. AB. Abnormal NO. Normal In case of 4-valve cylinder head loosen the lock nut and adjusting screw of rocker arm. Be careful that excessive tension is not applied to the valve bridge (VB), and loosen a locknut of valve bridge (VB). NOTE: when loosening a locknut of a valve bridge (VB), loosen the locknut while fixing the valve bridge with a wrench (W) so that the valve may not lean. L. Push the bridge head so that a valve bridge (VB) and two valve stem heads may contact each other uniformly, and adjust an adjusting bolt (AJ) so that a gap of the valve stem (AC) head may become 0. Tighten a locknut (RN) after a valve bridge (VB) is fixed with a wrench.

• Measuring valve clearance Insert a 0.2 or 0.3 mm thickness gauge between the rocker arm and valve cap / valve bridge, and adjust the valve clearance. Tighten the adjusting screw. mm Model

Standard valve clearance

3TNV82A~98

0.15 ÷ 0.25

4TNV106(T)

0.25 ÷ 0.35

51-40

Loosen

51. ENGINE

NOTE: when tightening a valve bridge (VB) locknut of 4valve head, tighten a locknut after fixing a valve bridge with a wrench (W) so that a bridge may not rotate and a valve may not lean. • Apply oil to the contact surface between adjusting screw and push rod. • Adjusting other cylinders In case of 4-cylinder engines, turn the crankshaft by 180° and make adjustment for the no. 3 cylinder. Then adjust the no. 4 and no. 2 cylinders in this order. The cylinder to be adjusted first does not have to be the no. 1 cylinder. Select and adjust the cylinder where the piston is the nearest to the top dead centre after turning, and make adjustment for other cylinders in the order of ignition by turning the crankshaft 180° each time. In case of 4-cylinder engines, turn the crankshaft by 240° and make adjustment for the no. 3 cylinder. Then adjust the no. 2 cylinder in this order. The cylinder to be adjusted first does not have to be the no. 1 cylinder. Select and adjust the cylinder where the piston is the nearest to the top dead centre after turning, and make adjustment for other cylinders in the order of ignition by turning the crankshaft 240° each time. 5. Fuel injection nozzle pressure inspection

CAUTION Wear protective glasses when testing injection from the fuel injection valve. Never approach the injection nozzle portion with a hand. The oil jetting out from the nozzle is at a high pressure to cause loss of sight or injury if coming into careless contact with it.

51-41

51. ENGINE (a) Injection pressure measurement Model

Standard MPa

3TNV82A TNV88 (CL)

19.6-20.6

3TNV82A TNV88 (CL) 4TNV94L 4TNV106 (T)

21.6-22.6

NOTE: as for the opening pressure of the brand-new fuel nozzle, about 0.5 MPa (73 psi), it decreases during engine operation for about 5 hours because of the initial wear of the spring etc. Therefore, adjust it to 0.5 MPa (73 psi) or higher than the standard value indicated in the table above when adjusting a new spare fuel nozzle. Remove carbon deposit at the nozzle hole thoroughly. before measurement. • Connect the fuel injection valve to the high pressure pipe of the nozzle tester (NT). • Operate the nozzle tester (NT) lever slowly and read the pressure at the moment when the fuel injection (IN) from the nozzle starts. • If the measured injection (IN) pressure is lower than the standard level, replace the pressure adjusting shim with a thicker one. Thickness of pressure adjusting shims

Injection pressure adjustment

mm 0.13-0.15-0.18-0.4-0.5-0.8

The injection pressure is increased by approx. 1.9 MPa, when the adjusting shim thickness is increased by 0.1 mm.

51-42

51. ENGINE Informative: fuel injection valve structure

F. F.O. return pipe joint N. Nozzle NB. Nozzle body NC. Nozzle case nut tightening: from 39.2 to 44.1 NmNH. Nozzle holder

NS. NV. NZ. PA. VS.

(b) Spray pattern inspection After adjustment to the specified valve opening pressure, use a nozzle tester and check the spray pattern and seat oil-tightness. Seat oil tightness check â&#x20AC;˘ After injecting a few times, increase the pressure gradually. Hold the pressure for about 5 seconds at a little before the valve opening pressure of 1.96 MPa, and check to see that oil does not drip from the tip end of the nozzle. â&#x20AC;˘ If extreme oil leak from the overflow joint exists during injection by the nozzle tester, check after retightening. If much oil is leaking, replace the nozzle assembly.

51-43

Nozzle spring Nozzle valve Nozzle spring seat Pressure adjusting shim Valve stop spacer

Normal Uniform spray pattern from each nozzle

51. ENGINE Spray and injection states • Operate the nozzle tester lever at a rate of once or twice a second and check no abnormal injection. • If normal injection as shown below cannot be obtained, replace the fuel injection valve. • No extreme difference between angles () • No extreme injection angle difference () • Finely atomized spray • Excellent spray departure Abnormal Extreme difference in angle () Extremely difference injection angle () Non atomized spray Stagnant spray • (c) Nozzle valve sliding test Wash the nozzle valve in clean fuel oil. Place the nozzle body vertically and insert the nozzle into the body to about 1/3 of its length. The valve is normal if it smoothly falls by its own weight into the body. In case of a new nozzle, remove the seal peel, and immerse it in clean diesel oil or the like to clean the inner and outer surfaces and to thoroughly remove rust-preventive oil before using the nozzle. Note that a new nozzle is coated with rust-preventive oil and is pasted with the seal peel to shut off outer air. (d) Nozzle punch mark (P) Design code Number of hole (4 hole) Diameter of hole (ø 0.24) Size: size P, size S Injection angle Nozzle insertion angle Code A: angled No code: no angle

51-44

51. ENGINE 51.2.2.7 Inspection every 2000 hours or 2 months Be sure to check the following points every 2000 hours or one year operation, whichever comes first. No. 1 2 3 4

Inspection item Coolant water path flushing and maintenance Fuel pipe and coolant pipe inspection and maintenance Intake/exhaust valve seat lapping Fuel injection timing adjustment Fuel injection pump inspection and adjustment

1. Coolant water path flushing and maintenance Rust and water scale will accumulate in the cooling system through many hours of operation. This lowers the engine cooling effect. Oil coolers (attached to turbocharged engines and some of naturally aspirated engines) quickly deteriorate the lube oil. The cleaning and maintenance of the following parts are necessary in accordance with the coolant water replacement. Cooling system parts: radiator, cooling water pump, thermostat, cylinder block, cylinder head, oil cooler. 2. Fuel pipe and coolant pipe inspection and maintenance Check the rubber hoses for fuel and coolant water pipes cracked. If cracked or degraded, replace them with new one. Replace the rubber hoses at least every 2 years even if 2000 hours have not elapsed yet. 3. Intake/exhaust valve seat lapping The adjustment is necessary to maintain proper contact of the valves and seats. Refer to 51.4.2.6. 4. Fuel injection timing adjustment / fuel injection pump inspection and adjustment The fuel injection timing and the fuel injection pump are adjusted so that engine performance may become the best condition. As for the inspection and adjustment of the fuel pump, it is based on the service manual of the MP pump of the separate volume. The fuel injection timing is adjusted by the following procedure.

51-45

51. ENGINE

As for the engine, which adopts a MP type fuel injection pump, the fuel injection angle (i) (note) is adjusted for the fuel injection timing adjustment, because the adjusting method of fuel injection timing like an in-line fuel pump cannot be applied. NOTE: The fuel injection angle (i) (cam angle) is the difference from the injection valve opening angle while the fuel injection pump being driven by a motor and the angle at the plunger lift 2.5 mm (0.09 in) of the fuel pump. And, as for the actual fuel injection angle (i), the measured value is recorded on the pump body by each every fuel pump.

Angle at plunger lift 2.5 mm C. Cam angle

I. Injection start angle NL. Nozzle lift i. Injection angle

The adjustment of fuel injection angle (i) In case that a fuel pump cover, installed with a gear case cover and the fuel pump are removed, and reassembled, the procedure of fuel injection angle adjustment is as follows. (As for the disassembly of a fuel injection pump, refer to 51.7.2.3). NOTE: Never loosen four flange screws, which fasten a pump flange and a fuel pump drive gear at the time of the removal of the fuel pump. When it is loosened, the adjustment of the fuel injection timing becomes very difficult.

D. Fuel pump driving gear GI. Gear installation, do F. Fuel injection pump not loosen nuts G. Idle gear F. Fuel injection pump M. I.D. mark

51-46

51. ENGINE • Before removing a fuel pump (FJ) drive gear (GC), make identification marks (M) on the gearing part of the pump drive gear and the idle gear with paint and so on (MG). • Make the mark-off line to the gear case precisely in accordance with the position of mark-off line of the fuel pump (MP). • Before removing a fuel pump, put the standard mark of a sticker (MS) for fuel injection angle adjustment in accordance with the mark-off line of the fuel pump (MP) and paste it on the gear case. • Remove a fuel pump, and read the fuel injection angle recorded in that fuel pump. • Read the injection angle recorded on a reassembled fuel pump and calculate the difference from the injection angle of the disassembled fuel pump. (When re-installation does the same fuel pump, the angular difference is zero). Fuel injection angle difference (cam angle) = (the fuel injection angle of a reassembled fuel pump) - (the fuel injection angle of a disassembled previous fuel pump)

FS. Fuel pump side GS. Gear case side

NOTE: tell the fuel pump number to Yanmar, and inquire the injection angle of the pump when it is hard to find out. • Put the fuel pump (FJ) on the gear case (GC) temporarily and install the drive gear on the cam shaft with checking the identification marks (M), which were put on the fuel pump drive gear and the idle gear at the time of the disassembling.

MO. Mark-off line

Tighten the installation nut of a pump drive gear. Model

Tightening t

Lubricating oil application (thread portion, and seat surface)

3TNV82A~TNV88 4TNV94L/98/106(T)

78 ÷ 88 113 ÷ 123

Not applied

51-47

51. ENGINE • Adjust the injection angle difference, (calculated in the above 5), at 0.25° in the unit in the installation angle of the fuel pump while reading the mark (minimum 0.5° and cam angle) of the adjustment sticker (MS). NOTE: push down the fuel pump in the outside direction of the cylinder block at +1 degree when a injection angle difference is +1 degree. Push it down to the cylinder block side when a difference is -1 degree. • Tighten the fuel pump installation nuts.

MP. Mark-off line on fuel pump

(Supplementary explanation 1) The installation angle of the fuel pump is as follows. Installation angle Model  (deg.) 3TNV82A~TNV88

4TNV94L/98/106(T)

4TNV106(T)

11.5

(Supplementary explanation 2) When the injection time is advanced (A) or delayed (D), the installation angle of the fuel pump is adjusted. When fuel injection timing is advanced for example at 2 degrees, loosen the nuts (P), which fix the fuel pump on the gear case, and turn the fuel pump body in the outside direction of the cylinder block at 1 degree, and tighten the pump installation nuts. And, when fuel injection timing is delayed, a pump is turned in that reverse direction.

51-48

51. ENGINE 51.2.3

ADJUSTING THE NO-LOAD MAXIMUM OR MINIMUM SPEED

1. After warming the engine up, gradually raise the speed and set it at the no-load maximum revolution. 2. If the no-load maximum revolution is out of the standard, adjust it by turning the high idle (H) limiting screw. 3. Then set the no-load minimum speed by adjusting the low idle (LI) limiting screw.

Standards Engine specification class

MP2 Fuel injection pump

(Unit: rpm) Rating speed No-load maximum No-load minimum 1500 1575-1625 1200 or more CL 1800 1870-1920 2000 2180-2230 800 or more (1100 or more for 4TNV106(T)) 2200 2395-2445 2400 2590-2640 VL 2500 2700-2750 2600 2785-2835 2800 2970-3020 3000 3185-3235 Note) The engine speed may differ from the above standard depending on an engine installed on a machine unit.

51-49

51. ENGINE 51.2.4

SENSOR INSPECTION

51.2.4.1 Oil pressure switch Disconnect the connector from the oil pressure switch (O). Keep the voltmeter probes (T) in contact with the switch terminal and cylinder block (C) while operating the engine. It is abnormal if circuit is closed.

Continuity test 51.2.4.2 Thermo switch Place the thermo switch in a container filled with (H) antifreeze or oil. Heat it while measuring the fluid temperature (Thermometer (TH)). The switch (TS) is normal if the voltmeter shows continuity when the fluid temperature is 107 Ăˇ 113 Â°C.

51-50

51. ENGINE 51.2.5

WATER LEAK CHECK IN COOLING WATER SYSTEM

Check coolant water leakage from the cooling water system visually. If any problem is found, Inspect as follows. 1. Fill coolant water to the normal level in the radiator, and install the cap tester (CT) on the radiator. 2. Operate the manual pump to set the pressure to 0.09 Âą 0.015 MPa. If the cap tester (CT) pressure gauge reading drops then, water is leaking from the cooling water system. Check the water leaking point. 51.2.6

RADIATOR CAP INSPECTION

Install the radiator cap (RC) on the cap tester. Set the instrument pressure to 0.09 Âą 0.015 MPa and check that the cap is open. If the cap does not open, replace the cap since it is abnormal.

51-51

51. ENGINE 51.2.7

THERMOSTAT INSPECTION

Place the thermostat (TE) in a container filled with water. Heat it while measuring the water temperature (Thermometer (TH)), and see that the thermostat (TE) is actuated at temperature of following table. Valve opening Full open lift Temperature Model (Temperature) (mm) (in) (°C)* 8 or more (85 °C) 69.5 ÷ 72.5 * Valve opening temperature is carved on the flange. All models

51.2.8

ADJUSTMENT

Perform the adjusting operation of a engine as follows after the maintenance job: 1. Supply fuel, lubricating oil and coolant NOTE: Check the levels of the lubricating oil and coolant water again after test running (for about 5 minutes) and add as required. 2. Start the engine, and carry out idling at a low revolution (700 to 900 rpm) for a few minutes. 3. Run in the engine for about five minutes at the rated revolution (no-load). Check any water, fuel or oil leak and existence of abnormal vibration or noise. Also check the oil pressure, coolant water temperature and exhaust gas colour. 4. Adjust the no-load minimum and maximum revolutions according to the specifications. 5. Perform loaded operation as required.

51-52

51. ENGINE 51.2.9

LONG STORAGE

Observe the following instructions when the engine is to be stored for a long period without operation: 1. Always drain coolant water in a cold season or before a long storage.(This is unnecessary when antifreeze is used.) NOTE: negligence of water draining will cause the coolant water remaining inside the engine to be frozen and expanded to damage the engine parts. Water draining procedure

2. 3. 4. 5. 6.

7. 8.

• Remove the radiator cap. • Loosen the water draining cock under the radiator to drain water from the inside. • Loosen the drain cock on the side surface of the cylinder to drain water from the inside. • After draining water, tighten the radiator cap and drain plug and cocks. Remove the mud, dust and oil deposit and clean the outside. Perform the nearest periodic inspection before the storage. Drain or fill the fuel oil fully to prevent condensation in the fuel tank. Disconnect the battery cable from the battery negative (-) terminal. Cover the silencer, air cleaner and electric parts with PVC cover to prevent water and dust from depositing or entrance. Select a well-ventilated location without moisture and dust for storage. Perform recharging once a month during storage to compensate for self-discharge.

51-53

51. ENGINE

51.3

TROUBLESHOOTING

51.3.1

PREPARATION BEFORE TROUBLESHOOTING

If the signs of a trouble appear, it is important to lecture on the countermeasure and treatment before becoming a big accident not to shorten the engine life. When the signs of a trouble appear in the engine or a trouble occurs, grasp the trouble conditions fully by the next point and find out the cause of sincerity according to the troubleshooting. Then repair the trouble, and prevent the recurrence of the trouble. 1. What is the most recurring symptom of the trouble situation? (e.g. strange exhaust gas colour) 2. Investigation of the past records of the engine Check a client control ledger, and examine the history of the engine. • Investigate the engine model name and the engine number. (Mentioned in the engine label). Examine the machine unit name and its number in the same way. • When was the engine maintained last time? • How much period and/or time has it been used after it was maintained last time? • What kind of problem was there on the engine last time? What kind of maintenance was carried out? 3. Hear the occurrence phenomenon from the operator of the engine in detail. 5 Modes + 1 for “5W1H” phenomenon occurrence: when, where, who, what, why and how. • When did the trouble happen at what kind of time? • Was there anything changed before the trouble? • Did the trouble occur suddenly, or was there what or a sign? • Has any related phenomenon occurred? ...(e.g. strange exhaust colour and starting failure at the same time) 4. After presuming a probable cause based on the above investigation, investigate a cause systematically by the next troubleshooting guide, and find out the cause of sincerity.

51-54

51. ENGINE 51.3.2

QUICK REFERENCE TABLE FOR TROUBLESHOOTING

The following table summarizes the general trouble symptoms and their causes. If any trouble symptom occurs, take corrective action before it becomes a serious problem so as not to shorten the engine service life.

Improper clearance of intake/ exhaust valve

 



Black

White

Black



Lap the valve seat. (See 51.4.2.6)

 



 Correct or replace. Replace the gasket. (See 51.4.2.2-11)

 



Worn piston ring, piston or cylinder 



Correct the ring joint positions. (See 51.4.4.4-6)



Reassemble correctly. (See 51.4.4.4-6)



Loosened connecting rod bolt



Excessive gear backlash

Turbocharger

Improper open/close timing of intake/exhaust valves



Disassemble and repair.



Adjust gear meshing. (See 51.4.3.4-2) Measure and replace. (See 51.4.2.5-2 and 4.2.7)

  Regular      

Fouled blower Waste gate malfunction Worn floating bearing

Measure and replace. (See 51.4.4.5-2) Tighten to the specified torque. (See 51.4.4.4-2)



Defective battery

 



Seizure of intake/exhaust valve

Replace the piston ring. (See 51.4.2.2-5-10)

  Repair or replace.



Reverse assembly of piston rings Worn crankpin and journal bearing



Perform honing and use oversize parts. (See 51.4.4.5-1-4 and 51.4.4.6)

 

Improper arrangement of piston ring joints

Foreign matter trapped in combustion chamber

Adjust the valve clearance. (See 51.2.2.6)



Seized crankpin metal or bearing

 



Seized or broken piston ring

Corrective action



Blowout from cylinder head gasket

Engine system

White



Compression leakage from valve seat Seizure of intake/exhaust valve

Normal

Much

Little

None

Cause

Engine does not start.

Exhaust smoke

During work

During idling

Exhaust colour

Uneven combustion sound

Engine starts but stops soon

Hunting

Abnormal engine sound

Starting failure

Strange Insufficient exhaust gas engine output colour High knocking sound during combustion

Trouble symptom



  

51-55



Adjust the valve clearance. (See 51.2.2.6) Wash the blower. Disassemble and inspect. Disassemble and inspect.

51. ENGINE

Coolant



Seizure of intake/exhaust valve



Seized or broken piston ring



Engine system

Worn piston ring, piston or cylinder Seized crankpin metal or bearing

Exhaust temperature rise

Pressure rise



Adjust the valve clearance. (See 51.2.2.6)



Lap the valve seat. (See 51.4.2.6)



Correct or replace. Replace the gasket. (See 51.4.2.2-11)

  

 



Perform honing and use oversize parts. (See 51.4.4.5-1-4 and 51.4.4.6)



Repair or replace.



Replace the piston ring. (See 51.4.2.2-5-10)

 

Improper arrangement of piston ring joints



Correct the ring joint positions. (See 51.4.4.4-6)

Reverse assembly of piston rings



Reassemble correctly. (See 51.4.4.4-6)

Worn crankpin and journal bearing



Measure and replace. (See 51.4.4.5-2)

Loosened connecting rod bolt



Tighten to the specified torque. (See 51.4.4.4-2)

Foreign matter trapped in combustion chamber



Seizure of intake/exhaust valve Defective battery

Disassemble and repair. Adjust gear meshing. (See 51.4.3.4-2)

Excessive gear backlash

Turbocharger

Pressure drop



Blowout from cylinder head gasket

Low water temperature

Much blow-by gas

Low L.O. pressure

Mixture with water

Diluted with fuel

Improper clearance of intake/exhaust valve Compression leakage from valve seat

Air intake

Corrective action Excessive consumption

Engine excessive fuel consumption

Difficulty in returning to low speed

Large engine vibration

Cause

Lubricating oil

Overheating

Trouble symptom



 

Measure and replace. (See 51.4.2.5-2 and 51.4.2.7) Regular

Improper open/close timing of intake/ exhaust valves

Adjust the valve clearance. (See 51.2.2.6)

Fouled blower

Wash the blower.

Waste gate malfunction

Disassemble and inspect.

Worn floating bearing

Disassemble and inspect.

51-56

51. ENGINE

Cooling Water System

Defective thermostat (kept closed) (See 51.2.2.7)

Insufficient cooling effect of radiator



Defective thermostat (kept opened) (See 51.2.2.7) or slipping fan belt (See 51.2.2.2-2)

Insufficient coolant water level



Water leak check in cooling water system (See 51.2.2.1-4)

Cracked water jacket

Repair or replace.

Slackened fan belt



Adjust the belt tension. (See 51.2.2.2-2)

Faulty thermostat

 

Check or replace. (See 51.2.2.7)

Improper properties of lubricating oil Lubricating system

Corrective action



Excessive cooling effect of radiator

 



Use proper lubricating oil. (See 51.1.3.2)

Leakage from lubricating oil piping system

Repair.

Insufficient delivery from trochoid pump

Check and repair. (See 51.5.5)

Clogged lubricating oil filter

Clean or replace.

Defective pressure regulating valve

Clean, adjust or replace.



Insufficient lubricating oil level

Add proper lubricating oil. (See 51.2.2.1-3)

Too early timing of fuel injection pump

  

Too late timing of fuel injection pump

    

Water entrance in fuel system



Fuel filter clogged

     

  

 



Air entrance in fuel system Clogged or cracked fuel pipe Insufficient fuel supply to fuel injection pump

Check and adjust. (See 51.2.2.7-4)

   

Improper properties of fuel oil

Fuel system

Black

White

Black

White

Normal

Much

Little

None

Cause

Engine does not start.

Exhaust smoke

During work

During idling

Exhaust colour

Hunting

Uneven combustion sound

Engine starts but stops soon

Strange Insufficient exhaust engine gas output colour

Abnormal engine sound

Starting failure

High knocking sound during combustion

Trouble symptom



Check and adjust. (See 51.2.2.7-4)



Use proper fuel oil. (See 51.1.3.1)

  

Perform draining from the fuel filter. (See 51.2.2.3 and 51.2.2.5) Clean or replace. (See 51.2.2.5) Bleed air (See 51.2.2.3) Clean or replace. Check the fuel tank cock, fuel filter, fuel pipe, and fuel feed pump.

Uneven injection volume of fuel injection pump

   

   Check and adjust.

Excessive fuel injection volume



Check and adjust.

Poor spray pattern from fuel injection nozzle Priming failure Clogged strainer at feed pump inlet

   

   Check and adjust. (See 51.2.2.6) Foreign matter trapped in the valve inside the priming pump. (Disassemble and clean.)

 

Clean the strainer.

51-57

51. ENGINE

Cooling Water System Lubricating system

Corrective action

Exhaust temperature rise

Pressure rise

Air intake

Pressure drop

Low water temperature

Much blow-by gas

Low L.O. pressure

Mixture with water

Diluted with fuel

Excessive consumption

Engine excessive fuel consumption

Coolant



Excessive cooling effect of radiator

Defective thermostat (kept closed) (See 51.2.2.7)



Defective thermostat (kept opened)



Insufficient cooling effect of radiator

 (See 51.2.2.7) or slipping fan belt (See 51.2.2.2-2) Water leak check in cooling water



Insufficient coolant water level

 system (See 51.2.2.1-4)

 

Cracked water jacket



Slackened fan belt



Faulty thermostat

 

Repair or replace.



Adjust the belt tension. (See 51.2.2.2-2) Check or replace. (See 51.2.2.7)

Improper properties of lubricating oil



 

Use proper lubricating oil. (See 51.1.3.2)

Leakage from lubricating oil piping system



Repair. Check and repair. (See 51.5.5)

Defective pressure regulating valve

   

Insufficient lubricating oil level



Insufficient delivery from trochoid pump Clogged lubricating oil filter

Too early timing of fuel injection pump

Clean or replace. Clean, adjust or replace. Add proper lubricating oil. (See 51.2.2.1-3)



Check and adjust. (See 51.2.2.7-4)



Too late timing of fuel injection pump

Fuel system

Difficulty in returning to low speed

Large engine vibration

Cause

Lubricating oil

Overheating

Trouble symptom



Check and adjust. (See 51.2.2.7-4)

Improper properties of fuel oil

Use proper fuel oil. (See 51.1.3.1)

Water entrance in fuel system

Perform draining from the fuel filter. (See 51.2.2.3 and 51.2.2.5)

Fuel filter clogged

Clean or replace. (See 51.2.2.5)

Air entrance in fuel system

Perform air bleeding (See 51.2.2.3)

Clogged or cracked fuel pipe

Clean or replace.

Insufficient fuel supply to fuel injection pump

Check the fuel tank cock, fuel filter, fuel pipe, and fuel feed pump.

Uneven injection volume of fuel injection pump

  

Excessive fuel injection volume Poor spray pattern from fuel injection nozzle

 Check and adjust.



 

  Check and adjust. Check and adjust. (See 51.2.2.6)



Priming failure

Foreign matter trapped in the valve inside the priming pump. (Disassemble and clean.)

Clogged strainer at feed pump inlet

Clean the strainer.

51-58



Black

White

Black

White

Normal

Much



Air/Exhaust Gas System

Little



Engine used at high temperatures or at high altitude



Clogged exhaust pipe



Starter motor defective

Air cleaner clogged



Study output drop and load matching.



Clean.

Repair or replace. (See chapter 51.8).

Open-circuit in wiring Battery voltage drop



Inspect and change the battery. (See 51.2.2.3)

Repair or replace. (See chapter 51.9). Repair. (See chapter 51.10).

Air cleaner clogged Engine used at high temperatures or at high altitude



Exhaust temperature rise

Pressure rise

Air intake

Pressure drop

Low water temperature

Overheating

Coolant

Much blow-by gas

Low L.O. pressure

Mixture with water

Diluted with fuel

Engine excessive fuel consumption

Difficulty in returning to low speed

Large engine vibration

Lubricating oil

Excessive consumption

Alternator defective

Cause Air/Exhaust Gas System

Clean. (See 51.2.4)

  

Trouble symptom

Electrical system

Corrective action

During work

Electrical system

Cause

Exhaust colour

Exhaust smoke

None

Engine does not start.

Engine starts but stops soon

Hunting

During idling

Strange Insufficient exhaust engine output gas colour

Uneven combustion sound

Starting failure

Abnormal engine sound

Trouble symptom

High knocking sound during combustion

51. ENGINE

Corrective action



Clean. (See 51.2.2.4)



Study output drop and load matching.

 Clean.

Clogged exhaust pipe

Starter motor defective

Repair or replace. (See chapter 51.8).

Alternator defective

Repair or replace. (See chapter 51.9).

Open-circuit in wiring

Repair. (See chapter 51.10).

Battery voltage drop

Inspect and change the battery. (See 512.2.3)

51-59

51. ENGINE 51.3.3

TROUBLESHOOTING BY MEASURING COMPRESSION PRESSURE

Compression pressure drop is one of major causes of increasing blow-by gas (lubricating oil contamination or increased lubricating oil consumption as a resultant phenomenon) or starting failure. The compression pressure is affected by the following factors: • Degree of clearance between piston and cylinder • Improper clearance of intake/exhaust valve • Gas leak from nozzle gasket or cylinder head gasket In other words, the pressure drops due to increased parts wear and reduced durability resulting from long use of the engine. A pressure drop may also be caused by scratched cylinder or piston by dust entrance from the dirty air cleaner element or worn or broken piston ring. Measure the compression pressure to diagnose presence of any abnormality in the engine. 1. compression pressure measurement method • After warming up the engine, remove the fuel injection pipe and valves from the cylinder to be measured. • Crank the engine before installing the compression gauge adapter. 1. *Perform cranking with the stop handle at the stop position (no injection state). 2. *See 51.12.2-18 for the compression gauge and compression gauge adapter. • Install the compression gauge and compression gauge adapter at the cylinder to be measured. 1. Never forget to install a gasket at the tip end of the adapter. • With the engine set to the same state as in 2,*1, crank the engine by the starter motor until the compression gauge reading is stabilized. 2. Standard compression pressure Engine compression pressure list (reference value) Compression pressure

at 250 rpm MPa Limit value 2,45 ± 0,1 2,55 ± 0,1 2,45 ± 0,1 2,75 ± 0,1

Engine mode 3TNV82A 3/4TNV84 3/4TNV84T TNV88 106(T)

Standard value 3,16 ± 0,1 3,24 ± 0,1 2,94 ± 0,1 3,43 ± 0,1

51-60

Deviation among cylinders MPa

0,2 ÷ 0,3

51. ENGINE

3. Engine speed and compression pressure (for reference)

CP. Compression pressure (MPa)

ES. Engine speed (rpm)

4. Measured value and troubleshooting When the measured compression pressure is below the limit value, inspect each part by referring to the table below. No. Piece Cause • Air cleaner element • Clogged element • Broken element 1 • Defect at element seal portion 2 • Valve clearance • Excessive or no clearance 3 • Valve timing • Incorrect valve clearance • Cylinder head gasket • Gas leak from gasket 4

• Intake/exhaust valve • Valve seat • Piston • Piston ring • Cylinder

Corrective action • Clean the element. • Replace the element. • Adjust the valve clearance. • Adjust the valve clearance. • Replace the gasket. • Tighten the cylinder screws again to the specified tightening torque. (See 51.4.2-2). • Lap the valve seat. (See 51.4.2-6). Replace the intake/exhaust valve.

• Gas leak due to worn valve seat or foreign matter trapping • Sticking valve • Gas leak due to scratching or • Perform honing and use oversize parts. wear (See 51.4.4(5)-(5-1), (5-4) and (6)).

51-61

51. ENGINE

51.4

DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES

51.4.1

COMPLETE DISASSEMBLY AND REASSEMBLY

51.4.1.1 Introduction Make preparation as follows before starting engine inspection and service: 1. Fix the engine on a horizontal base.

CAUTION Be sure to fix the engine securely to prevent injury or damage to parts due to falling during the work. 2. Remove the coolant water hose, fuel oil pipe, wire harness, control wires etc. connecting the driven machine and engine, and drain coolant water, lubricating oil and fuel. 3. Clean soil, oil, dust, etc. from the engine by washing with solvent, air, steam, etc. Carefully operate so as to prevent any foreign matter from entering the engine.

CAUTION Always wear glasses or other protectors when using compressed air or steam to prevent any foreign matter from getting in the eyes.

NOTA: any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit shall be replaced. Any part predicted to dissatisfy the standard or limit before the next service as estimated from the state of use should be replaced even when the measured value then satisfies the standard or limit.

51-62

51. ENGINE 51.4.1.2 Special service tools 1. Special Tools No. Name

Applicabile model and tool size Model

3TNV82A 4TNV94L98(T) Valve guide tool (for 4TNV106(T) extracting valve 4TNV84 guide) 3TNV84(T) 3/4TNV88 4TNV84T

Illustration

mm d2

5.5

* Locally manufactured

Model 3TNV82A 4TNV84 Valve guide tool (for 3TNV84(T) inserting valve 3/4TNV88 guide) 4TNV84T 4TNV94L·98(T) 4TNV106(T)

L1 12

L2 60

d1 13

mm d2 19

8.5 7 13.6

60 60 65

11 13 13

17 16 16

L1 25 20 20 20

L2 85 100 100 100

d1 23 26 30 37

mm d2 26 29 33 40

* Locally manufactured

Model

Connecting rod bushing replacer (for removal /installation of connecting rod bushing)

3TNV82A TNV84~88 4TNV94L·98 4TNV106(T) Allowance: d1

-0.3 (-0.011)

-0.6 (-0.023)

-0.3 (-0.011) -0.6 (-0.023)

* Locally manufactured

Valve spring compressor (for removal / installation of valve spring)

Stem seal inserter (for inserting stem seal)

Model 3TNV82A 4TNV84 3TNV84(T) 4TNV88 4TNV84T 4TNE94L·9 8 4TNE106(T)

d1 15.2

d2 21

d3 12

L1 15.8

L2 65

mm L3 4

16.2

13.5

18.8

12.9

11.5

10.0

15.2

11.8

15.2

15.5

* Locally manufactured

51-63

51. ENGINE No .

Name

Applicabile model and tool size

Filter wrench (for re6 moval / installation of L.O. filter)

Illustration

Standard tool Available on the market

Model TNV82A~88 Camshaft bushing tool 4TNV94L·98 7 (for extracting camshaft 4TNV106(T) bushing) Allowance: d1

L1 18 18 18 -0.3 (0.011) -0.6 (0.023)

L2 70 70 70

d1 45 50 58

mm d2 48 53 61

-0.3 (0.011) -0.6 (0.023)

* Locally manufactured

Cylinder bore mm 78 ÷ 84

Model

Flex-Hone (For re-honTNV82A ing of cylinder liner) TNV88~ 8 4TNV94L 4TNV98 4TNV106(T) Not used

Piston insertion tool (for inserting piston)

83 ÷ 95 89 ÷ 101 95 ÷ 108

*The above piston insertion tool is applicable to 60125 mm diameter pistons.

Piston ring replacer (for 10 removal / installation of Available on the market piston ring)

Crankshaft pulley in11 stalling tool. Locally manufactured

Standard tool Locally manufactured (For 4TNV94L)

51-64

51. ENGINE

2. Measuring instruments No. Name

Applicabile model and tool size

Dial gauge

Standard tool Measurements of shaft bending, and strain and gap of surfaces

Test indicator

Standard tool Measurements of narrow or deep portions that cannot be measured by dial gauge

Magnetic stand

Standard tool For holding the dial gauge when measuring using a dial gauge, standing angles adjustable

Micrometer

Standard tool For measuring the outside diameters of crankshaft, pistons, piston pins, etc.

Cylinder gauge

Standard tool For measuring the inside diameters of cylinder liners, rod metal, etc.

Calipers

Standard tool For measuring outside diameters, depth, thickness and width

Depth micrometer

Standard tool For measuring of valve sink

Square

Standard tool For measuring valve spring inclination and straightness of parts

V-block

Standard tool For measuring shaft bend

Torque wrench

Standard tool For tightening nuts and screws to the specified torque

51-65

Illustration

51. ENGINE No.

Name

Applicabile model and tool size

Illustration

Standard tool Thickness gauge For measuring gaps between ring and ring groove, and shaft joints during assembly

Cap tester

Standard tool

For checking water leakage

Standard tool Battery coolant tester

For checking concentration of antifreeze and the battery electrolyte charge status

Standard tool Nozzle tester

For measuring injection spray pattern of fuel injection nozzle and injection pressure

Standard tool Digital thermometer

For measuring temperatures Sensor

Contact type

For measuring engine revolutions by contacting the revolving shaft

Photoelectric type

For measuring revolution by sensing the reflective mark on the outer periphery of the revolving shaft

Standard tool Speedometer

Circuit tester

Standard tool

Part number: 380000303 Compression gauge kit

For measuring resistance, voltage and continuity of electrical circuits

For measuring compression pressure

51-66

Revolving shaft

Reflective mark

51. ENGINE 51.4.1.3 Complete disassembly Peripheral parts such as air cleaner, muffler and radiator differ in installation and types for each application. Therefore, description in this Chapter is started with the steps to be taken just after the peripheral parts have been removed. Step

Removal Parts 1. Thoroughly remove sand, dust, dirt and soil from the surface of the engine. 2. Drain coolant water and lubricating oil from the engine. 1. 2. 1. 2. 3. 4.

Remove turbocharger and exhaust manifold. Remove intake manifold and surge tank. Close the fuel cock valve of the fuel tank. 1. Remove high-pressure fuel pipe. Remove fuel return pipe. 2. Loosen the tightening nut on fuel injection nozzle retainer and extract the retainer and fuel injection nozzle. *) Fuel injection nozzle for Indirect injection 3. system is screwed type. 1. Remove rocker arm cover assembly. 1. Remove valve rocker arm shaft assembly. 1. 2. Remove the push rod. 2.

1. 6

7 8

2. 3. 4. 1. 2. 1. 2.

Observations

If nozzle seat is left on the cylinder head, remove the cylinder head before extracting nozzle seat. To prevent dust from entering fuel injection nozzle, fuel injection pump and high-pressure fuel pipe, seal their respective threads with a tape or the like. Whenever extracting fuel injection nozzle, replace nozzle protector with a new one.

Attach a tag with the reference No. of each cylinder to the push rod in order. Remove valve cap from the intake/exhaust valve head. 3. Note that tappet of the indirect injection system can be removed at the same time when push rod is extracted. 4. Attach a tag to tappet for each cylinder No. to put the tappet in order. Remove the fan mounting screw, and then 1. Never turn down alternator vigorously toward remove the fan. the cylinder block. Otherwise, your finger may be Loosen the adjusting screw for the V-belt nipped and alternator broken. adjuster, and then remove the V-belt. Remove alternator. Remove the spacer for cooling fan and V-pulley. Remove lubricating oil filter assembly. Extract dipstick form the oil dip-stick hole. Disconnect fuel return pipes. Remove the fuel filter.

51-67

51. ENGINE

Step 1. 9

2. 3. 1. 2. 3.

Removal Parts Observations Disconnect coolant water pipe from the cooling water pump. Remove thermostat assembly. Remove the cooling water pump. Remove cylinder head mounting screw. 1. Lay a cardboard or the like on the floor and place Remove cylinder head assembly. cylinder head assembly on it so as not to Remove cylinder head gasket. damage the combustion surface. 2. Order of loosening the cylinder head mounting screws.

Head bolt disassembly order 1B. Disassembly 4 cylinder head 1D. Disassembly 3 cylinder head 2C. Camshaft side 3F. Fan side

1. 2. 1. 2. 3. 1.

3. To remove the intake/exhaust valves from cylinder head assembly, take the following steps. • Using a valve spring compressor (see Chapter 51.5, 51.5-1), compress valve spring and remove valve cotter. • Remove valve retainer and valve spring. • Remove intake valve and exhaust valve. Remove crankshaft V-pulley mounting screw. 1. Extract crankshaft V-pulley by hitting the screw Using a puller, extract crankshaft V-pulley. of the puller using a plastic hammer or the like. Remove oil pan mounting screw under gear 1. Never fail to remove the reinforcing screw from case. the centre of the gear case. Remove gear case mounting screw. 2. When removing the gear case, carefully protect Remove gear case oil seal from damage. Remove the nut from fuel injection pump drive 1. Before removing fuel injection pump, make sure gear. Extract fuel injection pump drive gear using of the position of the arrow of the pump body for a puller. adjusting fuel injection timing as well as the position of the scribed line of the gear case flange. (Applies only to direct injection system.)

51-68

51. ENGINE

Step 14 15 16

Removal Parts 1. Remove lubricating oil pump.

Observations

1. Remove starting motor from flywheel housing sing. 1. Remove the flywheel mounting screw. 1. 2. Remove the flywheel. 1. Remove flywheel housing. 1. 2. Remove oil seal case with a screwdriver or the like by utilizing grooves on both sides of oil seal case. 1. Remove oil pan and spacer. 1. 2.

20 21

1. Remove idle gear shaft, and then remove idle 1. gear. 2. Remove the mounting screw of thrust bearing 2. through the hole of the camshaft gear. Remove camshaft assembly. 1. Remove gear case flange.

Carefully protect the ring gear from damage. Carefully protect the ring gear from damage mage.

Put the cylinder block with the attaching surface of the cylinder head facing down. Carefully protect the combustion surface of the cylinder block from damage. For indirect injection system, be careful to the possibility of the tapped to drop off when the cylinder block is turned upside down, because the tappet is cylindrical in shape. Turn the cylinder block aside and carefully prevent tappet from jamming on the cam. Preheat camshaft gear and camshaft assembly to 180Â° 200Â° which are shrink fitted, before removing them.

1. Remove lubricating oil strainer. 1. Remove crankpin side cap of the connecting 1. Before extracting piston, remove carbon rod. deposits from the upper wall of the cylinder using While turning crankshaft, place piston in the bottom fine sandpaper, while taking care not to damage dead center (BDC). the inner surface of the cylinder. 2. Make sure that the No. of the protection of the connecting rod matches the No. of the cylinder. 3. Take care not to let crankpin metal fall when removing connecting rod crankpin side cap.

51-69

51. ENGINE Step

Removal Parts Observations 1. Remove the main bearing cover screw. While 1. Before extracting crankshaft, measure the side shaking main bearing cap, remove main bearing gap around it. cap together with lower main bearing metal. 2. Extract crankshaft, taking care not to damage it. 3. Remove upper main bearing metal.

1. Remove piston and connecting rod assembly.

1. Remove tappet.

51-70

Apply a dial gauge (D1) to the end of crankshaft (C2). Force the crankshaft on both sides in the axial direction to measure the thrust gap. Alternatively, insert a thickness gauge directly between the base thrust metal and the thrust surface of the crankshaft to measure the gap. If the limit size is exceeded, replace the thrust metal with a new one. Thrust gap (All models) 2. Notice on the removal of thrust metal. • When removing thrust metal, ascertain the position and direction where thrust metal is installed in relation to the cap. • Make sure that the thrust metal groove is outward in relation to the cap. 1) To selectively remove a desired piston and connecting rod assembly without extracting crankshaft, take the steps itemized below: • Remove carbon deposits from the upper wall of the cylinder using fine sandpaper, taking care not to damage the inner surface of the cylinder. • While turning the crankshaft, with the connecting rod cap removed, raise the piston up to the top dead center (TDC). • Extract the piston rod/connecting rod assembly while tapping the connecting rod at the large end with the handle of a plastic hammer or the like.

51. ENGINE 51.4.1.4 Precautions before and during reassembly To reassemble the engine components, follow the disassembly procedure in reverse order. However, follow the precautions below and the precautions from in chapter 51.4 to in chapter 51.7 particularly before and during reassembly. 1. Cleaning the component Use particular care to clean the cylinder block, cylinder head, crankshaft, and camshaft. Ensure that they are free from chips, dust, sand, and other foreign matter. 2. Parts to be replaced during reassembly Be sure to replace the following parts with new ones during assembly. • Valve rod gasket • Head gasket packing • Nozzle protector and nozzle seat of the fuel injection valve • Various copper packing, O-rings and gasket packing.

51.4.1.5 Adjusting operation Make sure to perform adjusting operation after completing reassembly. Refer to section 51.2.5 for the operation procedure.

51-71

51. ENGINE 51.4.2

CYLINDER HEAD: DISASSEMBLY, INSPECTION AND REASSEMBLY

51.4.2.1 Components (2-valve cylinder head) NOTE: This figure show the 3TNV84

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Oil cooler Fan Thermostat Fuel filter V-pulley Oil screen Fuel injection valve Inlet manifold Exhaust manifold Rocker arm cover

11. 12. 13. 14. 15. 16. 17. 18. 19.

51-72

Spacer Oil / water separator Coolant pump Gear case Cylinder block Head gasket packing Thermo switch Cylinder head Joint

51. ENGINE 51.4.2.2 Disassembly procedure: Disassemble in the order of the numbers shown in the illustration. • Remove the alternator assy. (Point 1) • Remove the fan, pulley and V belt. • Remove the thermostat case. (Point 2) • Remove the fuel filter and fuel oil piping. (Point 3) • Remove the oil level gauge assy. • Remove the oil filter. (Point 4) • Remove the fuel injection pipes. (Point 5) • Remove the intake manifold assy. • Remove the exhaust manifold assy. • Remove rocker arm cover assembly. • Remove the rocker shaft assy, push rods and valve caps. (Point 6) • Remove the cylinder head assy and head gasket. (Point 7) • Remove the fuel injection valves and fuel return pipe. (Point 8) • Remove the intake/exhaust valves, stem seals and valve springs. (Point 9) • Remove the rocker arms from the rocker shaft.

51-73

51. ENGINE 51.4.2.3

Reassembly procedure:

Reverse order of the disassembly procedure. 1. Rocker arm cover 2. Rocker arm shaft 3. Adjustment 4. Rocker arm 5. Rocker arm support 6. Intake valve 7. Exhaust valve 8. Cylinder head 9. Split pin 10. Spring holder 11. Valve spring 12. Stem seal 13. Valve guide 14. Valve bridge 15. Valve cap

51-74

51. ENGINE 51.4.2.4 Servicing points Point 1 Disassembly • Loosen the mounting screws while supporting the alternator (A).

CAUTION Do not tilt the alternator (A) towards the cylinder block in haste since it may damage the alternator or pinch a finger. Reassemble • The belt (2) deflection shall be checked according to 51.2.2.2. Reassemble • Replace the belt (4) with a new one if cracked, worn or damaged. • Carefully prevent the belt from being smeared with oil or grease.

1. Set screw 3. Generator Point 2 Reassemble Check the thermostat function. (See 51.2.7) Point 3 Reassemble • Replace the fuel filter element with a new one. Disassembly • Cover the fuel pipe opening with tape to prevent intrusion of foreign matters.

51-75

5. C.W. pump 6. Crank pulley

51. ENGINE

Point 4 Reassemble • Replace the oil filter with a new one. • After fully tightening the filter manually, retighten it with a filter wrench (see 51.11.1-6) by 3/4 turn. Point 5 Disassembly • Cover the fuel injection pipe (8) and pump inlets and outlets with tape or the like to prevent intrusion of foreign matters. Point 6 1. Removing pipe seals (7) of 4-valve head. Disassembly • Take off a rocker arm cover in case of 4-valve head after removing fuel injection pipes (8) and pipe seals (7). NOTE: Attention is necessary because a fuel nozzle (9) is caught in a pipe seal and the pipe seal is damaged when a rocker arm cover is lifted with a pipe seal sticking to the rocker arm cover. • Insert a minus screwdriver (12) in the slit part of the rocker arm cover (10), and remove it when removing a pipe seal. Reassemble • Replace the used pipe seal (11) with a new one when removing a pipe seal.

13. Cap nut of fuel injection pipe

51-76

51. ENGINE

2. Breather system (A reductor to intake air system of blow-by gas) Emitting blow-by gas is harmful to natural environment. Therefore blow-by gas reductor is adopted to TNV series naturally- aspirated engines as breather system (Turbocharged engines emit blow-by gas). The system of model 3/4TNV84 is shown as a representative of that breather system in the right figure. Some of the combustion gas (16) passes through the clearance between the cylinder and the piston, piston ring, and flows to the crankcase. This is called blow-by gas (16). While it passes into the cylinder head and the rocker arm cover (RA), the blow-by gas mixes with splash oil and becomes sprayed-oil-mixed-with-blow-by-gas passing through the baffle plate (BP) inside a rocker arm cover (RA). And it passes through a diaphragm assy, and an intake manifold (IM), and is reduced in the combustion chamber. Pressure inside a crankcase is controlled by the function of the diaphragm assy, and suitable amount of blow-by gas is reduced in intake air system. Disassembling When a rocker arm cover (RA) is taken off, check whether oil or the like enter the diaphragm (D) space from a small hole on the side of a diaphragm cover or not without disassembling the diaphragm.

14. Cover 18. Diaphragm part 15. Center plate 17. Blow-by gas flow to diaphragm space

51-77

51. ENGINE

NOTE: 1. When a diaphragm (D) is damaged, pressure control inside the crankcase becomes insufficient, and troubles occur. When the internal pressure of the crankcase decreases too much due to the damage of a spring (S), much blow-by gas containing oil is reduced in intake air system, and it may cause the combustion defect by the early dirt of the intake valve or the urgent rotation of the engine by the oil burning. When pressure progresses in the crank case too much due to the wrong operation of the diaphragm and so on, it is considered that oil leakage from the joint of a oil pan, a oil seal and so on will occur. When a diaphragm (D) is damaged, blow-by is discharged from the breathing hole on the side of diaphragm cover, and not reduced in the intake manifold (IM). Therefore, be careful of the diaphragm trouble. 2. At lubricating oil replacement or lube oil supply The amount of lubricating oil isnâ&#x20AC;&#x2122;t to be beyond the standard upper limit (in the engine horizontallity, the up per limit mark of the dip stick). Since the blow-by gas reductor is adopted, be careful that the amount of oil mist may be inducted in the combustion chamber and the oil hammer sometimes may occur, when the lubricating oil quantity is beyond the upper limit or an engine is operated beyond the allowable maximum angle of an engine. Reassemble Replace the diaphragm with new one, when it is damaged.

51-78

51. ENGINE

Point 7 Disassembly • Keep the removed push rods by attaching tags showing corresponding cylinder Nos. Reassemble • Always apply oil to the contact portions of the push rods and clearance adjusting screws. Point 8 Disassembly • Loosen the cylinder head screws in two steps in the given order. • Place the cylinder head assy on a paper board to prevent the combustion face from any damage. Reassemble • Remove the head gasket with a new one. • Uniformly install the head screws manually after applying oil on the threaded and seat portions. • They shall be tightened in two steps in the reverse of the order for disassembly. • Tightening torque Nm TNV82A TNV84-88 First step 30.0 ÷ 34.0 41.1 ÷ 46.9 Second step 61.7 ÷ 65.7 85.3 ÷ 91.1

First step Second step

4TNV94L/98

4TNV106(T)

49.0 ÷ 58.8 103.1 ÷ 112.9

88.3 ÷ 98.1 188.0 ÷ 197.8

19. Fan side 20. Camshaft side

Point 9 Disassembly • Carefully remove the fuel injection valve so as not to leave the top end protector from being left inside the cylinder. Reassemble • Replace the fuel filter element with a new one.

51-79

21. Assembly 22. Disassembly

51. ENGINE

Point 10 Disassembly • When removing each intake/exhaust valve from the cylinder head, use a valve spring compressor (see 51.11.1-4) and compress the valve spring and remove the valve cotter). • Keep each removed intake/exhaust valve after attaching a tag showing the corresponding cylinder No. • If cotter burr is seen at the shaft of each intake/exhaust valve stem, remove it with an oilstone and extract the valve from the cylinder head. Reassemble • Replace the stem seal with a new one when an intake/exhaust valve is disassembled. • Carefully install each valve after oil application so as not to damage the stem seal. • Different stem seals are provided for the intake and exhaust valves. Do not confuse them since those for exhaust valves are marked with yellow paint. • After assembling the intake/exhaust valve, stem seal, valve spring, seat, and cotter, tap the head of the valve stem lightly for settling. • Do not forget to install the valve cap.

51.4.2.5 Inspection and measurement of parts 1. Cylinder head Clean the cylinder head, mainly the combustion surface, valve seats and intake/exhaust ports, remove carbon deposit and bonding agent, and check the surface state. (a) Appearance check Check mainly discoloration and crack. If crack is suspected, perform color check. (b) Combustion surface distortion Apply a straight-edge (1) in two diagonal directions and on four sides of the cylinder head, and measure distortion with a thickness gauge (2). mm Standard value Limit value Distortion 0.05 or less 0.15

51-80

51. ENGINE

(c) Valve sink Measure with the valve inserted to the cylinder head. (Depth micrometer (3)) mm Standard value Limit value 3TNV82A Inlet 0.35 ÷ 0.55 0.8 (2-valve head) Drain 0.30 ÷ 0.50 0.8 4TNV84 Inlet 0.30 ÷ 0.50 0.8 3TNV84(T) 3/4TNV88 Drain (2-valve head) 0.30 ÷ 0.50 0.8 4TNV84(T) 4TNV94/ 98(T)

Inlet Drain

(4-valve head)

4TNV106(T) Inlet (4-valve head) Drain

0.36 ÷ 0.56

0.8

0.35 ÷ 0.55

0.8

0.5 ÷ 0.7 0.7 ÷ 0.9

1.0 1.2

4. Valve sinking depth (d) Seat contact Apply a thin coat of minium on the valve seat (5). Insert the valve in the cylinder and push it against the seat to check seat contact. Standard: Continuous contact all around

51-81

51. ENGINE

2. Valve guide Mainly check damage and wear on the inside wall. Apply the service part code when replacing a part.

6. Measuring positions

7. Measuring positions Valve stem clearance Model Part name Intake value 3TNV82A (2-valve head) Exhaust value

4TNV84 3TNV84(T) 3/4TNV88 (2-valve head)

Intake value

Exhaust value

Intake value 4TNV84T (4-valve head) Exhaust value

4TNV94L 4TNV98(T) (4-valve head) 4TNV106(T) (4-valve head)

Intake value

Exhaust value

Intake value

Exhaust value

Position Valve guide inside Rod outer diameter Tolerance Valve guide inside Rod outer diameter Tolerance Valve guide inside Rod outer diameter Tolerance Valve guide inside Rod outer diameter Tolerance Valve guide inside Rod outer diameter Tolerance Valve guide inside Rod outer diameter Tolerance Valve guide inside Rod outer diameter Tolerance Valve guide inside Rod outer diameter Tolerance Valve guide inside Rod outer diameter Tolerance Valve guide inside Rod outer diameter Tolerance

51-82

Standard value 7,000 ÷ 7,015 6,945 ÷ 6,960 0,040 ÷ 0,070 7,000 ÷ 7,015 6,940 ÷ 6,955 0,045 ÷ 0,075 8,010 ÷ 8,025 7,955 ÷ 7,975 0,035 ÷ 0,070 8,015 ÷ 8,030 7,955 ÷ 7,970 0,045 ÷ 0,075 6,000 ÷ 6,015 5,960 ÷ 5,975 0,025 ÷ 0,055 6,000 ÷ 6,015 5,945 ÷ 5,960 0,040 ÷ 0,070 7,000 ÷ 7,015 6,945 ÷ 6,960 0,040 ÷ 0,070 7,000 ÷ 7,015 6,940 ÷ 6,955 0,045 ÷ 0,075 7,008 ÷ 7,020 6,960 ÷ 6,975 0,033 ÷ 0,060 7,008 ÷ 7,020 6,945 ÷ 6,960 0,048 ÷ 0,075

mm Limit value 7,08 6,90 0,18 7,08 6,90 0,18 8,10 7,90 0,18 8,10 7,90 0,18 6,08 5,90 0,15 6,08 5,90 0,17 7,08 6,90 0,17 7,08 6,90 0,17 7,08 6,92 0,16 7,08 6,90 0,18

51. ENGINE

3. Intake/exhaust valve Mainly clean and check damage and wear at the valve stem and seat. (a) Seat contact: See (1)-(d) above. (b) Stem outside diameter: See (2) above. (c) Valve head thickness (8) mm Model Piece Standard value Limit value Inlet 1.34 0.50 TNV82A~88 Drain 1.45 0.50 Inlet 1.71 1.00 4TNE94·95 Drain 1.65 1.00 Inlet 2.00 1.30 4TNE106(T) Drain 2.00 1.30 (d) Valve stem bend mm Limit value 0.01 (e) Overall length mm Standard value Limit value 3TNV82A

Intake/ Exhaust

Intake/ Exhaust Intake/ 4TNV94·98 Exhaust Intake/ 4TNV106(T) Exhaust

9. Length

TNV84~88

115

114.5

126

125.5

4. Valve spring Mainly inspect damage and corrosion. Free length standard 3TNV82A 44.4 TNV84~88 42.0 4TNV94·98 47.5 4TNV106(T) 50.6

mm Inclination limit 1.2 1.2

11. Free length

12. Inclination

51-83

10. Stool

51. ENGINE

5. Valve rocker arm Mainly inspect valve head cap contact surface, inside surface defects and wear. Slight surface defects shall be corrected with an oilstone. mm Limit Model Piece Standard value value Arm hole 16.00 ÷ 16.02 16.07 diameter Shaft TNV82A~88 outside 15.97 ÷ 15.98 15.94 diameter Tolerance 0.016 ÷ 0.054 0.13 Arm hole 18.50 ÷ 18.52 18.57 diameter 4TNV94/98(T) Shaft 18.47 ÷ 18.49 18.44 4TNV106(T) outside diameter Tolerance 0.01 ÷ 0.05 0.13

6. Rocker arm shaft Mainly inspect seizure and wear at the surface in sliding contact with the arm. The rocker shaft diameter shall be as specified in (5.5) above.

7. Push rod Mainly inspect the surface in contact with the tappet and adjusting screw. Slight surface defects shall be corrected with an oilstone. Bend limit 0.03 mm or lower 8. Valve clearance adjusting screw Mainly inspect the surface in contact with the push rod. Slight surface defects shall be corrected with an oilstone. 9. Rocker arm spring Mainly inspect surface defects and corrosion.

51-84

51. ENGINE 51.4.2.6 Valve seat correction

NOTE: Always check the oil clearance between the valve and valve guide before correcting the valve seat. If it exceeds the limit, replace the valve or valve guide first to make the clearance satisfy the standard. After correction, wash the valve and the cylinder head sufficiently with diesel oil to remove all grinding powder or compound.

1. If the seat surface is slightly roughened: perform (A) and (B) as described below. (A): Lap the valve and seat with a mixture of valve compound and engine oil. (B): Lap with engine oil only. 2. If the seat is heavily roughened but the width is almost normal, correct with a seat grinder or seat cutter (3) first. Then perform lapping (A) and (B). Seat cutter angle

Inlet 120

Drain 90

1. Seat angle 2. Seat width

3. If the seat is heavily roughened and the width is much enlarged, grind the seat inner surface with a seat grinder (4) whose center angle is 40°, then grind the seat outer surface with a grinder whose center angle is 150° to make the seat width match the standard. Then perform seat correction as described in 2), and then carry out lapping (A) and (B).

Grinding wheel angle

1 40

2 150

5. Grindstone

51.4.2.7 Valve guide replacement 1. Use a valve guide extraction tool (51.12.1-1) and extract the valve guide from the cylinder head. 2. Put liquid nitrogen or ether (or alcohol) with dryice added in a container and put the valve guide for replacement in it for cooling. Then insert it in with a valve guide inserting tool (Refer to No. 2 of 51.4.1.2).

CAUTION Do not touch the cooled valve guide with bare hands to avoid skin damage. 3. Check the inside diameter and finish to the standard inside diameter as required with a reamer.

51-85

51. ENGINE

4. Check the projection from the cylinder head. mm Model 3TNV82A 4TNV84 3TNV84(T) 4TNV88 4TNV84T 4TNV94L 4TNV98(T) 4TNE106(T)

Number of valves

Projection 11,7 ÷ 12,0

2 valves

14,7 ÷ 15,0 8,2 ÷ 8,5

4 valves

9,7 ÷ 10 13,4 ÷ 13,6 6. Valve guide extracting 7. Projection and inserting tool 8. Valve guide 9. Cylinder head

51.4.2.8 Valve stem seal replacement Always use a new seal after the intake/exhaust valve is disassembled. Since the one for the exhaust valve is marked with yellow paint, do not confuse the intake and exhaust valves. 1. Apply engine oil to the lip. 2. Push with the inserting tool (Refer to No.5 of 51.4.1.2) for installation.

10. Valve stem seal insert- 12.Valve guide ing tool 13.Cylinder head 11. Stem seal 3. Measure and check the projection of valve stem seal to keep proper clearance between valve guide and stem seal. mm Number of Model Projection valves 3TNV82A 15.7 ÷ 16.0 4TNV84 2 valves 3TNV84(T) 18.7 ÷ 19.0 4TNV88 4TNV84T 9.9 ÷ 10.2 4TNV94L 4 valves 11.7 ÷ 12.0 4TNV98(T) 4TNE106(T) 15.4 ÷ 15.6 14. Stem seal 15. Valve guide 16. Tolerance

51-86

17. Stem seal projection 18. Valve guide projection

51. ENGINE 51.4.3

GEAR TRAIN AND CAMSHAFT

51.4.3.1 Components NOTE: This figure shows the 3TNV84

1. 2. 3. 4. 5. 6. 7. 8.

Camshaft driving gear Coolant pump Crankshaft pulley Gear case Fuel injection pump Idler gear Crankshaft gear Starter motor

9. 10. 11. 12. 13. 14. 15.

51-87

Flywheel Cam shaft Gear case flange Oil seal Fuel pump spacer Flywheel housing Donâ&#x20AC;&#x2122;t disassemble: pump flange 16, fuel pump drive gear 17, flange bolt 18

51. ENGINE 51.4.3.2 Disassembly procedure Disassemble in the order of the numbers shown in the illustration. • Perform steps 1) to 12) of the cylinder head disassembly procedure. • Remove the cooling water pump. • Remove the crankshaft pulley. (See Point 1 of 51.4.3.4) • Remove the gear case cover. (See Point 2 of 51.4.3.4) • Remove the fuel injection pump. (See Point 3 of 51.4.3.4) • Remove the idle gear assy. (See Point 4 of 51.4.3.4) • Remove the PTO drive gear. (See Point 5 of 51.4.3.4) • Remove the starting motor. • Remove the flywheel. (See Point 6 of 51.4.3.4) • Remove the camshaft assy. (See Point 7 of 51.4.3.4) • Remove the gear case. (See Point 8 of 51.4.3.4) • Remove the oil seal from the gear case cover. (See 51.4.3.6)

51.4.3.3 Reassembly procedure Reverse order of the disassembly procedure.

51-88

51. ENGINE 51.4.3.4 Servicing points Point 1 Disassembly • Remove the crankshaft pulley using a gear puller after removing the crankshaft pulley setscrew. When removing the pulley using the gear puller, use a pad and carefully operate so as not to damage the thread. Set the gear puller securely to prevent the pulley from being damaged. Reassemble • Apply grease MG2 to the oil seal lips. For the oil seal with double lips dust seal, further slightly apply engine oil on the lips so as not to damage them. • Clean by wiping off any oil on both taper surfaces using detergent. • Be sure to use the crankshaft pulley installing tool so as not to damage the oil seal lips. (See 51.4.3 (6) Oil seal replacement) • When installing the crankshaft pulley, apply lube oil to the setscrew to tension it and carefully assemble so as not to damage the oil seal. Nm Model Tightening torque 3TNV82A~TNV88 112.7 ÷ 122.7 4TNV94L/98/106(T) 107.9 ÷ 127.5 Point 2 Reassemble • When installing the gear case, do not forget to install the two reinforcing screws at the centre. • Measure the backlash of each gear. mm Limit 3TNV82A~88 Standard value value Crankshaft gear (4) Crankshaft gear (2) 0,07 ÷ 0,15 0,17 Fuel injection pump (1) Idle gear (7), PTO gear (3) Lubricating oil pump gear (6) 0,11 ÷ 0,19 0,21 4TNV94L-106(T)

Standard value

Limit value

5. Rotating direction

Crankshaft gear (4) Crankshaft gear (2) 0,08 ÷ 0,14 0,16 Fuel injection pump (1) Idle gear (7), PTO gear (3) Balancer gear 0,12 ÷ 0,18 0,20 (only 4TNV106(T)). Lubricating oil pump gear (6) 0,09 ÷ 0,15 0,17 • Apply sealant and install the gear case by correctly positioning the two dowel pins.

51-89

51. ENGINE

Point 3: (Refer to 51.7.2.5) Disassembly • Remove the mounting nut of the fuel injection pump drive gear, remove the gear using the gear puller, and remove the fuel injection pump. Do not forget to remove the stay on the rear side. When extracting the gear using the gear puller, use a pad at the shaft and carefully operate so as not to damage the thread. Reassemble • Tightening torque for fuel pump drive gear nut (without lube oil). Nm Model Tightening torque TNV82A~88 78 ÷ 88 4TNV94L/98/106(T) 113 ÷ 123 Point 4 Reassemble • Assemble crankshaft gear A, fuel injection pump drive gear B and camshaft gear C at the same time by aligning with idle gear A, B and C marks. • Install the idle gear shaft with the oil hole facing upward. Point 5 Reassemble • Install the PTO drive gear with its inner spline side facing the flywheel.

51-90

51. ENGINE

Point 6 Disassembly • Install a screw to be used as a handle in the hole at the end face of the flywheel and remove carefully so as not to damage the ring gear. Reassemble • Flywheel mounting screw: apply lube oil Nm Model 3TNV82A~88 4TNV94L/98/106(T)

Tightening torque 83.3 ÷ 88.2 186.2 ÷ 205.8

Point 7 Disassembly Measure the camshaft side gap (10). mm Piece Standard value Side gap 0.05 ÷ 0.20

Limit value 0.30

• If the measured side gap (10) exceeds the limit, replace the thrust metal (9).

Disassembly • Since the camshaft gear (8) is shrink-fit, heat it to 180 °C ÷ 200 °C for extraction. • For camshaft removal, raise the engine with its mounting flange at the bottom. After removing the thrust metal mounting screw from the camshaft gear hole, extract the camshaft carefully so as not to damage the bearing bushing. • Rotate the camshaft a few turns before extracting it to prevent the tappet from being caught by the cam. • After removing the camshaft, set the engine horizontal and fix it on the base.

CAUTION Unforeseen injury may arise due to falling of slipping when raising the engine vertically or returning it to the horizontal position. Proceed carefully so as not to lose balance.

51-91

51. ENGINE

Point 8: Gear case Reassemble • Do not forget to install the oil pan mounting screws on the bottom side when installing the gear case. • Apply sealant and install the gear case by matching the two dowel pins.

51.4.3.5 Inspection and measurement of parts 1. Cam shaft Mainly check the contact between the tappet and cam contact surface, bearing seizure and wear, and gear damage. (a) Shaft bend measurement Support the camshaft with V blocks (12). Rotate the camshaft and measure the runout at the center of the camshaft and at each journal with a dial gauge (11); half of the runout is the bend. mm Piece Standard value Limit value Bend 0 ÷ 0.02 0.05

(b) Intake/exhaust cam height measurement mm Model Standard value 3TNV82A~88 38.600 ÷ 38.800 4TNV94L·98 43.400 ÷ 43.600 4TNV106(T) 50.900 ÷ 51.100

Limit value 38.350 43.150 50.650

(c) Measurement of camshaft outer diameter and bearing hole diameter. Measure the camshaft outer diameter with a micrometer (13). The oil clearance shall be calculated by subtracting the measured camshaft outside diameter from the camshaft bushing inside diameter after insertion to the cylinder measured with a cylinder gauge.

51-92

51. ENGINE

Model

Position Gear side

3TNV82A~TNV88 Middle position

Flywheel side

Gear side

TNV94L/98(T)

Middle position

Flywheel side

Gear side

4TNV106(T)

Middle position

Flywheel side

Piece Bushing inside diameter Camshaft outside diameter Oil clearance Bushing inside diameter Camshaft outside diameter Oil clearance Bushing inside diameter Camshaft outside diameter Oil clearance Bushing inside diameter Camshaft outside diameter Oil clearance Bushing inside diameter Camshaft outside diameter Oil clearance Bushing inside diameter Camshaft outside diameter Oil clearance Bushing inside diameter Camshaft outside diameter Oil clearance Bushing inside diameter Camshaft outside diameter Oil clearance Bushing inside diameter Camshaft outside diameter Oil clearance

2. Idler gear Mainly check the bushing seizure and wear, and gear damage (18). Measurement of shaft outer diameter (17) and bushing inner diameter. mm Piece Standard value Limit value Shaft outside 45.950 ÷ 49.975 45.900 diameter Bushing inside 46.000 ÷ 46.025 46.075 diameter Tolerance 0.025 ÷ 0.075 0.175 3. PTO drive gear Mainly check sticking of bearings on both sides, gear damage and looseness, and gear shaft damage and wear.

Standard value 44.990 ÷ 45.055 44.925 ÷ 44.950 0.040 ÷ 0.130 45.000 ÷ 45.025 44.910 ÷ 44.935 0.065 ÷ 0.115 45.000 ÷ 45.025 44.925 ÷ 44.950 0.050 ÷ 0.100 49.990 ÷ 50.055 49.925 ÷ 49.950 0.040 ÷ 0.130 50.000 ÷ 50.025 49.910 ÷ 49.935 0.065 ÷ 0.115 50.000 ÷ 50.025 49.925 ÷ 49.950 0.05 ÷ 0.100 57.980 ÷ 58.050 57.910 ÷ 57.940 0.040 ÷ 0.140 58.000 ÷ 58.030 57.895 ÷ 57.925 0.075 ÷ 0.135 58.000 ÷ 58.030 57.910 ÷ 57.940 0.050 ÷ 0.120

15. Idler gear

51-93

16. Shaft

Limit value 45.130 44.890 0.240 45.100 44.875 0.225 45.100 44.890 0.210 50.130 49.890 0.240 50.100 49.875 0.225 50.100 49.890 0.210 58.105 57.875 0.250 58.105 57.860 0.245 58.105 57.875 0.230

51. ENGINE 51.4.3.6 Oil seal replacement (Gear case side) 1. Replace the oil seal with a new one when the gear case is disassembled. Extract the used oil seal. 2. Insert a new oil seal. Fit the position of the oil seal i sertion to the end face of the gear case. (Refer to the below figure). 3. Apply grease to the oil seal tips. For the oil seal with double lips (19) (dust seal), further, slightly apply engine oil on the oil seal lip so as not to damage them, when installing the pulley. NOTE: pay attention not to drop any oil on the taper surface of the crankshaft. If dropped, clean by wiping off using detergent. 4. Carefully install the crankshaft pulley (21) so as not to damage the oil seal lips. Especially for the engine installed the (oil/dust) seal with double lips, be sure to use the crankshaft pulley installing tool (20).

51.4.3.7 Camshaft bushing replacement Replace the bushing using the special service tool (Refer to No. 7 of 51.4.1.2)

51-94

51. ENGINE 51.4.4

CYLINDER BLOCK

51.4.4.1 Components NOTE: This figure shows the 3TNV84.

1. 2. 3. 4. 5. 6. 7.

Oil screen Oil pan spacer Oil pan Oil suction pipe Piston e connecting rod Flywheel housing Bearing cap

8. 9. 10. 11. 12. 13. 14.

51-95

Crankshaft Tappet Piston ring Oil seal case Flywheel Oil seal Gear case flange

51. ENGINE 51.4.4.2 Disassembly procedure: Disassemble in the order of the numbers shown in the illustration. • Perform steps 1) to 12) of the cylinder head disassembly procedure. • Perform steps 1) to 12) in the gear train disassembly procedure. • Remove the oil pan. (See Point 1 of 51.4.4.4) • Remove the lubricating oil suction pipe. • Remove the piston with the rod. (See Point 2 of 51.4.4.4) • Remove the mounting flange (See Point 3 of 51.4.4.4) • Remove the bearing metal caps. (See Point 4 of 51.4.4.4) • Remove the crankshaft. (See Point 5 of 51.4.4.4) • Remove the tappets. • Remove the pistons and rings. (See Point 6 of 51.4.4.4) • Remove the oil seal from the mounting flange. (See 51.4.4.8 of 51.4.4.4)

51.4.4.3 Reassembly procedure: Reverse order of the disassembly procedure.

51.4.4.4 Servicing points Point 1: Oil pan Disassembly • Sealant is applied to the oil pan mounting surface on the block. Carefully operate so as not to damage or distort the bonding surface. Reassemble • Apply sealant before reassembly. Point 2: Piston w/rod Disassembly • Measure the connecting rod side gap. mm Standard value 0.20 ÷ 0.40 • Carefully remove the carbon deposit on top of the cylinder so as not to damage the inner side of the cylinder.

1. Thickness gauge

51-96

2. Crankshaft

51. ENGINE

• Set the piston at the BDC position and remove the connecting rod cap. Then set the piston at the TDC (top dead centre) position, and push the connecting rod big end with a wooden bar or a hammer. Proceed carefully so as not to cause the cylinder block catch the rod big end. Set the rod caps and crankpin metals in their correct combinations. Reassemble • Apply oil especially carefully to the sliding contact surfaces of the pistons, rods and rings. • Use the piston insertion tool (see 51.12.1-9) to insert each piston w/rod in the cylinder block and install the bearing metal cap. Rod bolt tightening torque Nm Model Standard (apply lube oil) 3TNV82A 37.2 ÷ 41.2 TNV84~88 44.1 ÷ 49.0 4TNV94L·98 53.9 ÷ 58.8 4TNV106(T) 78.5 ÷ 83.4 Point 3: mounting flange Disassembly Place the engine on a stable base with the cylinder block upper surface facing down, and remove the mounting flange carefully so as not to damage the combustion surface. Reassemble Apply sealant and install the mounting flange by matching the two dowel pins. After assembly, raise the engine with its mounting flange on the bottom side.

CAUTION Unforeseen injury may arise due to falling of slipping when raising or reversing the engine. Proceed carefully so as not to lose balance.

51-97

51. ENGINE

Point 4: journal bearing cap Disassembly • Before removing the journal bearing, measure the crankshaft side gap. Measure it in either method because there are the next two methods. 1. Install a dial gauge on the cylinder block (3), and move the crankshaft (4) forwards and backwards, and measure the side gap as shown in the figure on the right.

2. Put a thickness gauge (7) directly in the clearance between the thrust metal (5) and the crankshaft (4), and measure clearance. Side gap standard mm Model Standard value Limit value All models 0.13 ÷ 0.23 0.28 Reassemble • If the side gap exceeds the standard, replace the thrust metal (5) with an oversize one. Machine the standard width (8) of the crankshaft thrust part into the dimension of the below table at the same time. Refer to a parts catalogue when ordering the part.

6. Bearing cap

The surface finishing precision (refer to 51.4.4.5(2): 1,6 0.25 mm Oversized thrust metal (0.25 DS) mm 0.25 DS 3TNV82A TNV84~88 4TNV94L·98 4TNV106(T)

Standard thickness 2.055 ÷ 2.105 2.055 ÷ 2.105 2.055 ÷ 2.105 2.555 ÷ 2.605

The standard width of the crankshaft thrust part mm Model 3TNV82A TNV84~88 4TNV94L·98 4TNV106(T)

Standard thickness 25.250 ÷ 25.271 28.250 ÷ 28.271 32.250 ÷ 32.275 36.250 ÷ 36.275)

51-98

9. Thrust face

51. ENGINE

Disassembly • Remove the bearing caps, cap side bearings, and thrust metals (14). Place each thrust metal with identification of the position and direction. The position number of reassembling is punched on a metal cap (except for both ends) and a cylinder block.

10. Flywheel side 13. Block side main bear11. Gear side ing metals 12. Cap side main bearing metals Reassemble • Carefully install each thrust metal so that the grooved one is positioned away from the cap. • Do not confuse the upper (15) and lower (17) main bearing metals. The main bearing upper rings (block side) (15) have a hole (16), which the lower rings do not have. The “arrow” mark on the cap (22) shall face the flywheel. Tighten the screws of the cap of the main bearing (18). 19. Thrust metal Main bearing cap screw tightening torque (apply lube oil) Nm Model Standard thickness 3TNV82A 76,4 ÷ 80,4 TNV84~88 93,2 ÷ 98,1 4TNV94L·98 108,1 ÷ 117,9 4TNV106(T) 186,2 ÷ 205,8

21. Mark

51-99

20. Groove

51. ENGINE

Point 5: Crankshaft Disassembly • Remove the crankshaft. Remove each main bearing metal upper (block side) and pair it with the metal cap side lower metal.

CAUTION Carefully prevent damage to the bearing or finger injury when removing the crankshaft because it is heavy.

Point 6: Piston pin and rings Disassembly • Using the piston ring replacer (see 51.4.1.2), remove the piston rings. • Remove the circlip and remove the piston pin by pushing it out.

Reassemble • Install each piston ring on the piston, with the punched manufacturer’s mark facing upward (23). Reassemble • The piston ring joints shall be staggered at 120° intervals. Do not position the top ring joint vertical to the piston pin. The coil expander joint shall be opposite to the oil ring joint.

24. Oil ring joint 25. Second ring joint

51-100

26. Top ring joint 27. Expander joint

51. ENGINE

Reassemble â&#x20AC;˘ When installing the piston pin to the rod and piston, the punched match mark on the big end of the connecting rod shall be opposite to the size mark on the piston top. Reassemble â&#x20AC;˘ Install the piston in the cylinder clock with the punched mark on the big end of the rod on the nozzle side. (The embossed mark at the connecting rod I-beam section shall be on the flywheel side).

28. 29. 30. 31.

Camshaft side Nozzle side Piston ID mark Flywheel side Cylinder size mark

34. Engraved mark 35. Camshaft side

51-101

32. Embossed mark (Flywheel side) 33. Match mark

36. Flywheel side

51. ENGINE 51.4.4.5 Inspection and measurement of parts 1. Cylinder block Especially clean head surface, cylinder bores and oil holes, and check after removing any carbon deposit and bonding agent. (a) Appearance check Check if there is any discoloration or crack. If crack is suspected, perform color check. Sufficiently clean the oil holes and check they are not clogged. (b) Cylinder bore and distortion Measure at 20 mm (0.78) below the crest of the liner, at 20 mm (0.78) from the bottom end and at the center. Roundness: Roundness is found as follows though it is the simple method. Measure cylinder diameters of the A direction and the B direction on each section of a, b and c. Roundness is the maximum value among those difference values. Cylindricity: Cylindricity is found as follows though it is the simple method. Measure cylinder diameters of a, b and c sections in the A direction, and calculate the difference in maximum value and minimum value of the measured diameters. In the same way measure and calculate the difference in the B direction. Cylindricity is the maximum value between those difference values.

mm Piece

Cylinder inside diameter

Cylinder bore

Roundness Cylindricity

Model 3TNV82A TNV84 TNV88 4TNV94L 4TNV98 4TNV106(T) all TNV

51-102

Standard value 82,000 ÷ 82,030 84,000 ÷ 84,030 88,000 ÷ 88,030 94,000 ÷ 94,030 98,000 ÷ 98,030 106,000 ÷ 106,030

Limit value 82,200 84,200 88,200 94,130 98,130 106,130

0.01 or less

0,03

51. ENGINE

(c) If the limit is exceeded or any surface defect is found, repair by boring and honing. Use an oversized piston (and new piston rings) as required. Oversized piston (0.25 mm (0.0008), with piston rings) Model Standard (mm) 3TNV82A 82.250 3TNV84(T) 84.250 4TNV84 4TNV84T 84.250 3/4TNV88 88.250 4TNV94L 94.250 4TNV98 98.250 4TNV106 106.250 4TNV106T 106.250 Cylinder dimension after boring and honing Cylinder dimension Model (mm) 3TNV82A 82.250 ÷ 82.280 3TNV84(T) 84.250 ÷ 84.280 4TNV84 3/4TNV88 88.250 ÷ 88.280 4TNV94L 94.250 ÷ 94.280 4TNV98 98.250 ÷ 98.280 4TNV106(T) 106.250 ÷ 106.280

Honing angle (deg.)

Surface roughness

Roundness/Cylindricity (mm)

30 ÷ 40 degrees

Rmax 1.0 ÷ 3.5

0.01 or less

2. Crankshaft Mainly check seizure and wear of the crankpins and journals. Since the crankshaft gear is shrink-fitted, heat to 180° to 200° when extraction is necessary. (a) Shaft portion color check After washing the crankshaft, inspect it by means of color check or a magnaflux inspector. Replace it if cracked or heavily damaged. Slight defects shall be corrected by grinding.

51-103

51. ENGINE

(b) Crankshaft bend Support the crankshaft journals at both ends with Vblocks (40). Use a dial gauge (39) and measure the runout (38) at the center journal while rotating the shaft to inspect the bend (37). Limit value 0.02 mm or lower

(c) Crankpin and journal measurement Measure the outer diameter, roundness and taper at each crankpin (42) and journal. Correct by grinding if unevenly wear, roundness exceeding the limit or insufficient outside diameter is found. Replace if the defect is excessive.

41. Crankshaft journal

51-104

51. ENGINE

Crankpin mm Model and Item Standard value 3TNV82A Pin outside diameter 42.952 ÷ 42.962 Metal thickness 1.487 ÷ 1.500 Oil clearance 0.038 ÷ 0.090 TNV84~88 Pin outside diameter 47.952 ÷ 47.962 Metal thickness 1.492 ÷ 1.500 Oil clearance 0.038 ÷ 0.074 4TNV94L·98 Pin outside diameter 57.952 ÷ 57.962 Metal thickness 1.492 ÷ 1.500 Oil clearance 0.038 ÷ 0.074 4TNV106(T) Pin outside diameter 63.952 ÷ 63.962 Metal thickness 1.984 ÷ 1.992 Oil clearance 0.054 ÷ 0.090 If the oil clearance exceeds the limit, use an undersized bearing.

Limit value 42.902 0.150 47.902 0.150 57.902 0.150 63.902 0.150

Undersized crankpin bearing (0.25 mm) Model Standard thickness mm 3TNV82A 1.612 ÷ 1.625 TNV84~88 1.617 ÷ 1.625 4TNV94L·98 1.617 ÷ 1.625 4TNV106(T) 2.109 ÷ 2.117 Pin machining dimension Model Pin machining dimension mm 3TNV82A Ø 42.702 ÷ 42.712 TNV84~88 Ø 47.702 ÷ 47.712 4TNV94L·98 Ø 57.702 ÷ 57.712 4TNV106(T) Ø 63.702 ÷ 63.712 Crank journal mm Model and Item Standard value 3TNV82A Journal outside diameter 46.952 ÷ 46.962 Metal thickness 1.987 ÷ 2.000 Oil clearance 0.038 ÷ 0.080 TNV84~88 Journal outside diameter 53.952 ÷ 53.962 (Selective assembly) Metal thickness 1.995 ÷ 1.990 Oil clearance 0.038 ÷ 0.068 4TNV94L·98 Journal outside diameter 64.952 ÷ 64.962 (Selective assembly) Metal thickness 1.995 ÷ 2.010 Oil clearance 0.038 ÷ 0.068 4TNV106(T) Journal outside diameter 75.952 ÷ 75.962 (Selective assembly) Metal thickness 2.488 ÷ 2.503 Oil clearance 0.052 ÷ 0.082 If the oil clearance exceeds the limit, use an undersized bearing.

51-105

Limit value 46.902 0.150 53.902 0.150 64.902 0.150 75.902 0.150

51. ENGINE

Undersized crankpin bearing (0.25 mm) Model Standard thickness (mm) 3TNV82A 2.112 ÷ 2.125 TNV84~88 2.112 ÷ 2.125 4TNV94L·98 2.112 ÷ 2.125 4TNV106(T) 2.605 ÷ 2.618 Crankshaft Journal machining dimension Model Pin machining dimension (mm) 3TNV82A Ø 46.702 ÷ 46.712 TNV84~88 Ø 53.702 ÷ 53.712 4TNV94L·98 Ø 64.702 ÷ 64.712 4TNV106(T) Ø 75.702 ÷ 75.712 • Dimension R and finishing precision of crankshaft journal and pin As for grinding processing of journal and pin, machine it by using the grinding wheel of the dimension R of below table. Surface finishing precision standard on journal and pin: Ry = 0.8S surface polishing (43) Surface finishing precision standard on the thrust side of crankshaft arm: 1,6 44. Crankpin mm Model 3TNV82A TNV84~88 4TNV94L·98(T) 4TNV106(T)

Standard thickness 3.5 + 0.3/ 0 94.0 + 0.3/ 0

51-106

45. Crank journal

51. ENGINE

NOTE: lf the oil clearance is excessive though the thicknesses of the journal and crankpin metals are normal or if partial uneven wear is observed, re-grind the crankshaft and use an oversized metals. lf rust or surface roughening exists on the rear side of the metals, coat it with blue or minimum. Then assemble the crankpin metal to the connecting rod, and tighten the rod screw to the specified torque to check the metal for contact. lf the contact surface occupies 75% or more, the metal is normal. lf the contact surface is smaller, the metal interference is insufficient. Replace the metal with a new one.

• Thrust metal inspection (a) Inspect any damage or wear. (b) Measure side gap and thrust metal thickness Side gap and thrust metal thickness mm Side gap Model Standard value Limit value TNV82A~88 0.14 ÷ 0.22 4TNV94L·98 0.13 ÷ 0.23 4TNV106(T) 0.13 ÷ 0.23 If the side gap is exceeded, use an oversized thrust metal. Oversized metal (0.25 mm) Model Standard thickness mm 3TNV82A 2.15 TNV84~88 2.15 4TNV94L·98 2.055 ÷ 2.105 4TNV106(T) 2.555 ÷ 2.605 3. Piston Especially clean the combustion surface, circumference, ring grooves and piston pin hubs, and check after removing any carbon deposit. Any burr at a ring groove or snap ring groove shall be removed. If crack is suspected, perform color check. (a) Piston outside diameter measurement Measure the long diameter at H mm from the bottom end of the piston of the oval hole in the vertical direction to the piston pin hole.

51-107

Thrust metal thickness Standard value Limit value 1.930 ÷ 1.980 1.850 1.930 ÷ 1.980 1.850 2.430 ÷ 2.480 2.35

51. ENGINE

Piston outside diameter Outside diameter Standard value 81.950 ÷ 81.980 83.945 ÷ 83.975 87.945 ÷ 87.975 93.945 ÷ 093.955) 97.940 ÷ 097.950 105.930 ÷ 0105.960

Model 3TNV82A 3,4TNV84(T) 3,4TNV88 4TNV94L 4TNV98(T) 4TNV106(T)

Limit value 81.905 83.900 87.900 93.900 97.895 105.880

If the clearance between piston and cylinder exceeds the limit, use an oversized piston. (Refer to the tables of oversized pistons, oversized piston rings and cylinder boring dimension on 51.4.4.5 (1)(c). (b) Piston pin hole measurement Measurement of piston pin outer diameter and piston pin inner diameter. Calculate the clearance between piston pin and piston pin hole. If any data exceeds the limit, replace the part with a new one.

mm Model

Piece

Pin inner diameter Pin 3TNV82A outside diameter Tolerance Pin inner diameter Pin 3TNV84~88 outside diameter Tolerance Pin inner diameter Pin 4TNV94L 4TNV98(T) outside diameter Tolerance Pin inner diameter Pin 4TNV106(T) outside diameter Tolerance

Standard value

Limit value

23.000 ÷ 23.009

23.039

22.995 ÷ 23.000

22.965

0.000 ÷ 0.014

0.074

26.000 ÷ 26.009

26.039

25.995 ÷ 26.000

25.965

0.000 ÷ 0.014

0.074

30.000 ÷ 30.009

30.039

29.989 ÷ 30.000

29.959

0.000 ÷ 0.020

0.080

37.000 ÷ 37.011

37.039

36.989 ÷ 37.000

36.959

0.000 ÷ 0.022

0.080

PIN.Measure at position (a), (b) and (c) in direction (A) and (B). HOLE. Measure at positions (a), (b) and (c) in direction (A) and (B).

51-108

Clearance between piston and cylinder 0.035 ÷ 0.065 0.040 ÷ 0.070 0.050 ÷ 0.080

mm Measurement position (H) 22 ÷ 25 22 22 30

51. ENGINE

(c) Piston ring, ring groove and end clearance measurement â&#x20AC;˘ Except for the top ring (46), to measure the piston ring groove width, first measure the width of the piston ring. Then insert the piston ring into the ring. Then insert the piston ring into the ring groove. Insert a thickness gauge in between the piston ring and groove to measure the gap between them. Obtain the ring groove width by adding ring width to the measured side clearance. â&#x20AC;˘ To measure the end clearance, push the piston ring into the sleeve using the piston head, insert a thickness gauge in end clearance to measure. The ring shall be pushed in to approx. 30 mm above the bottom end of the cylinder. For the top ring, measure only the piston ring joint end clearance in normal state.

47. Second ring

48. Oil ring

49. Width

50. Shim

51. Head surface 52. Cylinder block

53. Piston ring 54. Joint end clearance

51-109

51. ENGINE Piston ring dimension mm Model

Piece Top ring

TNV82A/84 Second ring

Oil ring

Top ring

TNV88

Second ring

Oil ring

Top ring

4TNV94L· 98

Second ring

Oil ring

Top ring

4TNV106 (T)

Second ring

Oil ring

Piece Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance

Standard value 2.065 ÷ 2.080 1.970 ÷ 1.990 0.075 ÷ 0.110 0.200 ÷ 0.400 2.035 ÷ 2.050 1.970 ÷ 1.990 0.045 ÷ 0.080 0.200 ÷ 0.400 4.015 ÷ 4.030 3.970 ÷ 3.990 0.025 ÷ 0.060 0.200 ÷ 0.400 2.060 ÷ 2.075 1.970 ÷ 1.990 0.070 ÷ 0.105 0.200 ÷ 0.400 2.025 ÷ 2.040 1.970 ÷ 1.990 0.035 ÷ 0.070 0.200 ÷ 0.400 4.015 ÷ 4.030 3.970 ÷ 3.990 0.025 ÷ 0.060 0.200 ÷ 0.400 2.040 ÷ 2.060 1.940 ÷ 1.960 0.080 ÷ 0.120 0.250 ÷ 0.450 2.080 ÷ 2.095 1.970 ÷ 1.990 0.090 ÷ 0.125 0.450 ÷ 0.650 3.015 ÷ 3.030 2.970 ÷ 2.990 0.025 ÷ 0.060 0.250 ÷ 0.450 2.520 ÷ 2.540 2.440 ÷ 2.460 0.060 ÷ 0.100 0.300 ÷ 0.450 2.070 ÷ 2.085 1.970 ÷ 1.990 0.080 ÷ 0.115 0.450 ÷ 0.600 3.015 ÷ 3.030 2.970 ÷ 2.990 0.025 ÷ 0.060 0.300 ÷ 0.500

51-110

Limit value 1.950 0.490 2.150 1.950 0.200 0.490 4.130 3.950 0.180 0.490 1.950 0.490 2.140 1.950 0.190 0.490 4.130 3.950 0.180 0.490 1.920 0.540 2.195 1.950 0.245 0.730 3.130 2.950 0.180 0.550 2.420 0.540 2.185 1.950 0.235 0.680 3.130 2.950 0.180 0.600

51. ENGINE

4. Link rod (a) Appearance check Inspect the portion near the boundary of the chamfered portion and I-beam section of the big and small ends of the connecting rod as well as the portion near the oil hole of the bushing at the small end for cracks, deformation, and discoloration. (b) Measurement of twist (56) and parallelism (55). Use a connecting rod aligner (58) and measure twist and bends. mm Piece Standard dimension Limit dimension Twist and 0.03 or less per 100 mm 0.08 parallelism 57. Mandrel (c) Rod small end measurement Measure the pin outside diameter according to 51.4.4.5 (a) described above. mm (in) Model Piece Standard value Limit value 3TNV82A Piston pin Bushing 23.025 ÷ 23.038 23.068 inner diameter Pin outside 22.995 ÷ 23.000 22.967 diameter Tolerance 0.025 ÷ 0.043 0.101 TNV84~88 Piston pin Bushing 26.025 ÷ 26.038 26.068 inner diameter Pin outside 25.995 ÷ 26.000 25.967 diameter Tolerance 0.025 ÷ 0.043 0.101 4TNV94L· Piston pin 98 Bushing 30.025 30.038 30.068 inner diameter Pin outside 29.987 30.000 29.959 diameter Tolerance 0.025 0.051 0.109 4TNV106 Piston pin (T) Bushing 37.025 37.038 37.068 inner diameter Pin outside 36.989 37.000 36.961 diameter Tolerance 0.025 0.049 0.107

51-111

51. ENGINE

If the bushing is to be replaced because the oil clearance exceeds the limit, use spare part.

60. Cylinder gauge (d) Rod big end measurement Measure the crankpin and bushing according to 51.4.4.5 (c) described above. Calculate the oil clearance of a crank pin metal and a crank pin from the measured values of the crank pin metal inner diameter and the crank pin outside diameter. Replace a crank pin metal if the oil clearance becomes about the limit dimension of the below table. Correct by grinding if unevenly wear, roundness exceeding the limit or insufficient outside diameter is found. Also use an undersized metal. When measuring the inside diameter of the rod big end, install the crankpin metals in the rod big end not to mistake the top and bottom of the metals and tighten the rod screws by the standard torque. 61. Cylinder gauge Tightening torque of connecting rod screw Model 3TNV82A TNV84/88 4TNV94L/98 4TNV106(T)

Tightening torque

Lubricating oil application (threaded portion and bearing seat surface)

37.2 รท 41.2 44.1 รท 49.0 53.9 รท 58.8 78.5 รท 83.4

Lube oil applied

51-112

51. ENGINE

Standard of rod big end mm Model 3TNV82A

TNV84/88

4TNV94L/98

4TNV106(T)

Piece Connecting rod bushing inner diameter Connecting rod pin inner diameter Metal thickness Tolerance Connecting rod bushing inner diameter Connecting rod pin inner diameter Metal thickness Tolerance Connecting rod bushing inner diameter Connecting rod pin inner diameter Metal thickness Tolerance Connecting rod bushing inner diameter Connecting rod pin inner diameter Metal thickness Tolerance

5. Tappet Mainly check the tappet contact surface with the cam and push rod. Slight surface defects shall be corrected with an oilstone. (a) Tappet stem outside diameter measurement mm Limit Model Piece Standard value value TNV84~88 Tappet hole inner 12.000 ÷ 12.025 12.045 diameter Rod outer 11.975 ÷ 11.990 11.955 diameter Tolerance 0.010 ÷ 0.050 0.090 4TNV94L·9 Tappet hole 8 inner 12.000 ÷ 12.018 12.038 diameter Rod outer 11.975 ÷ 11.990 11.955 diameter Tolerance 0.010 ÷ 0.043 0.083 4TNV106(T) Tappet hole inner 14.000 ÷ 14.018 14.038 diameter Rod outer 13.966 ÷ 13.984 13.946 diameter Tolerance 0.015 ÷ 0.052 0.092

Standard value

Limit value

42.952 ÷ 42.962)

42.902

43.000 ÷ 43.042

1.487 ÷ 1.500 0.038 ÷ 0.090

0.150

47.952 ÷ 47.962

47.902

48.000 ÷ 48.026

1.492 ÷ 1.500 0.038 ÷ 0.074

0.150

57.952 ÷ 57.962

57.902

58.000 ÷ 58.026

1.492 ÷ 1.500 0.038 ÷ 0.074

0.150

63.952 ÷ 63.962

63.902

64.016 ÷ 64.042

1.984 ÷ 1.992 0.054 ÷ 0.090

0.150

62. Abnormal surface

51-113

contact

63. Normal contact surface

51. ENGINE 51.4.4.6 Cylinder bore correction 1. Slight uneven worn, flawed, etc. shall be corrected by honing only. If the cylinder is unevenly worn partially, flawed or otherwise damaged and cannot be repaired simply by honing, rebore the cylinder first and then hone. See 51.4.4.5 (c) for the boring dimension. 2. Items to be prepared for honing • Flex-Hone (64) (see No.8 of 51.4.1.2) • Electric drill (65) • Honing fluid (66) (50:50 of lubricating and diesel oil) (67) 3. Apply the honing fluid to the Flex-Hone and turn the electric drill at 300 to 1200 rpm. Then insert the FlexHone into the cylinder bore while turning it, and move it up and down for about 30 sec. to obtain a honing mark with a cross hatch angle of 30° to 40°. NOTE: avoid faster revolution than 1200 rpm since it may cause breakdown. Do not insert or extract the Flex-Hone in stopped state because the cylinder will be damaged.

H1. Time for honing H2. Boring and honing interval H3. Service life of cylinder block 64. Increase in L.O.C.

65. Honing 66. Boring 67. Honing

51-114

51. ENGINE 51.4.4.7 Piston pin bushing replacement Replace bushing by using the special service tool (see 51.4.1.2).

51.4.4.8 Oil seal replacement (Flywheel housing side) 1. Replace oil seal, when a flywheel housing is removed. Extract the used oil seal. 2. Insert a new oil seal with the oil seal insertion tool. 3. Apply lithium grease.

51-115

51. ENGINE

51.5

LUBRICATION SYSTEM

51.5.1

LUBRICATION SYSTEM DIAGRAM

Oil screen Bypass valve Fuel injection pump Hydraulic switch Regulator valve Oil pump

Cylinder body • Main gallery Intermediate gear shaft

Oil suction pipe (strainer)

Camshaft bearing

Crank journal

Rocker arm bearing

Crankpin

Rocker arm Tappet • Cam face Oil pan

NOTE: It varies in the specifications of each model whether Oil cooler and Piston cooling of the * mark are attached.

51-116

51. ENGINE 51.5.2

TROCHOID PUMP COMPONENTS

Trochoid pump (3TNV82A~TNV88)

Trochoid pump (4TNV94L/98/106)

1. 2. 3. 4.

51.5.3

DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)

1. Loosen the belt, and remove the radiator pulley, fan and V-belt. (See 51.4.2.2. 2). 2. Remove the crankshaft pulley. (See 51.4.3.2. 3). 3. Remove the gear case cover. (See 51.4.3.2. 4). 4. Remove the lubricating oil pump assy from the gear case for 4TNV94/98/106. (51.5.4 Point 1) Remove the lube oil cover from gear case cover for 3TNV82A-88. (51.5.4 Point 1) 5. Remove the pressure regulating valve from the lubricating oil pump body. (51.5.4 Point 2)

51-117

Outer rotor Inner rotor Cover Control valve

5. 6. 7. 8.

Gear case Punch Crankshaft Mark

51. ENGINE 51.5.4

SERVICING POINTS

Point 1 Disassembly • Check if the pump rotates smoothly and see that there is no play between the shaft and gear, and inner rotor. Reassemble NOTE: Always check if the pump rotates smoothly after installation on the gear case. Running the engine when the pump rotation is heavy may cause the pump to be burnt. 1. 3TNV82A-88 • Apply lube oil to rotor (outer/inner) insertion part. • Assemble the outer rotor so that the mark of the end face may become a cover side when inserting it in the gear case. • Fasten a lube oil pump cover by the standard torque. Tightening torque: 6.9 ± 1.5 Nm • When replacing the lube oil pump, replace the whole assy. 2. 4TNV94L/98/106 • Apply lube oil to lube oil pump insertion part of gear case. • Install the outer rotor in the gear case so that the punch mark on the end face is seen. • When replacing the lube oil pump, replace the whole assy. Point 2 Disassemble-Reassemble • Only wash the pressure regulating valve. Disassembly is unnecessary unless any abnormality in operation is detected.

51-118

51. ENGINE 51.5.5

INSPECTION AND MEASUREMENT OF PARTS

51.5.5.1 Trochoid pump inspection and measurement 1. Outside clearance and side clearance of outer rotor Insert a gap gauge between a outer rotor and a pump body, and measure the clearance. Outside clearance Model 3TNV82A~88 4TNV94L/98 4TNV106(T)

Standard value 0.12 ÷ 0.21 0.100 ÷ 0.155 0.100 ÷ 0.165

mm Limit value 0.30 0.25 0.25 1. Outer case

5. Gear case

When measuring a side clearance, put a right-angle gauge to the pump body, insert a gap gauge and measure the clearance. Side gap Model 3TNV82A~88 4TNV94L/98 4TNV106(T)

Standard value 0.02 ÷ 0.07 0.05 ÷ 0.10 0.03 ÷ 0.12

mm Limit value 0.12 0.15 0.17

2. Inner rotor and gear hub clearance (3TNV82A4TNV88)

Piece Inside clearance of inner rotor

Piece

Gear hub diameter Rotor inner diameter Width across flat Width across flats of gear hub clearance of inner Width across flats of rotor rotor

Standard dimension (mm) 53.05 ÷ 53.15 53.45 ÷ 53.55 49.45 ÷ 49.75 49.95 ÷ 50.05

8. Crank gear 9. Inner rotor

51-119

Standard Standard clearance clearance limit (mm) (mm) 0.3 ÷ 0.5

0.6

0.2 ÷ 0.6

0.7

10. Width across flats of rotor 11. Rotor inner diameter

51. ENGINE

3. Rotor shaft clearance (4TNV94L/98/106) Measure the outside diameter of rotor shaft (12) and the shaft hole diameter of gear case (13). Calculate the clearance from that difference.

14. Shaft outside diameter 15. Bearing inner diameter mm Model 4TNV94L/98

4TNV106(T)

Inspection item Gear case bearing inner diameter Rotor shaft outer diameter Rotor clearance Gear case bearing inner diameter Rotor shaft outer diameter Rotor clearance

51-120

Standard value

Limit value

12.980 ÷ 13.020

13.05

12.955 ÷ 12.970 0.035 ÷ 0.065

12.945 0.105

13.000 ÷ 13.020

13.05

12.955 ÷ 12.965 0.035 ÷ 0.065

12.945 0.105

51. ENGINE

51.6

COOLING SYSTEM

51.6.1

COOLING WATER SYSTEM

Thermostat

Radiator

Bypass

Cylinder head

Cylinder block

Coolant expansion tank

Coolant pump

L.O. cooler

51.6.2

COOLING WATER PUMP COMPONENTS

NOTE: This figure shows the 4TNV84

1. Thermostat cover 2. Thermostat 3. Coolant pump

4. Cylinder head 5. Joint

6. Thermo switch 7. V-pulley

51-121

8. Spacer 9. Fan

51. ENGINE 51.6.3

DISASSEMBLY (REVERSE THE PROCEDURE BELOW FOR ASSEMBLY)

1. Remove alternator. (See 51.4.2.2. 1). 2. Remove the fan, V-belt and pulley. (See 51.4.2.2. 2). 3. Remove the cooling water pump. (Point 1, under 51.6.4 below) 4. Remove the thermostat. (Point 2, under 51.6.4 below)

51.6.4

SERVICING POINTS

Point 1 Disassemble-Reassemble: â&#x20AC;˘ Check to see that the cooling water pump (12) bearing is free from abnormal noise, sticking or play and water leakage from the bearing. If replacement is necessary, replace the whole cooling water pump assy.

NOTE: Replace the O-ring (10) of the cooling water pump with new one when disassembling. And, be sure to use the special O-ring for each engine model, because the material is different, although the dimension is the same as a commercial part. (Refer to the right figure). Point 2 Disassemble: Check the thermostat function. See 51.2.7 for the inspection method. 11. Joint

51-122

51. ENGINE

51.7

FUEL INJECTION PUMP/GOVERNOR

Only the outline of the MP fuel pump is explained in this chapter. Refer to the MP pump service manual of the separate volume for the disassembly and assembly.

51.7.1

INTRODUCTION

It is described about the features of the fuel injection pump, YDP-MP, manufactured by Yanmar, disassembly, assembly and adjustment procedure. Fuel injection pump is the most important equipment, which is enable to make the sensitive adjustment according to the variable load of the engine. Therefore all of the parts are required not only very precise machining but also finest, assembling with top The careful arrangement of keeping off the dust and the rust when disassemble, adjustment and reassemble of the fuel injection pump is made in the market. Yanmar YDP-MP Pump is a distributor type pump which is unified of Mono-plunger, a distributing shaft, a hydraulic head which equipped the delivery valve for each cylinder, pump housing which has a cam shaft internally and governor. The fuel, which is pressurized by the up and down movement of the plunger driven by the cam-rotation, is supplied through the distributor shaft, which is rotating accordingly. There are two models of Yanmar pump: YDP-MP2 and YDP-MP4, and the plunger diameter and the fuel cam diameter differ. 51.7.2

FUEL INJECTION PUMP

51.7.2.1 Fuel system diagram

51-123

51. ENGINE

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

Fuel tank Water separator Fuel feed electric pump Fuel filter Orifice Pressure control valve Low pressure gallery Trochoid pump Oil seal Engine oil Engine crankcase Cam

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

51-124

High pressure gallery Fuel injection valve Injection pump Overflow orifice Tappet Fuel return Joint Nozzle Accumulator Timer piston Plunger Distributor shaft

51. ENGINE 51.7.2.2 External view and components NOTE: This figure shows the 3TNV84.

1. 2. 3. 4. 5. 6. 7. 8. 9.

V-belt / V-pulley Fuel injection valve Fan Donâ&#x20AC;&#x2122;t disassemble: pump flange, fuel pump drive gear Drive gear nut Fuel pump spacer Water separator Fuel injection pump Cylinder head

10. 11. 12. 13. 14. 15. 16. 17. 18.

51-125

Fuel filter Fuel injection valve Inlet manifold Coolant pump Camshaft driving gear Crankshaft gear Gear case Oil seal Crankshaft pulley

51. ENGINE 51.7.2.3 Disassembly procedure: Disassembly from the engine body • Remove the fan, pulley and V belt. • Remove the fuel injection pipe, fuel oil piping, fuel return pipe and rear stay. See point 1 of 51.7.2.5. • Remove the fuel injection pump cover (the cover of the drive gear). • Make ID marks on the gearing part of the pump drive gear and the idle gear with paint and so on. See point 2 of 51.7.2.5. • Loosen a fuel pump drive gear nut, and remove a pump drive gear from the fuel pump by using a gear puller. (See Point 3 of 51.4.3.4) • Remove a drive gear nut carefully not to drop it to the inside of the gear case. • Record the installation angle of the fuel pump precisely by using a mark-off line and a sticker. See (4) of 51.2.2.7. • Remove the fuel injection pump. See point 3 of 51.7.2.5.

Fuel pump (4 cylinder)

Fuel pump (3 cylinder)

19. Fuel injection valve 20. Fuel pump 21. Governor side

51.7.2.4 Assembly procedure Reverse the disassembly procedure and adjust the fuel injection timing finally. See (4) of 51.2.2.7.

51-126

22. Drive side 23. Cylinder no. 1 24. Engine

51. ENGINE 51.7.2.5 Servicing points Point 1 Disassembly • Block an entrance with the tape so that trash may not enter the fuel injection pipe and the fuel injection pump (25). Point 2 Disassembly • After putting the I.D. marks (26) on the gearing part of the pump drive gear (30) and the idle gear (27) with paint and so on, remove the gear installation nut (29). NOTE: do not remove the four flange screws (28).

Reassemble • Reassemble the pump driving gear while checking the I.D. marks (30) on the driving gear (26) and idle gear (27). Tightening torque of the gear installation nut Model TNV82A~88 4TNV94~106(T)

Lubricating oil application (threaded portion and seat surface)

78 ÷ 88 113 ÷ 123

Not applied

51-127

51. ENGINE Point 3 Disassembly There is an acoustic material part to name as fuel pump spacer (32) between the fuel pump (33) and the cylinder block (31). Loosen fuel pump mounting screws with a closed wrench (36) while disassembling the fuel pump. NOTE: an intake manifold may obstruct the disassembly of the fuel pump (33) by the engine model. Remove the fuel pump after removing the intake manifold (35) first. Reassemble When installing a fuel pump on the gear case, put a fuel pump spacer between the cylinder blocks, and install it.

34. Cylinder head

51-128

51. ENGINE

51.8

TURBOCHAGER: DISASSEMBLY, INSPECTION AND REASSEMBLY

51.8.1

STRUCTURE AND FUNCTIONS

51.8.1.1 Main specifications

Applicable engine model (application)

3TNV84T(CL, VM) 4TNV84T(CL) RHB31

Turbocharger model Turbocharger specification Turbine type Blower (compressor) type Lubrication method Max. continuous allowable speed 250.000 Max. continuous allowable gas inlet temperature Dry weight N 24 Note) VM application is provided with the waste gate.

3TNV84T(VM)

RHB51 Standard (w/waste gate) Radial flow Centrifugal External lubrication 180.000

RHF5

750 41

51.8.1.2 Construction

AI. Air inlet AO. Air outlet GI. Gas inlet

4TNV106T(CL, VM)

GO. Gas outlet OI. Oil inlet OO. Oil outlet

51-129

51. ENGINE 51.8.1.3 Structural and functional outline No. 1 2 3 4 5 6 7 8 9 10

Part name Turbine shaft Oil sprayer Turbine side seal ring Seal plate Journal bearing Thrust bushing Compressor housing Hexagon head screw M5 M5 spring washer Compressor side clamp

No. 11 12 13 14 15 16 17 18 19 20

1. Turbine The exhaust gas from the engine is accelerated at the nozzle portion in the turbine housing and blown onto the turbine impeller to rotate the turbine shaft. This is called the turbine. A seal ring and heat insulating plate are installed to prevent the bearing from adverse influence of the gas. 2. Compressor The compressor impeller installed on the turbine shaft rotates with the shaft to suck and compress air for feeding into the intake manifold. This is called “blower” or “compressor”. 3. Bearings Thrust bearing As the turbine shaft is constantly applied with a thrust force, this bearing prevents the shaft from being moved by the thrust force. Radial bearing A floating bearing is adopted. Since the bearing moves with the turbine shaft as the oil films are formed both inside and outside the bearing, the bearing sliding speed is slower than the turbine shaft speed, resulting in higher dynamic stability.

51-130

Part name Turbine housing Hexagon head screw M6 Turbine side clamp Lock washer Bearing housing Stopper clip M3 countersunk flat head screw Compressor wheel Shaft end nut Heat protector

51. ENGINE

4. Compressor side sealing mechanism To prevent the intake air and oil form leaking, a seal ring and a seal plate are provided to form a double wall structure on the rear side of the compressor impeller. 5. Exhaust valve When the blower side pressure (intake air pressure) exceeds the specified level, the exhaust gas at the turbine inlet is partially bypassed to the exhaust discharge side to control the turbine rpm so as to maintain the intake pressure at the specified level for improving the response to load variation in the low to medium speed range and to minimize black smoke generation. It consists of a control assembly separated from the turbocharger and a valve assembly installed in the turbine impeller chamber.

51-131

51. ENGINE 51.8.1.4 Components

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part name Turbine shaft Oil sprayer Seal ring (turbine side) Seal plate Journal bearing Thrust bushing Compressor housing Flanged nut Spring washer Clamp Turbine housing Edge bolt Lock plate Thrust bushing Bearing housing Stopper clip Edge bolt

No. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

51-132

Part name Impeller Locknut Heat protector Seal ring Seal ring Edge bolt Lock washer Liquid gasket Waste gate actuator Hose Adapter Clip Stopper clip Waste gate valve Link plate Edge bolt Washer

51. ENGINE 51.8.2

SERVICE STANDARDS AND TIGHTENING TORQUE

51.8.2.1 Maintenance standard

C. Compression side

Turbine side

1. RHF5 type

Turbine shaft journal outside diameter (A) Turbine shaft seal ring groove width (E) Turbine shaft Compressor side seal ring groove width (G1) Compressor side seal ring groove width (G2) Turbine shaft run-out Journal bearing inside diameter (C) Bearing Journal bearing outside diameter (D) Bearing housing inside diameter (B) Thrust bearing width (J) Thrust bushing Thrust bushing groove dimension (K) Turbine side (bearing housing) (F) Seal ring fixing Compressor side (seal ring) (H1) area Compressor side (seal ring)(H2) Rotor play in axial direction Rotor play in radial direction

51-133

Standard dimension 7.99 ÷ 8.00 1.25 ÷ 1.28 1.22 ÷ 1.23 1.02 ÷ 1.03 0.002 8.01 ÷ 8.03 12.32 ÷ 12.33 12.40 ÷ 12.41 3.99 ÷ 4.01 4.04 ÷ 4.05 15.00 ÷ 15.02 12.40 ÷ 12.42 10.00 ÷ 10.02 0.03 ÷ 0.06 0.08 ÷ 0.13

Unit: mm Wear limit 7.98 1.29 1.31 1.11 0.011 8.04 12.31 12.42 3.98 4.07 15.05 12.45 10.05 0.09 0.17

51. ENGINE

2. RHB31/RHB51 type

Turbine shaft journal outside diameter (A) Turbine shaft seal ring groove width (E) Turbine Compressor side seal ring groove width (G1) shaft Compressor side seal ring groove width (G2) Turbine shaft run-out Journal bearing inside diameter (C) Bearing Journal bearing outside diameter (D) Bearing housing inside diameter (B) Thrust bearing width (J) Thrust bushing Thrust bushing groove dimension (K) Turbine side (bearing housing) (F) Seal ring Compressor side (seal ring) (H1) fixing area Compressor side (seal ring)(H2) Rotor play in axial direction Rotor play in radial direction

Standard dimension RHB31 RHB51 6.257 ÷ 6.263 7.99 ÷ 8.00 1.038 ÷ 1.062 1.25 ÷ 1.28 1.02 ÷ 1.03 1.22 ÷ 1.23 0.82 ÷ 0.83 1.02 ÷ 1.03 0.002 0.002 6.275 ÷ 6.285 8.01 ÷ 8.03 9.940 ÷ 9.946 12.32 ÷ 12.33 9.995 ÷ 10.005 12.40 ÷ 12.41 3.59 ÷ 3.61 3.99 ÷ 4.01 3.632 ÷ 3.642 4.04 ÷ 4.05 11.00 ÷ 11.018 15.00 ÷ 15.02 9.987 ÷ 10.025 12.40 ÷ 12.42 7.968 ÷ 8.00 10.00 ÷ 10.02 0.022 ÷ 0.053 0.03 ÷ 0.06 0.061 ÷ 0.093 0.08 ÷ 0.13

Unit: mm Wear limit RHB31 RHB51 6.25 7.98 1.07 1.29 1.04 1.31 0.84 1.11 0.005 0.011 6.29 8.04 9.93 12.31 10.01 12.42 3.58 3.98 3.65 4.07 11.06 15.05 10.04 12.45 8.01 10.05 0.07 0.09 0.12 0.17

51.8.2.2 Tightening torque 1. RHF5 type Nm Piece Turbine housing setscrew Compressor housing setscrew Thrust bearing set screw Seal plate set screw Blower impeller set nut (left-handed screw)

Thread diameter M8 M5 M3 M3 M5

Tightening torque 27 ÷ 29 4.2 ÷ 5.2 1.2 ÷ 1.4 1.2 ÷ 1.4 1.8 ÷ 2.2

2. RHB31/RHB51 type Nm Piece Waste gate actuator setscrew Lock plate setscrew Thrust bearing set screw Seal plate set screw Blower impeller set nut (left-handed screw)

Thread diameter M5 M6 M8 M3 M3 M5

51-134

Tightening torque RHB31 3.9 ÷ 4.9 11.8 ÷ 12.8 11.8 ÷ 12.8 1.2 ÷ 1.4 1.2 ÷ 1.4 0.9 ÷ 1.1

RHB51 3.9 ÷ 4.9 11.8 ÷ 12.8 27.0 ÷ 28.9 1.2 ÷ 1.4 1.2 ÷ 1.4 1.8 ÷ 2.2

51. ENGINE 51.8.3

PERIODIC INSPECTION PROCEDURE

51.8.3.1 Periodic inspection intervals Periodically inspect the turbocharger for the overall conditions and fouling. The inspection interval varies with the operating conditions, but refer to the table below for the guideline for each application.

Application For vehicles (automobiles) For construction machinery For farming machinery For marine use Rotor rotation Rotor play Overhaul and overall inspection Oil filter cleaning and inspection Replacement of engine oil

Inspection interval Every 6 months or Every 12 months or Every 24 months or 60.000 km 150.000 km 300.000 km Every 6 months or 500 Every 12 months or 1000 Every 24 months or 2000 hrs hrs hrs Every 6 months or 200 Every 12 months or 400 Every 24 months or 800 hrs hrs hrs Every 6 months or 1500 Every 12 months or 3000 Every 24 months or 6000 hrs hrs hrs m m m Based on engine operation manual

51.8.3.2 Inspection procedure 1. Rotor rotation inspection Inspect the rotor rotation by listening to any abnormal sound generation during rotation. For inspection with a sound detecting bar, bring the tip end of the bar into strong contact with the turbocharger case and raise the engine speed gradually. If any high pitch sound is generated at intervals of 2 to 3 seconds, the rotation is abnormal. Since the bearing or rotor may be defective in this state, either replace or overhaul the turbocharger. 2. Rotor play check. Remove the turbocharger from the engine and inspect the rotor play in the axial and radial directions according to the procedure below. After removing the turbocharger from the engine, always bind the oil inlet and outlet holes with adhesive tape.

Rotor play in axial direction

AP. Axial play (Maintenance standard: from 0.03 to 0.06 mm) (Wear limit: 0.09 mm) DG. Dial gauge MB. Magnet base MT. Move the turbine shaft in the axial direction TW. Turbine wheel chamber

51-135

51. ENGINE 51.8.3.3 Waste gate valve adjustment procedure Rotor play in radial direction

DG. Dial gauge MB. Magnet base MT. Move the turbine shaft in the radial direction at the same time on the left and right sides

OI. Oil inlet OU. Oil outlet RP. Radial play (Maintenance standard: from 0.08 to 0.13 mm) (Wear limit: 0.17 mm)

It is indispensable to adjust the waste gate valve opening pressure and lift after its overhaul or inner parts replacement. Negligence of this adjustment will adversely affect the engine performance. NOTE: If the adjustment is impossible, give up overhaul but replace the whole turbocharger assembly. 1. Method for checking the waste gate valve opening pressure and lift (a) Equipment Prepare the equipment shown in the figure below.

51-136

51. ENGINE

(b) Measuring instruments and devices Dial gauge Capable of measuring 0 to 10 mm (A flat head type is recommendable.) Pressure gauge Mercury column or electrical type (capable of measuring from 0 to 1500 mmHg) Pressure regulating valve Allowing gradual adjustment in a range between 0 and 2 kgf/cm2 Pressure relief valve Used for suppressing the air supply pressure at 5 kgf/cm2 or less. Pressure gauge Bourdon tube pressure gauge (from 0 to 10 kgf/cm2)

A. C. CA. DG. M. N.

Adapter Clip Compressed air Dial gauge Manometer Hose

PG. Pressure gauge PR. Pressure regulating valve PV. Pressure reducing valve WA. Waste gate actuator WG.Waste gate valve

(c) Check method 1. Set the manometer control pressure (Pc) applied to the waste gate actuator to 0 and set the dial gauge to the zero point. 2. Gradually open the pressure regulating valve and measure the Pc value when the actuator rod is operated by 2 mm. 3. For the hysteresis, let the rod move to 3 mm first. The gradually close the pressure regulating valve, measure the pressure when the rod is moved to 2 mm and obtain the difference from the pressure measured in b above.

51-137

51. ENGINE

4. Precautions • Set the dial gauge on the extension line of the actuator rod. • The piping and joints shall completely be free from leak. • Fix the turbocharger and dial gauge securely. • If an electric manometer is used, it shall have sufficient precision. • Even when an electric manometer is used, use of a mercury column type manometer in combination is recommended for calibration and daily check. • The speed for increasing/decreasing Pc by means of the pressure regulating valve shall be very slow near the measuring point. If the mm position is exceeded, restart from the beginning. • Do not apply more then 0.49 MPa (71 psi) to the actuator.

2. Waste gate actuator leak test Apply 0.12 MPa to the actuator and keep this condition for one minute. The actuator is correctly operating if pressure is 0.11 MPa or higher.

51-138

51. ENGINE 51.8.4

DISASSEMBLY PROCEDURE

51.8.4.1 Preparation for disassembly In addition to the general tools, the following special tools are required for turbocharger disassembly and reassembly:

Name

Bar

Use

Illustration

For removing thrust bearing and thrust bushing Material: Copper or brass

Pliers

For removing floating bearing circlip

Pliers

For removing seal ring

For thrust bearing installation (for M3): 1.3 Nm Torque driver for TORX screw For seal plate installation (for M3): 1.3 Nm (multifunctional type) 0.5 to 4.9 Nm

Box wrench

Item sold on market

For fixing turbine shaft (mm dodecagonal) Box only may be used.

Torque wrench (single purpose)

For following bolts and nuts: M8: mm, Nm M8: mm, Nm M5: mm, Nm For measuring play in axial and radial directions: to be installed on a dial gauge

Probe

51-139

51. ENGINE 51.8.4.2 Inspection before disassembly 1. Inspect the turbine wheel and compressor impeller for any undesirable contact and the rotor for smooth rotation. 2. Measure the rotor play as described in section 8.3 (2.2). • Rotor end play wear limit: mm • Rotor radial play wear limit: mm

51.8.4.3 Disassembly The mounting angles of the turbine housing, bearing housing and compressor housing are determined according to its mounting state on the engine. Put match marks before starting disassembly. NOTE: the number after each part is the one described in the structural drawing in 8.1 (2). 1. Compressor housing removal • Remove the flanged hexagon head screw 8 and the plate on the compressor side 10. • Remove compressor impeller 7. NOTE: liquid gasket is applied on the surface of compressor housing 7 where bearing housing 15 is mounted. When disassembling compressor housing 7, carefully operate so as not to damage the compressor impeller. 2. Compressor impeller removal • Set a box spanner (10 mm) (0.39 in) on the turbine side end of the turbine shaft, and remove shaft end clamp 18. NOTE: pay attention to the loosening direction since the shaft end nut has left-handed screw. • Remove compressor impeller 18. 3. Turbine housing removal • Remove hexagon nut 12 and turbine side keep plate 13. • Remove turbine housing 11. 4. Turbine shaft extraction • Hold heat insulating plate 20 lightly with a hand, and extract turbine shaft 1. NOTE: if the turbine shaft is hard to be extracted, tap the compressor side end of the shaft lightly with a wooden hammer. • Remove heat insulating plate 20.

51-140

51. ENGINE 5. Seal plate removal • Use the Torx driver and loosen M3 Torx T-type machine screw 17 for seal plate mounting. • Remove seal plate 4. NOTE: liquid gasket has been applied to the seal plate and bearing housing mounting surface. • Remove oil thrower 2 from the seal plate. 6. Slide bearing and thrust bushing removal • Use the Torx driver and loosen the M3 Torx T-type machine screw for thrust bearing installation. • Use the bar (copper) and remove thrust bearing 6 and thrust bushing. 7. Floating bearing removal • Use the stop ring pliers and remove circlip 16 from bearing housing 15. • Remove floating bearing 5 from bearing housing 15. 8. Seal ring removal • Remove turbine side seal ring 3 from turbine shaft 1. • Remove compressor side seal ring (small) and compressor side seal ring (large) from oil thrower 2.

51-141

51. ENGINE 51.8.5

WASHING AND INSPECTION PROCEDURE

51.8.5.1 Washing 1. Inspection before washing Visually inspect each part before washing to check trace of seizure, wear, foreign matter or carbon adhesion. Carefully inspect for identifying the cause of trouble especially when a fault has occurred. Major inspection items Check points Carbon adhesion state Lubrication status (wear, seizure, discoloration, etc.)

Oil leaking

• • • • • • • • • • •

Checking position Turbine shaft 1, turbine side seal ring and rear side of turbine wheel Heat insulating plate 20 mounting portion and inside of bearing housing 15 Turbine shaft 1, journal portion and thrust bushing oil thrower 2 Floating bearing 5 and thrust bearing 6 Bearing housing 15 and inner wall of bearing fitting ring Inner wall of turbine housing 11 Outer surface of bearing housing 11 and heat insulating plate 20 mounting portion Turbine shaft 1, turbine side seal ring and rear side of turbine wheel Inner wall of compressor housing 7 Rear side of compressor impeller 18 Surface and seal ring inserting portion of seal plate 4

2. Washing procedure Keep the following in mind when washing the parts:

Piece a) Turbine shaft

b) Turbine wheel chamber

c) Blower blade and chamber d) Others

Tools and detergent Tools • Bucket(500 x 500) • Heat source: Steam or gas burner • Brush

Procedure • Boil the turbine in the washing bucket. Do not strike the blade to remove the carbon. • Immerse in the detergent until the carbon and other deposits are softened. • Use a plastic scraper or hand hair scrubber to remove the softened deposits. Detergent • Protect the bearing surface and seal ring groove on the • Standard carbon turbine shaft so as not to be damaged. removing agent • Any deposit remaining on the turbine shaft due to improper washing may cause unbalancing. Be sure to remove thoroughly. Never use a wire brush. Tools • Boil the turbine in the washing bucket. • Same as for turbine shaft • Immerse in the detergent until the carbon and other deposits are softened. Detergent • Use a plastic scraper or hard hair scrubber to remove the Same as for turbine shaft softened deposits. Tools • Immerse in the washing bucket until the deposit is • Bucket(500 x 500) softened. • Brush • Use a plastic scraper or hard hair scrubber to remove the Detergent softened deposits. Never use a wire brush. • Wash all other parts with diesel oil. • Clean the lubricating oil path by blowing with compressed air. • Be especially careful so as not to damage or corrode the parts.

51-142

51. ENGINE 51.8.5.2

Inspection procedure

1. Compressor housing 7 Inspect the compressor housing for any contact trace with the compressor impeller, surface defect, dent or crack at joint surface, and replace it if defective. 2. Turbine housing 11 Inspect any trace of contact with the turbine wheel, exfoliation due to degradation by oxidation of the cast surface, thermal deformation or crack. Replace with a new one of defective. 3. Compressor impeller 18 Inspect any contact trace, chipping, corrosion or deformation. Replace with a new one of defective.

4. Turbine shaft 1 • Inspect any contact trace, chipping, thermal discoloration or deformation at the turbine wheel. Check the shaft portion for bend, the journal portion for thermal discoloration or abnormal wear, and the seal ring groove for surface defect or wear. Replace with a new one if defective. • Measure the turbine shaft journal outside diameter (A) and seal ring groove width (E). Replace with a new turbine shaft if beyond the wear limit. Wear limit of journal outside diameter (A) RHF5 ......... 7.98 mm (0.31 in) RHB51 ....... 7.98 mm (0.31 in) RHB31 ....... 6.25 mm (0.24 in) Wear limit of ring groove width (E) RHF5 ......... 1.29 mm (0.05 in) RHB51 ....... 1.29 mm (0.05 in) RHB31 ....... 1.07 mm (0.04 in) • Measure the turbine shaft run-out, and replace with a new turbine shaft if it exceeds 0.011 mm.

5. Heat insulating plate 20 Inspect the heat insulating plate for any contact trace, thermal deformation or corrosion. Replace with a new part if defective.

51-143

51. ENGINE

6. Thrust bushing, oil sprayer (2) and thrust bearing (6). Inspect each part for wear, surface defect and discoloration. Replace with a new one if defective even within the wear limit. (a) Thrust bushing Measure the distance between grooves (K) of the thrust bushing, and replace with a new one if the wear limit is exceeded. Wear limit RHF5.......... 4.07 mm RHB51 ....... 4.07 mm RHB31 ....... 3.65 mm (b) Oil thrower 2 Measure the seal ring groove widths (G1) and (G2), and replace with a new one if the wear limit is exceeded. Wear limit RHF5.......... G1: 1.31 mm, G2: 1.11 mm RHB51 ....... G1: 1.31mm, G2: 1.11 mm RHB31 ....... G1: 1.04 mm, G2: 0.84 mm

(c) Thrust bearing 6 Measure the thrust bearing width (J), and replace with a new one if the wear limit is exceeded. Wear limit RHF5.......... 3.98 mm RHB51 ....... 3.98 mm RHB31 ....... 3.58 mm

7. Floating bearing 5 â&#x20AC;˘ Inspect the floating bearing for abnormal wear, discoloration or surface defect. Replace with a new one of defective. â&#x20AC;˘ Measure the inside diameter (C) and outside diameter (D). Replace the bearing if either wear limit is exceeded. Wear limit RHF5.......... Outside diameter (D): 12.31 mm Inside diameter (C): 8.04 mm RHB51 ....... Outside diameter (D): 12.31 mm Inside diameter (C): 8.04 mm RHB31 ....... Outside diameter (D): 9.93 mm Inside diameter (C): 6.29 mm

51-144

51. ENGINE

8. Bearing housing 15 • Inspect the housing for cast surface exfoliation due to oxidation and degradation, dent or crack. • Inspect circlip 16 for chipping or crack, and replace with a new one if defective. • Measure the (B) and (F) portions of the bearing housing shown in the figure below. • Replace with a new one if either wear limit is exceeded. Wear limit of bearing housing inside diameter (B) RHF5 ......... 12.42 mm RHB51 ....... 12.42 mm RHB31 ....... 10.01 mm Wear limit of turbine side seal ring inserting portion (F) RHF5 ......... 15.05 mm RHB51 ....... 15.05 mm RHB31 ....... 11.03 mm

BF. Bearing fitting ring CS. Compressor side

9. Seal plate 4 • Inspect the seal plate for any contact trace, joint surface defect, dent or crack. Replace it if defective. • Measure the seal ring inserting dimensions (H1 and H2) on the compressor side, and replace the seal ring with a new one if either wear limit is exceeded. Wear limits RHF5 ......... H1: 12.45 mm), H2: 10.05 mm RHB51 ....... H1: 12.45 mm, H2: 10.05 mm RHB31 ....... H1: 10.04 mm, H2: 8.01 mm

10. Seal rings Replace seal rings with new ones. 11. Inspect keep plates 10, 13 and screws for any deformation, and replace defective parts with new ones. Also replace M3. Torx machine screws with new ones.

51-145

IP.Inner plate TS.Turbine side

51. ENGINE 51.8.6

ASSEMBLY PROCEDURE

51.8.6.1 Preparation for reassembly 1. Prepare general tools, special tools, liquid gasket and Loctite No. 242 before reassembling the turbocharger. 2. Always replace the following parts with new ones: • Turbine side seal ring 1pc. • Compressor side seal ring (large) 1pc. • Compressor side seal ring (small) 1pc. • M3 machine screws 3pcs. • M3 machine screws 4pcs.

AO. Applicable only to the one closest the turbine FA. For all other than above FM. Floating metal

51.8.6.2 Reassemble 1. Floating bearing installation • Use the snap ring pliers and install inner circlip 16 on bearing housing 15. • Install floating bearing 5 in bearing housing 15. • Use the snap ring pliers and install outer circlip 16 on bearing housing 15. NOTE: The circlip joint shall be positioned as shown in the figure at right above. The rounded side of the circlip shall face the bearing. Apply lubricating oil on the floating bearing before reassembly.

51-146

LO. Lubricating oil inlet MU. Match up contact surface VT. View from the turbine 1. Snap ring

51. ENGINE 2. Turbine shaft installation • Fit the seal ring onto turbine shaft 1. • Install heat insulating plate 20 on the turbine side of bearing housing 15. • Apply lubricating oil on the journal portion of the turbine shaft and insert the shaft from the turbine side of bearing housing 15. NOTE: carefully operate so as not to damage the floating bearing by the turbine shaft. The seal ring joint shall be positioned on the lubricating oil inlet side after centering with the turbine shaft.

3. Thrust bearing installation • Fit thrust bushing on turbine shaft 1. • Apply lubricating oil on the bearing portion of thrust bearing 6 and install it in bearing housing 15. • Apply Loctite on the threaded portion of M3 Torx T machine screw 17 for thrust bearing installation, and use Torx torque driver for installation by tightening to the specified torque. Tightening torque: 1.3 ± 0.1 Nm 4. Seal plate installation • Fit the seal ring on oil thrower 2. • Insert oil thrower 2 into seal plate 4. NOTE: the seal ring joint portion shall be positioned as illustrated at right. • Apply liquid gasket on the seal plate mounting surface on the compressor side of bearing housing 15. NOTE: see the illustration below for the applying position.

VC. View from the compressor

Applying thickness: 0.1 ÷ 0.2 mm • Install seal plate 4 on bearing housing 15. • Apply Loctite on the threaded portion of M3 machine screw for seal plate mounting, and tighten it with a torque screwdriver. Tightening torque: 1.3 ± 0.1 Nm

CP. Carefully prevent the liquid gasket from leaking out to this area LG. Liquid gasket applying position

51-147

51. ENGINE 5. Compressor impeller installation • Fit compressor impeller 18 onto turbine shaft 1. • Set a box spanner (10 mm) on the turbine side end of turbine shaft 1, and tighten shaft end nut 19. NOTE: since the shaft end nut has left-handed screw, pay attention to the tightening direction. Tightening torque: 2.0 ± 0.2 Nm 6. Turbine housing installation • Install bearing housing 15 on turbine housing 11 by aligning the match marks put before disassembly. NOTE: in case of part replacement, check the oil inlet and outlet positions and the exhaust gas inlet position before reassembly. • Install the turbine side keep plate and tighten hexagon head screw M8 12. Tightening torque: 285 ± 10 Nm 7. Compressor housing installation • Apply liquid gasket on the compressor side flange of bearing housing 15. NOTE: see section (4) 3) for the portion to be applied. Applying thickness: 0.1 ÷ 0.2 mm • Check the mark and install the compressor housing 7 on the bearing housing 15. NOTE: when a part is replaced, confirm a position of an oil entrance and a position of an air exit, and assemble it. • Install the keep plate 10 on compressor side, and tighten hexagon head screw M8 8. Tightening torque: 48 ± Nm

51-148

51. ENGINE 8. Rotor play measurement See the inspection procedure in section 8.3.2 for the measurement method. If the rotor play does not satisfy the standard, reassembly is necessary since assembly error or use of a wrong part is conceivable. Service standard of rotor play in axial direction RHF5 ......... 0.03 ÷ 0.06 mm RHB51 ....... 0.03 ÷ 0.06 mm RHB31......... 0.022 ÷ 0.053 mm Service standard of rotor play in radial direction RHF5 ......... 0.08 ÷ 0.13 mm RHB51 ....... 0.08 ÷ 0.13 mm RHB31......... 0.061 ÷ 0.093 mm

51-149

51. ENGINE 51.8.7

HANDLING AFTER DISASSEMBLY AND REASSEMBLY

When installing the turbocharger on the engine or handling the turbocharger after installation, strictly observe the instructions given below. Especially pay careful attention for preventing foreign matter entrance into the turbocharger.

51.8.7.1 Instructions for turbocharger installation Lubrication system • Pour new lubricating oil through the oil filler port before installation on the engine, and manually turn the turbine shaft to lubricate the floating and thrust bearings. • Flush the oil inlet pipe from the engine and outlet pipe, and check no crushed pipe nor dirt or foreign matter remaining in the pipes. • Connect the pipes securely so as to ensure no oil leak from joints. Intake system • Check no foreign matter or dirt in the intake line. • Connect securely to prevent any air leak from joints with the intake duct and air cleaner. Exhaust system • Check no dirt or foreign matter in the exhaust system. • Since heat resistant steel is used for the bolts and nuts, do not use general bolts and nuts for installation. Always apply anti-seizure agent on fastening bolts and nuts to be tightened. (Use heat-resistant hexagon bolts for the turbine housing). • Connect exhaust pipes securely to prevent gas leak from each pipe joint.

51-150

51. ENGINE 51.8.8

TROUBLESHOOTING

Sufficient turbocharger performance and required engine output cannot be obtained if there is any fault. In such a case, first check each engine part to see there is no engine fault. Then inspect the turbocharger for troubleshooting according to the procedure shown below.

51.8.8.1 Excessively exhaust smoke 1. Insufficient intake air volume Cause 1. Clogging of air cleaner element 2. Blocked air intake port 3. Leak from a joint in intake line

Corrective action • Replace or wash the element. • Correct to the normal state. • Check and repair.

2. Turbocharger revolution failure Cause 1. Deposit of impurities in oil sticking on the turbine side seal portion to make turbine revolution heavy 2. Sticking bearing • Insufficient lubrication or clogged lubrication piping • Excessively high oil temperature • Unbalanced rotating part • Insufficient warming up or sudden stop from loaded operation (no-load operation) 3. Contact or breakdown of turbine wheel or blower vane • Excessive revolution • Excessive exhaust temperature rise • Foreign matter invasion • Worn bearing • Assembly defect

• • • • • • • • •

Corrective action Turbocharger overhaul (disassembly and washing) with lubricating oil replacement Turbocharger overhaul (disassembly and repair) Lubricating oil line inspection, repair of defective portion and lubricating oil replacement Rotating part replacement or washing Strict observance of instructions in operation manual Inspection and repair of each engine part Perfect foreign matter elimination in disassembled state, followed by inspection and repair of individual air cleaner and engine components Turbocharger overhaul (disassembly and repair) Reassemble

3. Influence of exhaust resistance Cause Corrective action 1. Exhaust gas leak before the turbocharger to decrease • Joint inspection and correction its revolutions • Correct to the normal state. 2. Deformed or clogged exhaust pipe to decrease turbocharger revolutions

51.8.8.2 White smoke generation Cause Corrective action 1. Clogged or deformed oil return pipe causing oil flow to • Repair or pipe replacement the blower or turbine side • Turbocharger disassembly and repair 2. Excessive bearing wear causing abnormal wear or damage of seal ring

51-151

51. ENGINE 51.8.8.3 Sudden oil decrease Cause 1. Excessive bearing wear causing abnormal wear or damage of seal ring

Corrective action • Turbocharger disassembly and repair

51.8.8.4 Decrease in output Cause 1. Gas leak from any part in exhaust piping 2. Air leak from discharge side of blower 3. Clogging of air cleaner element 4. Fouled or damaged turbocharger

Corrective action • Inspection and repair of defective portion • Element cleaning or replacement • Turbocharger disassembly and repair or replacement

51.8.8.5 Poor (slow) response (starting) of turbocharger Cause Corrective action 1. Hard carbon deposit on the turbine side (wheel sealing • Turbocharger disassembly and washing with lubricating oil replacement portion) to make turbine shaft revolution heavy • Engine combustion state inspection, followed by 2. Incomplete combustion improvement of combustion to normal state

51.8.8.6 Abnormal sound or vibration 1.

Abnormal sound generation Cause Corrective action 1. Excessively narrowed gas path due to clogged nozzle • Turbocharger disassembly and washing in turbine wheel chamber or reverse flow of blower discharge in acceleration (generally called “surging”) • Turbocharger disassembly and repair or replacement 2. Contact rotating part

Vibration

Cause Corrective action 1. Loosened intake, exhaust or oil pipe connection with • Turbocharger installation status check and repair of defective portion the turbocharger 2. Damaged bearing, contact between rotating part and • Turbocharger disassembly with repair or replacement, or perfect removal of foreign matters in case of foreign adjacent part, or chipping of turbine wheel or blower matter invasion vane due to foreign matter invasion • Repair or replacement of rotating part 3. Unbalanced rotating part

51-152

51. ENGINE

51.9

STARTER MOTOR

As a representative example of starter, the one for 4TNV94L·98 and 4TNV106 (T) is shown in this chapter. 51.9.1

4TNV94L/98

51.9.1.1 Specifications Manufacturer’s model (Hitachi) Rated output Weight Revolution direction (as viewed from pinion) Engagement system Terminal voltage/current No-load Revolution Terminal voltage/current Load Torque Clutch system Pinion projection voltage (at 100°C) Pinion DP or module/number of teeth Difference (O-ring, oil seal) Application

kW kg V/A rpm V/A Nm V -

51-153

S13-204 2.3 5.5 Right Magnetic shift 11/140 or less 4100 or more 2.5/1050 or less 24.5 or more Overload 8.6 or less M3/9 Dry (none) Standard value

S13-205            Wet (with) Option

51. ENGINE 51.9.1.2 Components

3. 4. 5. 6. 7. 9. 11.

Through bolt Rear cover Brush Field coil Rotor Magnetic switch Shift lever

13. 14. 18. 19. 20. 21.

51-154

Bearing retainer Gear case Pinion shaft Clutch assy O-ring Oil seal

51. ENGINE 51.9.1.3 Troubleshooting

Is the shift lever NO at the neutral position?

Are the battery charge and NO terminal connection normal without any corrosion?

Set the shift lever at the neutral position

• Charge battery, or replace it • Connect the battery terminal and repair corrosion

YES NO Is the starting motor magnetic switch actuating sound head?

Engine starting failure? YES Can the engine NO be cranked?

Inspect the wiring up to the magnetic switch and repair if necessary • Key switch • Safety relay • Magnetic switch • Connection state

YES Is the starting motor NO sound heard? YES NO

• Adjust / dimension • Inspect the shift lever for deformation, the return spring for fatigue and the pinion for sliding • Repair meshing between pinion and ring gear or replace as needed

Pinion and ring gear meshing normal?

YES Pinion roller clutch damage, inspection and replacement. Reduction gear damage inspection and replacement

NO Connect the M terminal of the individual starting motor with the battery. Does the motor run?

• Inspect the brush and replace if worn • If brushes are nor worn, replace the motor (yoke assy or armature)

YES Magnetic switch contact defect. Change.

When the starter motor is wetted with water, always replace the magnetic switch even if operation is normal.

YES Is the NO (slow revolution) revolution normal? YES

Are the battery charge and NO terminal connection normal without any corrosion?

In case of anomaly (immediately disconnect the battery negative terminal)

YES NO

Check the fuel system

Is the lube oil viscosity normal?

Change.

The motor does not stop even when the key switch is turned OFF

Repair or replace the starting motor

Repair or replace the key switch, starter motor relay or magnetic switch.

YES Does the engine run when the YES starting motor is replaced with a new one? Slow revolution

Inspect the inside of the engine

Inspection item

Causes and remedies

51-155

51. ENGINE 51.9.1.4 Names of parts and disassembly procedure 1. Disassembling order

1. Nut M8 (disconnect the connecting wire). See the disassembly drawing. 2. Screw M4 (2) 3. Through bolt M5 (2) 4. Rear cover 5. Brush holder 6. Yoke assy. 7. Rotor 8. Bolt M6 (2) 9. Magnetic switch

10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

2. Disassembly procedure â&#x20AC;˘ Nut M8 Remove the magnetic switch nut M8 (12 mm) (1) and disconnect the connecting wire (22).

51-156

Dust cover Shift lever Screw M4 (3) Bearing retainer Gear case Pinion stopper clip Pinion stopper Return spring Pinion shaft Clutch assy

51. ENGINE

• Screw M4 (2) • Through bolt M5 (2) • Rear cover Remove the M4 screw fastening the brush holder and remove through bolt M5 for rear cover removal.

• Brush holder Pull the brush spring up with the brush spring puller. On the negative (-) side, bring the brush spring into contact with the side of the brush for lifting from the commutator surface. On the positive (+) side, extract the brush from the brush holder.

• Yoke assy. • Rotor Remove the brush holder. The armature and yoke assy can now be removed.

• Bolt M6 (2) • Magnetic switch Remove bolt M6 (10 mm), and the magnetic switch can be removed.

51-157

51. ENGINE

• Dust cover • Shift lever Take the dust cover out from the gear case. The shift lever can be removed.

• Screw M4 (3) • Bearing retainer • Gear case Remove screw M4, and the bearing retainer and clutch assy can be removed.

• Pinion stopper clip Remove the bearing retainer at the edge and the bearing, and shift the pinion stopper toward the pinion. use a plain screwdriver and pry to remove the pinion stopper clip.

• • • •

Pinion stopper Return spring Pinion shaft Clutch assy Remove the pinion stopper clip. The pinion stopper, return spring, pinion shaft and bearing retainer can be removed. Disassembly is completed now.

51-158

51. ENGINE 51.9.1.5 Inspection and Maintenance 1. Rotor (a) Commutator outside diameter Measure the commutator outside diameter and replace the commutator if the measured value is less than the limit. mm Standard value Limit value 36.5 35.5

(b) Armature coil continuity test Check continuity between commutator segments with a multimeter (M). Good if continuity exists. In case of no continuity (coil disconnection), replace the armature.

(c) Armature coil insulation test Inspect the continuity between a commutator segment and the shaft or core with a multimeter (M). Good if no continuity exists. If continuity exists (coil short circuit), replace the armature.

(d) Armature and commutator run-out Use a dial gauge and measure the armature core runout and commutator run-out. Correct or replace if the limit is exceeded. mm Standard value Limit value A. Armature 0.03 0.2 C. Commutator 0.03 0.2

51-159

51. ENGINE

(e) Commutator surface inspection If the commutator surface is roughened, grind with 500 to 600 emery cloth grain.

(f) Commutator insulation depth Measure the depth of the insulating material between commutator segments, and correct it if it is less than the limit. mm Standard value Limit value A. Armature 0.5 รท 0.8 0.2

A. Abnormal H.Hack-saw C. Commutator IM.Insulating material CS. Commutator segment N.Normal

2. Field coil (a) Field coil continuity test Check continuity between field coil terminals. Good if continuity exists. If there is no continuity (coil disconnection), replace the field coil.

(b) Field coil insulation test Check continuity between field coil terminal and yoke. Good if no continuity exists. If continuity exists (coil short circuit), replace the armature.

51-160

51. ENGINE

3. Brush Measure the length of the brush (B). Replace with a good one if the length is less than the limit. mm Standard value Limit value 15 9

4. Brush holder (a) Brush holder insulation test Check the continuity between the brush holder (+ side) and base (- side) with a multimeter (M). Good if no continuity exists. If continuity exists (insulation defect), replace the brush holder.

(b) Brush spring inspection Inspect the brush spring pressure. N Standard spring force 31 รท 39

5. Magnetic switch When the starting motor is wetted with water, always replace the magnetic switch with a new even if the function is normal. (a) Shunt coil continuity test Check the continuity between the S terminal and the switch body. Good if continuity exists. If there is no continuity (coil disconnection), replace the magnetic switch.

51-161

51. ENGINE

(b) Series coil continuity test Check continuity between the S and M terminals. Good if continuity exists. If there is no continuity (coil disconnection), replace the magnetic switch.

(c) Contact continuity test Depress the magnetic switch with the plunger at the bottom. Check continuity between the B and M terminals with a multimeter M. Good if continuity exists. If there is no continuity (coil continuity defect), replace the magnetic switch.

6. Pinion clutch (a) Pinion inspection Manually rotate the pinion. Inspect if it is rotated smoothly in the driving direction, and is locked in the opposite direction. Replace the pinion clutch if abnormal.

(b) Pinion sliding inspection Check if the pinion slide smoothly in the axial direction. If damaged, rusted or heavy in sliding, repair it. If grease is applied too much on the pinion shaft, sliding becomes heavy.

51-162

51. ENGINE 51.9.1.6 (c) Ball bearing inspection Rotate the ball bearing while holding the outer race with fingertips. Inspect if it is sticking or it there is play.

51.9.1.7 Maintenance standard Spring force Standard height/wear limit Magnetic switch resistance, series coil/shunt coil (at 20 °C) (68 °F) Standard diameter/limit diameter Difference between maximum Repair limit/repair accuracy Commutator and minimum diameter Brush

Mica undercut depth chips Armature front Armature rear Bearing type Pinion front Pinion rear L dimension (pinion projection length)

Repair limit/repair accuracy

Nominal number

N mm  mm

35 15/9 0.27/0.60 36.5/35.5

0.2/0.03

mm mm

0.2/0.5 0.8 6903DDU 608DDU 60004DDU 6904DDU 0.3-1.5

51.9.1.8 Assembly The assembly procedure is the reverse of the disassembly procedure, but pay attention to the following points: 1. Grease application points • Gears in the gear case • Shift lever operating portion • Pinion sliding portion • Magnetic switch plunger sliding portion Use the specified grease as below table at all points.

Pinion and magnetic switch plunger sliding portions Gears Shift lever operating portion

MG2

51-163

51. ENGINE

2. Magnetic switch assembly â&#x20AC;˘ Install the shift lever on the magnetic switch with the torsion spring in-between.

â&#x20AC;˘ For installation on the gear case, install the magnetic switch with the shift lever on the gear case after pulling the pinion out. Fix the magnetic switch by tightening a built-in bolt M6. Do not forget to install the dust cover (adjusting shim).

3. Pinion projection length Connect the positive (+) lead from the battery to terminal S and negative (-) lead to terminal M. Turn the switch ON and measure the pinion moving distance L in the thrust direction. Perform this test within 10 seconds. mm Standard value L 0.3 Ăˇ 1.5

NOTE: Before measuring the dimension, pull the pinion out lightly in the direction of the arrow.

If the measured L dimension is outside the standard range, either insert or remove the dust cover (adjusting shim 0.5 mm, 0.8 mm for adjustment.

51-164

51. ENGINE 51.9.1.9 Characteristic test Since the characteristics can be checked roughly by means of a simple no-load test as explained below. NOTE: complete the test quickly since the rating of the starting motor is 30 seconds. 1. No load test Fix the starting motor on a test bench and connect wiring as shown in Fig.31. When the switch is closed, a current flows in the starting motor, which is rotated at no-load. Measure the current, voltage and number of revolutions then and check if they satisfy the specified characteristics.

A. B.

Ammeter Battery

51-165

Voltmeter

51. ENGINE 51.9.2

FOR 4TNV106(T)

51.9.2.1 Specifications Manufacturerâ&#x20AC;&#x2122;s model (Hitachi) Yanmar code Rated voltage Rated output Serviceability limit Revolution direction (as viewed from pinion) Clutch system Engagement system Pinion: Module/number of teeth Weight Pinion projection voltage (at 100 Â°C) Terminal voltage/current No-load Revolution Terminal voltage/current Load Torque Revolution

S13-138

V kW sec kg V V/A rpm V/A Nm rpm

12 3.0 30 Right Roller clutch Magnetic shift M3/9 7.3 8 or less 12/180 or less 3000 or more 9/500 16.7 or more 1270 or more

51.9.2.2 Configuration drawing

1. 2. 3. 4. 5. 6. 7. 8. 9.

Gear case Magnetic switch Rear cover Gear shaft Pinion stopper Shift lever Needle bearing Pinion Ball bearing

10. 11. 12. 13. 14. 15. 16. 17.

51-166

Oil seal Rotor Yoke Through bolt Terminal E O-ring Brush Ball bearing

51. ENGINE 51.9.2.3 Troubleshooting Engine does not start.

Can the engine be cranked?

Does the starting motor revolve?

Are the battery charge and NO terminal connection normal without any corrosion?

YES

• Charge battery, or replace it • Connect the battery terminal or repair corrosion

YES YES

Does the gear shift revolve?

Inspect pinion roller clutch for damage and replace if necessary.

NO Does the starting motor relay operate?

Inspect the starting motor relay wiring system and repair if necessary • Key switch • Starter motor relay • Connection state

YES

Inspect the reduction gear (armature, gear shaft) for damage and replace if necessary.

Is the starting motor magnetic switch actuating sound heard?

NO • Inspect the wiring up to the magnetic switch and repair if necessary

YES NO Are pinion and ring gear engaging normally?

• Adjust the dimension • Inspect the shift lever for deformation, the return spring for fatigue and the pinion for sliding • Repair engagement between pinion and ring gear or replace as needed

YES Does the motor revolve NO when M terminal of starting motor is connected to the battery?

• Inspect the brush and replace if worn • If brushes are nor worn, replace the motor (yoke assy or armature)

YES Are pinion and ring gear engaging normally? YES Is the NO (slow revolution) revolution normal? YES Inspect the ignition and fuel systems.

Are the battery charge and terminal NO connection normal without any corrosion?

1 Upon abnormality: Immediately disconnect battery negative terminal

YES NO Is the engine oil viscosity normal?

the

Replace the engine oil.

The motor does not stop even when the key switch is turned OFF

Repair or replace the starting motor

Repair or replace the key switch, starter motor relay or magnetic switch.

YES

Does the engine run when the starting motor is replaced with a new one? NO

Inspection item

Inspect the inside of the engine

Causes and remedies

51-167

YES

51. ENGINE 51.9.2.4 Component names and disassembly procedure 1. Disassembly procedure 2. Disassembly diagram

1. 2. 3. 4.

Disconnect the lead. Remove the magnetic switch. Remove the rear cover. Remove the brush holder.

5. 6. 7. 8.

51.9.2.5 Disassembly procedure 1. Disconnect the lead. Loosen the M8 nut (12 mm) of the magnetic switch and disconnect the lead.

51-168

Disassemble the gear case and center bracket. Remove the shift lever pin. Remove the gear case dust cover. Remove the pinion.

51. ENGINE

2. Removing magnet switch Remove the M6 bolts (10 mm x 2).

3. Removal of rear cover Remove the brush holder tightening screws (4 mm Ă&#x2DC; x 2) and the M5 through bolts (x 2). Then, disconnect the rear cover from the yoke using a minus screwdriver.

51-169

51. ENGINE

4. Removal of brush holder For the negative (â&#x20AC;&#x201C;) brush, bring the brush spring into contact with the side of the brush for lifting from the commutator surface. For the positive (+) brush, extract the pull out the brush from the brush holder. After the brush holder is removed, the armature and yoke can be disassembled.

5. Separating gear case from center bracket Remove three M6 bolts (10 mm) fastening the gear case to the center bracket. After removal of the M6 bolts, the centre bracket and oil seal can be removed.

51-170

51. ENGINE

6. Removal of shift lever pin Remove the M6 nut (10 mm) and pull out the shift lever pin. Now the dust cover, shift lever, gear case and gear shaft can be removed.

7. Removal of gear case dust cover Remove the two M5 bolts (using 4 mm hexagon wrench) to disassemble the dust cover from the gear case.

51-171

51. ENGINE

8. Removal of pinion Slide the pinion stopper towards the pinion and remove the pinion stopper clip using a minus screwdriver.

51.9.2.6 Inspection and Maintenance 1. Rotor â&#x20AC;˘ Check the commutator for rough surface. If so, smooth the surface using 500 to 600 emery cloth grain. If the outside periphery of the commutator has been deflected over 0.2 mm, repair by a lathe.

51-172

51. ENGINE

â&#x20AC;˘ Measure the depth of the insulating material between commutator segments, and correct if it is less than 0.2 mm.

â&#x20AC;˘ Armature coil continuity and earth tests Test type Measurement point Continuity test Across commutator Between commutator and shaft or Earth test armature

Replace if needed.

51-173

Normal Yes

Abnormal (cause) None (open circuit)

None

Yes (short-circuiting)

51. ENGINE

2. Field coil â&#x20AC;˘ Field coil continuity and earth tests Test type Measurement point Continuity test Across commutator Between commutator and shaft or Earth test armature

Replace if needed.

51-174

Normal Yes

Abnormal (cause) None (open circuit)

None

Yes (short circuit)

51. ENGINE

3. Brush • Check wear of the brush and the brush spring force.

L. Limit N. New

• Check of brush movement If the brush does not move smoothly, inspect the brush holder for bending and the brush holder sliding surface for dirt. Repair or clean as needed. • Check the continuity between the insulated brush holder (positive (+)) and the brush holder base (negative (-)). If they are electrically continuous, replace since the holder is grounded.

51-175

U. Used

51. ENGINE

4. Magnetic switch continuity test Test type Measurement point Shunt coil Between C and ground Series coil C and M

Replace if needed.

Shunt coil Series coil

S13-138 Resistance (at 20 °C) 0.6 0.218

5. Pinion • Check the pinion teeth for wear and damage. Replace with a new element if necessary. • Check if the pinion slides smoothly. If it is damaged or rusted or does not slide smoothly, repair. • Check springs for damage, and replace if necessary. • Ball bearing If abnormalities such as irregular noises are detected to the ball bearing, replace with a new one.

51-176

Normal Yes None

Abnormal (cause) None (open circuit) Yes (short-circuiting)

51. ENGINE 51.9.2.7 Assembly The assembly procedure is the reverse of the disassembly procedure, but pay attention to the following points:

1. Apply grease as instructed below. Greasing point Sliding portions and head of plunger Pinion metal and metal portions of gear case Spline portions of pinion Sliding portions of shift lever Deceleration gear

Grease type

MG2

2. Armature thrust No adjustments are needed for the thrust. 3. Gear shaft thrust Some thrust washers of 1.0 and 0.25 mm thickness are provided between the center bracket and gear shaft supporting surface. Make sure to check them at reassembly. If washers are deformed or worn, replace them with new ones. The thrust washer is correct if its thickness is between 0.05 and 0.3 mm. If it exceeds 0.3 mm, make sure the thrust is not zero.

51.9.2.8 Adjustment 1. Pinion projection length L by magnetic switch

51-177

51. ENGINE

Measure the pinion moving distance L (0.3 to 1.5 mm) in the thrust direction when the pinion is protruded by the magnetic switch. If the distance L is outside the standard range, adjust by the dust cover as shown below.

Battery

Switch

D. Dust cover

51.9.2.9 Maintenance standard mm Brush

Spring force N (kgf) Standard / Limit height Outside diameter

Commutator

Bending Depth of insulation mica Armature shaft diameter

Standard dimensions

Bearing on gear case side Sliding portion of pinion

Ball bearing

Rotor

Standard value Limit value Limit value Correction accuracy Limit value Correction accuracy Front Rear Gear shaft diameter Hole diameter Shaft diameter Hole diameter Front Rear

Length L (pinion projection length)

51-178

31.4 18/6 37 36 0.2 0.05 0.2 0.5 ÷ 0.8 25 12 13.95 ÷ 13.968 14.00 ÷ 14.018 13.95 ÷ 13.968 14.03 ÷ 14.05 6905DDU 6001DDU 0.3 ÷ 1.5

51. ENGINE

51.10 ALTERNATOR As a representative example of alternator, the alternator of 40A is shown in this chapter. 51.10.1

THE 40A ALTERNATOR FOR 3TNV84 AND OTHER MODELS

51.10.1.1 Components 1. Parts related to the alternator

1. Joint 2. V-belt adjuster

2. Alternator components of the disassembly and assembly

5. 6. 7. 8. 9. 10.

Nut Spring washer Washer Rear bracket Spacer Stator

11. 12. 13. 14. 15. 16.

51-179

Front bracket Cover Bearing Coupler Bearing Pulley

3. Generator 4. Gear case

51. ENGINE 51.10.1.2 Specifications Manufacturer’s model (Hitachi) Serviceability limit Battery voltage Nominal output (13.5V heat) Rating speed Operating revolution Grounding characteristics Direction of revolution (viewed from pulley) Integrated regulator Weight Pulley (outside diameter) Belt shape

V A rpm rpm kg mm -

ACFA68 Continuous 12 40 5000 1350 ÷ 18000 Minus side grounding Right IC regulator 2.8 69.2 Type A

51.10.1.3 Wiring diagram

B. K. L.

Battery Key switch Load

La. Charge lamp (max. 3.4 W) R. IC regulator T. Alternator assy

• Don’t do miss-wiring and short-circuit of each terminal. • Don’t short-circuit between IG and L (connect through the charge lamp). • Don’t connect a load between L and E. • Don’t remove a battery terminal and a B terminal when rotating. • Shut out a battery switch during the alternator stop. • Tightening torque of each terminal: 1.7-2.3 Nm.

51-180

51. ENGINE 51.10.1.4 Standard output characteristics The standard output characteristics of this alternator are shown as the right figure. (13.5 V constant) (ambient temperature: 25°C)

A. Output current C. Cold

H. Hot S. Alternator speed (x 103 rpm)

51.10.1.5 Inspection 1. V belt inspection • Inspect the matter whether there are not crack, stickiness and wear on the belt visually. Check that a belt doesn’t touch the bottom part of the pulley groove. If necessary, replace the V belt set. • V belt tension: (Refer to 51.2.2.2) D. Defect E. Clearance

2. Visual check of wiring and check of unusual sound • Confirm whether wiring is right or there is no looseness of the terminal part. • Confirm that there is no unusual sound from the alternator during the engine operation. 3. Inspection of charge lamp circuit • Move a start switch to the position of on. Confirm lighting of the charge lamp. • Start an engine, and confirm the lights-out of the lamp. Repair a charge lamp circuit when a lamp doesn’t work.

51-181

N. Normal

51. ENGINE 51.10.1.6 Troubleshooting

Turn ON the starter switch key. Does the charge lamp come ON?

OFF Disconnect GN coupler (L, IG)

Ground L-terminal of the OFF driven machine side coupler (L, IG). Does the charge lamp come ON?

Replace the charge lamp. The charge lamp is available from the driven machine manufacturer.

Inspect the rotor coil and brush IC-RG. ON Turn the key to “START”. (the engine starts).

Inspect or replace the fan belt, and inspect the alternator.

The lamp flashes.

Inspect the diode (side).

At idling Does the charge lamp goes OFF?

The lamp is lit dimly. OFF Increase the engine speed to 1500 rpm and turn the light switch to ON. Excessive voltage drop between BAT and battery (+side) terminal.

VB - VL > 0.5 v

Does the charge lamp come ON?

The lamp is lit dimly.

Measure VB and VL at BAT L-terminal during idling. L-terminal defective conduction. Inspect the diode (-side).

VB - VL < 0.5 v

Measure VB at BAT terminal with the engine running at 1500 rpm.

VB > 15.5

VB = 13 ÷ 5

Replace IC-RG

Turn the light switch to ON during idling.

Does charge ON?

the ON lamp

OFF Observations • Use a fully charged battery • DC voltmeter: 0 to 30 V 0.5 class • The check method id also applicable to the bench test

Explanation on abbreviations: GN: Alternator IC-RG: IC regulator VB: BAT terminal voltage VL: L terminal voltage

51-182

Inspect the auxiliary diode.

Not abnormal.

51. ENGINE

51.11

ELECTRIC WIRING

51.11.1

ELECTRIC WIRING DIAGRAM

1. Wiring of starter must be observed as follows otherwise it causes miss starting or damage of startermotor. • Total electric resistance of battery cable (1) + (2) should be less than 2/1000  Reference: AV 15: 1.4 m, AV 20: 2.2 m AV 30: 3.8 m, AV 40: 4.6 m • Total electric resistance of wiring for starter (3)~(6) should be less than 5/100  Reference of terminal resistance: 15/1000per coupler 0 per screw setting • Battery earth cable (1) connection on shall be ensured. Painted surface may not be used (for earthing) avoiding the miss contact. 2. Battery treatment must be observed as follows. Otherwise it may cause burning of electric equipment or components. Alternator (diodes) burning caused by battery cable connection reversely is not warranted. • Battery should be fixed by fitting. (not to move). • Battery cable length should be adjusted properly and clamped not to be connected reversely. • Not loose the battery cable terminal, nor turn the battery switch off during the engine running. 3. Only the specified load should be applied on the alternator (L) and (P) line. 4. Check any surge current or voltage occurred under normal operations and erroneous operations, and confirm the circuit no surge occurs. Especially provide the flywheel diode for (C-LOAD) and diode for (L-LOAD).

51-183

MARK B W R L G Y Br Lg Sb O P Gr R/W

COLOR Black White Red Blue Green Yellow Brown Light green Sky blue Orange Pink Gray Red / White

51. ENGINE

NOTE: Engine stop solenoids 1. Permissible resistance of solenoide circuit should be less than 0.07  to guarantee permissible lowest voltage 9 V to work solenoid (pull coil). (terminal resistance: 15/1000per coupler 0 per screw setting. Coupler resistance of solenoid doesn’t need to be counted) Reference: AV2 (0.0088 /m):  8.0 m, without terminal resistance AV3 (0.0056 /m): 12.5 m, same as above When you exceed permissible resistance, adopt the circuit impressed from the power supply to the solenoid directly using a relay........... refer to # 2. High temperature parts, such as an exhaust pipe, should not approach for the pull power fall of solenoid, and heating prevention of inner coil temperature. (permissible ambient temperature: -30 ÷ 100 °C) 3. Install fuse to protect the harness against trouble such as short circuit or continuous drive of pull-coil. 4. The power supply of solenoid may not be common with the line of alternator initial excitator as shown in this drawing. (Otherwise, solenoid may loose stop function due to the power supply from alternator (L) terminal). 5. In case of waterproof connect or application, connector should be fixed by fitting to prevent lead wire break. 6. In case of emergency stop of machine for safety will be applied, switch location should be shown as a. 7. In case of the solenoid circuit resistance would be limit, # wiring is applicable. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

For 4TNV84(T), 88 starter motor DC12V 1.4 kW For 3TNV82A, 84(T), 88 starter motor DC12V 1.2 kW Battery DC12V Fusible link Generator CC12V-40A Timer 15±1.5 sec Pre-heat lamp (after 15 sec OFF) less than 3.4 W Air heater DC12V-400 W Charge lamp DC12V 3.4 W Safety relay 20A fuse 5A fuse

MARK B W R L G Y Br Lg Sb O P Gr R/W

COLOR Black White Red Blue Green Yellow Brown Light green Sky blue Orange Pink Gray Red / White

20. Pilot lamp DC12V less than 3.4 W 21. 22. Electrical feed pump DC12V 1.5 A 23. Lubricating oil pressure switch CC12V 1A 0.5 kg/ cm2 OFF 24. C.W. temp switch DC12V 0.4A 110°C ON 25. Solenoid DC12V hold 0.49 A pull 36.5 A 26. Timer 1±1.5 sec 27. Relay DC12V 40A 28. Solenoid DC12V hold 0.49 A pull 36.5 A 29. Diode 600 V,1.1 A

51-184

51. ENGINE

51-185

51. ENGINE 51.11.2

PRECAUTION ON ELECTRIC WIRING

51.11.2.1 Generator In the cases listed below the warranty shall not be deemed to apply. Please be sure to read these conditions carefully when planning to use it with other equipment. Also be certain to give appropriate guidance on usage to the user. 1. When the battery cable can be connected backwards The alternator diode will be damaged and recharging made impossible if the plus and minus ends of the battery cable are confused. The stator coil will also be burned as a result. To prevent this, supply the user with a cable of such a length or structure that the plus and minus ends cannot be confused. Also warn the user not to connect the cable backwards. 2. When charging output voltage is used for control purposes The engine speed at starting is not proportional to the output voltage of the alternator, so this output voltage must not be used for any control systems. It is especially wrong to use it for the control signal of the safety relay for cutting the starter motor because this will damage the starter motor and cause engine starting failure.

3. When the L line is used for control purposes Consult with dealer first before connecting any load other than the charge lamp to the L line. Damage to the alternator and related equipment will not be warranted without such prior consultation. 4. Non-use of wiring diagram Use without prior consultation of any wiring diagram other than that provided by dealer removes any breakdown of any electrical equipment from the warranty.

51-186

51. ENGINE

5. Regarding lamp control Once the charge lamp goes out after the start of charging, it does not come on again even if the engine speed falls and charging is insufficient. The lamp will not light again if the charging circuit is normal. The lamp only comes on during operation if the alternator itself is broken or the drive V-belt breaks. However, when an LED is used for the charge lamp, the LED will shine faintly even during normal operation. This is due to the control system for the alternator lamp and is not an abnormality.

6. Use of a non-specified V-belt Use of a non-specified V-belt will cause inadequate charging and shorten the life of the belt. Use a belt of the specified type.

7. Direct high pressure washing is prohibited Water will enter the brush if the alternator is washed directly at high pressure, causing inadequate charging. Warn users not to use direct, high-pressure washing.

Use of agricultural or other chemicals (direct contact or airborne) Adhesion of agricultural and other chemicals, especially those with high sulphur content, to the IC regulator corrodes the conductor on the substrate, leading to over-charging (battery boiling) and charging malfunctions. Consult with Yanmar prior to use in such an environment. Use without prior consultation removes any breakdown from the warranty.

51-187

51. ENGINE 51.11.2.2 Starter motor In the cases listed below the warranty shall not be deemed to apply. Please be sure to read these conditions carefully when planning to use it with other equipment. Also be certain to give appropriate guidance on usage to the user. 1. Starting performance in the case of using an untested battery The starting performance of the engine is closely dependent on the battery capacity. This battery capacity is itself affected by the climate and the type of equipment installation. The details regarding ambient temperature and equipment installation vary depending on the OEM, so dealer cannot decide the battery capacity on its own. Confer with dealer in advance after checking these conditions and fix the battery capacity on the basis of confirmatory tests.

2. When the resistance of the battery cable exceeds the specified value The combined total resistance of the battery cable in both directions between the starting motor and battery should be within the value indicated on the wiring diagram. The starting motor will malfunction or break down if the resistance is higher than the specified value.

3. When the resistance of the starter circuit exceeds the specified value The combined total resistance of the wiring between the starting motor and key switch (or power relay or safety relay, depending on the application) should be within the value indicated on the wiring diagram. Engine starting will be difficult if the resistance is higher than the specified value. This can also blow the magnetic switch at the point of contact and consequently burn the rotor coil.

51-188

51. ENGINE

4. When there is no safety relay Over-running (when the electric current flows for too long) is a major cause of starting failure. This burns the rotor and the clutch. Excessive work and failure of the key switch to return properly are the main causes of over-running. The user must be given sufficient warning about this. Be sure to use the safety relay to prevent over-running. This safety relay is supplied as an option. Consult Yanmar first when planning to install a safety relay at your own company. In the case of failure to consult with Yanmar, our warranty will not be applied to all the electrical equipment.

5. When there is too much rust due to the entry of water The water-proofing of the starting motor is equivalent to R2 of JIS D 0203. This guarantees that there will be no damage from the sort of exposure encountered in rain or when water is poured on from a bucket. You should, however, avoid the use of high-pressure washing and steeping in water.

6. Regarding the heat resistance of the starter motor The starter motor has heat resistance for an ambient temperature of 80Â° and surface temperature of 100Â°. Insulators must be installed to prevent overheating when used near high temperature parts such as the exhaust system.

7. Corrosion of magnet switch contact point by corrosive gas. When using equipment with a dry clutch, ammonium gas generated by friction is liable to corrode the contact of the magnet switch. Be sure to install a vent in the clutch case.

51-189

51. ENGINE 51.11.2.3 Current limiter In the cases listed below the warranty shall not be deemed to apply. Please be sure to read these conditions carefully when planning to use it with other equipment. Also be certain to give appropriate guidance on usage to the user. 1. When an over-discharged battery is used Use of booster starting with an over-discharged battery (when the voltage has dropped to 8V or less) will destroy other electrical equipment by generating an abnormally high voltage. A specialized battery charger should be used to recharge such an over-discharged battery (when the voltage has dropped to 8V or less).

2. When checks for malfunctioning are not performed When high voltage noise from other electrical equipment is impressed on the current limiter upon turning off the key switch, the current limiter can be damaged and cause loss of control over the output voltage. Other electrical equipment may also be damaged if this happens, so surge killers should be fitted to the electrical equipment whenever necessary. Be sure to check prior to mass production whether electrical noise might damage the current limiter by turning the key switch and other electrical equipment on and off while the engine is running, using both the vehicle and the wire harness that will be used in mass production.

3. Removal of the battery cable during operation The current limiter may malfunction if the battery cable and/or battery are removed during operation, depending on the kind of electrical equipment being used, causing loss of control over the output voltage. In such cases, the current limiter and other electrical equipment will be damaged by the generation of a continuous high voltage of 24-43V (for 5.000 rpm dynamo). All electrical equipment falls outside the scope of the warranty under these circumstances. Be sure to warn the user not to remove the battery cable and/or battery during operation.

51-190

51. ENGINE

4. If the battery cable can be attached in reverse The current limiter’s SCR diode will be destroyed if the plus and minus ends of the battery cable are connected the wrong way around. This causes charging malfunctioning and burns the harness. Give the user a cable of such a length that it cannot be connected the wrong way and warn the user against connecting the cable backwards.

5. Non-use of wiring diagram Use without prior consultation of any wiring diagram other than that provided by dealer removes any breakdown of any electrical equipment from the warranty.

6. Installation environment Observe the following when installing the current limiter: • Do not install it on the engine. • Place it in a well-ventilated place with an ambient temperature of 65°C or less. • Ensure that the cooling air flows in the right direction for the current limiter’s cooling fins. • Do not use the earth wire of the current limiter to earth any other electrical equipment.

51-191

51. ENGINE 51.11.2.4 Section area and resistance of electric wire 1. Allowable maximum cable length (Terminal resistance is not included).

Cable construction Resistor Cable diame(/m) Element No. ter 3 41 ø 0.32 0.005590 5 65 ø 0.32 0.003520 8 50 ø 0.45 0.002320 15 84 ø 0.45 0.001380 20 41 ø 0.80 0.000887 30 70 0.80 0.000520 40 85 0.80 0.000428 50 108 0.80 0.000337 60 127 0.80 0.000287 85 169 0.80 0.000215 100 217 0.80 0.000168 Note1) Allowable maximum resistance of Battery cable Note2) Allowable maximum resistance of Starting motor circuit Cable size mm2

2. Terminal resistance Generally, a terminal resistance is 15 m  per coupler and 0  per screw setting. This resistance should be included in allowable maximum resistance when the cable length is planned.

51-192

2 m  Note1 (m) 0.36 0.57 0.86 1.45 2.25 3.85 4.67 5.93 6.97 9.30 11.90

20 m  Ref. (m) 3.58 5.68 8.62 14.49 22.55 38.46 46.73 59.35 69.69 93.02 119.05

50 m  Note 2 (m) 8.94 14.20 21.55 36.23 56.37 96.15 116.82 148.37 174.22 232.56 297.62

51. ENGINE

51.12 MAINTENANCE STANDARD 51.12.1

ENGINE TUNING

No. 1

Inspection item Gap at intake/exhaust valve heads

TNV82A~98 mm 4TNV106(T)

Between alternator Used part and crank pulley New part V-belt tension Between alternator Used part mm and radiator fan New part at 98N Between radiator Used part fan and crank New part pulley 3TNV82A~TNV88(VM) Fuel injection pressure 4TNV94L~106(T) MPa 3TNV82A~TNV88(CL) TNV82A Compression pressure TNV84 (at 250 min-1) MPa 3/4TNV84T TNV88-106 3TNV82A,84 Coolant 3TNV84T,88 Capacities 4TNV84(T) 0.88 (Only engine body) (litres) 4TNV94L98(T) 4TNV106(T) 3TNV82A Lubricating oil capacity 3TNV84(T)/88 (oil pan) 4TNV84(T)/88 (litres) 4TNV94L/98(T) 4TNV106(T) (CL class) 4TNV106(T) (VM class) 3TNV82A~98 4TNV98T 4TNV106(T) Lubricating oil pressure (VM, WO balancer) MPa 4TNV106(T) (CL, WO balancer) 4TNV106(T) (VM, W balancer) Oil pressure switch operating pressure MPa (kgf/cm2)

Standard value 0.15 ÷ 0.25 0.25 ÷ 0.35 10 ÷ 14 8 ÷ 12 7 ÷ 10 5÷8 9 ÷ 13 7 ÷ 11 21.57 ÷ 22.55 19.6 ÷ 20.6 3.16 ± 0.1 3.24 ± 0.1 2.94 ± 0.1 3.43 ± 0.1 1.8 2.0 2.7 4.2 6.0 Full Effective 5.5 1.9 6.7 2.8 7.4 3.4 10.5 4.5 14.0 9.0 14.0 7.5 at rated speed 0.29 ÷ 0.39

All models

0.06 or above

0.34 ÷ 0.44 (3.5 ÷ 4.5) 0.05 ± 0.01 (3.5 ÷ 4.5)

80 ÷ 84

10 Thermo switch actuating temperature (degrees °C)

51-193

2.45 ± 0.1 2.55 ± 0.1 2.45 ± 0.1 4 2.75 ± 0.1 at low idle speed

0.31 ÷ 0.49

69.5 ÷ 72.5

All models option

0.39 ÷ 0.49

Valve opening Temperature degrees °C 9 Thermostat

Limit value -

107 ÷ 113

Full opening lift (mm) (temperature) 8 or more (85 degrees °C) 10 or more (95 degrees °C) -

51. ENGINE 51.12.2

ENGINE BODY

51.12.2.1 Cylinder head 1. Cylinder head Inspection item Combustion surface distortion Inlet Drain Inlet

Standard value 0.05 or less 0.35 ÷ 0.55 0.30 ÷ 0.50 0.30 ÷ 0.50

Limit value 0.15 0.8 0.8 0.8

Drain

0.30 ÷ 0.50

0.8

Inlet Drain Inlet 4TNV106(T) (4-valve head) Drain Inlet Seat angle Deg. Drain Seat correction angle degrees

0.36 ÷ 0.56 0.35 ÷ 0.55 0.5 ÷ 0.7 0.7 ÷ 0.9 120 90 40.150

0.8 0.8 1.0 1.2 -

3TNV82A (2-valve head) Valve sink mm

Valve seat (2-valve, 4-valve)

TNV84~88 (2-valve head) 4TNV84T(4-valve)

4TNV94L·98(T) (4-valve head)

51-194

51. ENGINE

2. Intake/exhaust valve and guide

Inspection item Valve guide inside Inlet Valve stem outside diameter Tolerance 3TNV82A (2-valve head) Valve guide inside Drain Valve stem outside diameter Tolerance Valve guide inside Inlet Valve stem outside diameter 4TNV84 Tolerance 3TNV84(T) 3/4TNV88 Valve guide inside (2-valve head) Drain Valve stem outside diameter Tolerance Valve guide inside Inlet Valve stem outside diameter Tolerance 4TNV84T (4-valve head) Valve guide inside Drain Valve stem outside diameter Tolerance Valve guide inside Inlet Valve stem outside diameter 4TNV94L Tolerance 4TNV98(T) Valve guide inside (4-valve head) Drain Valve stem outside diameter Tolerance Valve guide inside Inlet Valve stem outside diameter Tolerance 4TNV106(T) (4-valve head) Valve guide inside Drain Valve stem outside diameter Tolerance 3TNV82A 4TNV84, 3TNV84(T), 4TNV88 Valve guide projection from cylinder head 4TNV84T 4TNV94L, 4TNV98(T) 4TNV106(T) Valve guide driving-in method

51-195

Standard value 7.000 ÷ 7.015 6.945 ÷ 6.960 0.040 ÷ 0.070 7.000 ÷ 7.015 6.940 ÷ 6.955 0.045 ÷ 0.075 8.010 ÷ 8.025 7.955 ÷ 7.975 0.035 ÷ 0.070 8.015 ÷ 8.030 7.955 ÷ 7.960 0.045 ÷ 0.075 6.000 ÷ 6.015 5.960 ÷ 5.975 0.025 ÷ 0.055 6.000 ÷ 6.015 5.945 ÷ 5.960 0.040 ÷ 0.070 7.000 ÷ 7.015 6.945 ÷ 6.960 0.040 ÷ 0.070 7.000 ÷ 7.015 6.940 ÷ 6.955 0.045 ÷ 0.075 7.008 ÷ 7.020 6.945 ÷ 6.960 0.048 ÷ 0.075 7.008 ÷ 7.020 6.960 ÷ 6.975 0.033 ÷ 0.060 11.7 ÷ 12.0

mm Limit value 7.08 6.90 0.18 7.08 6.90 0.18 8.10 7.90 0.18 8.10 7.90 0.18 6.08 5.90 0.15 6.08 5.90 0.17 7.08 6.90 0.17 7.08 6.90 0.17 7.08 6.92 0.16 7.08 6.90 0.18 -

14.7 ÷ 15.0

8.2 ÷ 8.5 9.7 ÷ 10.0 13.4 ÷ 13.6 Cold-fitted

51. ENGINE

3. Valve spring

Inspection item 3TNV82A (2-valve) 4TNV84,3TNV84(T), 4TNV88 (2-valve) 4TNV84T(4-valve) 4TNV94L, 4TNV98(T), (4-valve) 4TNV106(T) (4-valve) 3TNV82A (2-valve) 4TNV84, 3TNV84(T), 4TNV88 (2-valve) 4TNV84T(4-valve) 4TNV94L, 4TNV98(T), (4-valve) 4TNV106(T) (4-valve)

Free length

Inclination

Standard value 44.4 42.0 37.4 39.7 50.6 -

mm Limit value 43.9 41.5 36.9 39.2 50.1 1.4 1.4 1.3 1.4 1.5

4. Rocker arm and shaft

Model TNV82A~88

4TNV94L/98(T)/106(T)

Inspection item Arm shaft hole diameter Shaft outside diameter Tolerance Arm shaft hole diameter Shaft outside diameter Tolerance

Standard value 16.000 ÷ 16.020 15.966 ÷ 15.984 0.016 ÷ 0.054 18.500 ÷ 18.520 18.470 ÷ 18.490 0.010 ÷ 0.050

mm Limit value 16.07 15.94 0.13 18.57 18.44 0.13

5. Push rod mm Inspection item

Standard value -

Bend

51-196

Limit value 0.03

51. ENGINE 51.12.2.2 Gear Train and Camshaft 1.

Cam shaft

Inspection item Side gap Bending (1/2 the dial gauge reading) 3TNV82A-TNV88 Cam height 4TNV94L·98 4TNV106(T) Shaft outside diameter / Metal inside diameter Bushing inside diameter Gear side Camshaft outside diameter Tolerance Bushing inside diameter TNV82A~TNV88 Intermediate Camshaft outside diameter Tolerance Bushing inside diameter Flywheel side Camshaft outside diameter Tolerance Bushing inside diameter Gear side Camshaft outside diameter Tolerance Bushing inside diameter 4TNV94L/98(T) Intermediate Camshaft outside diameter Tolerance Bushing inside diameter Flywheel side Camshaft outside diameter Tolerance Bushing inside diameter Gear side Camshaft outside diameter Tolerance Bushing inside diameter 4TNV106(T) Intermediate Camshaft outside diameter Tolerance Bushing inside diameter Flywheel side Camshaft outside diameter Tolerance

Standard value 0.05 ÷ 0.20 0 ÷ 0.02 38.600 ÷ 38.800 43.400 ÷ 43.600 50.900 ÷ 51.100 44.990 ÷ 45.055 44.925 ÷ 44.950 0.040 ÷ 0.130 45.000 ÷ 45.025 44.910 ÷ 44.935 0.065 ÷ 0.115 45.000 ÷ 45.025 44.925 ÷ 44.950 0.050 ÷ 0.100 49.990 ÷ 50.055 49.925 ÷ 49.950 0.040 ÷ 0.130 50.000 ÷ 50.025 49.910 ÷ 49.935 0.065 ÷ 0.115 50.000 ÷ 50.025 49.925 ÷ 49.950 0.05 ÷ 0.100 57.980 ÷ 58.050 57.910 ÷ 57.940 0.040 ÷ 0.140 58.000 ÷ 58.030 57.895 ÷ 57.925 0.075 ÷ 0.135 58.000 ÷ 58.030 57.910 ÷ 57.940 0.050 ÷ 0.120

mm Limit value 0.30 0.05 38.350 43.150 50.650 45.130 44.890 0.240 45.100 44.875 0.225 45.100 44.890 0.210 50.130 49.890 0.240 50.100 49.87 0.225 50.100 49.890 0.210 58.105 57.875 0.250 58.105 57.860 0.245 58.105 57.875 0.230

2. Idle gear shaft and bushing mm Inspection item Shaft outside diameter Bushing inside diameter Tolerance

Standard value 45.950 ÷ 45.975 46.000 ÷ 46.025 0.025 ÷ 0.075

51-197

Limit value 45.900 46.075 0.175

51. ENGINE

3. Backlash of each gear

Model 3TNV82A~88 4TNV94L 4TNV98(T) 4TNV106(T)

Inspection item Crank gear, cam gear, idle gear, fuel injection pump gear and PTO gear Crank gear, cam gear, idle gear, fuel injection pump gear and PTO gear Lubricating oil pump gear Balancer drive gear (only for 4TNV106(T))

Standard value

mm Limit value

0.07 ÷ 0.15

0.17

0.08 ÷ 0.14

0.16

0.09 ÷ 0.15

0.17

0.12 ÷ 0.18

0.20

51.12.2.3 Cylinder block 1.

Cylinder block mm

Inspection item 3TNV82A TNV84 TNV88 Cylinder inside diameter 4TNV94L 4TNV98 4TNV106(T) Roundness Cylinder bore Inclination

51-198

Standard value 82.000 ÷ 82.030 84.000 ÷ 84.030 88.000 ÷ 88.030 94.000 ÷ 94.030 98.000 ÷ 98.030 106.000 ÷ 106.030

Limit value 82.200 84.200 88.200 94.130 98.130 106.130

0.01 or less

0.03

51. ENGINE

2. Crankshaft

Inspection item Bending (1/2 the dial gauge reading) Pin outside diameter Metal inside diameter 3TNV82A Metal thickness Tolerance Pin outside diameter Metal inside diameter TNV84~88 Metal thickness Tolerance Crankpin Pin outside diameter Metal inside diameter 4TNV94L·98 Metal thickness Tolerance Pin outside diameter Metal inside diameter 4TNV106(T) Metal thickness Tolerance Journal outside diameter Metal inside diameter 3TNV82A Metal thickness Tolerance Journal outside diameter Metal inside diameter TNV84~88 Selective pairing Metal thickness Tolerance Crank journal Journal outside diameter Metal inside diameter 4TNV94L·98 Selective pairing Metal thickness Tolerance Journal outside diameter Metal inside diameter 4TNV106(T) Selective pairing Metal thickness Tolerance

Standard value 42.952 ÷ 42.962 43.000 ÷ 43.042 1.487 ÷ 1.500 0.038 ÷ 0.090 47.952 ÷ 47.962 48.000 ÷ 48.026 1.492 ÷ 1.500 0.038 ÷ 0.074 57.952 ÷ 57.962 58.000 ÷ 58.026 1.492 ÷ 1.500 0.038 ÷ 0.074 63.952 ÷ 63.962 64.016 ÷ 64.042 1.984 ÷ 1.992 0.054 ÷ 0.090 46.952 ÷ 46.962 47.000 ÷ 47.032 1.987 ÷ 2.000 0.038 ÷ 0.080 53.952 ÷ 53.962 54.000 ÷ 54.020 1.995 ÷ 1.990 0.038 ÷ 0.068 64.952 ÷ 64.962 65.000 ÷ 65.020 1.995 ÷ 2.010 0.038 ÷ 0.068 75.952 ÷ 75.962 76.014 ÷ 76.034 2.488 ÷ 2.503 0.052 ÷ 0.082

mm Limit value 0.02 42.902 0.150 47.902 0.150 57.902 0.150 63.902 0.150 46.902 0.150 53.902 0.150 64.902 0.150 75.902 0.150

3. Thrust bushing mm Crankshaft side gap

Inspection item All models

Standard value 0.13 ÷ 0.23

51-199

Limit value 0.28

51. ENGINE

4. Ring and piston Piston

Inspection item

Piston outside diameter (Measure in the direction vertical to the piston pin).

Piston diameter measure position (Upward from the bottom end of the piston)

3TNV82A

TNV84~88 Piston pin 4TNV94L·98

4TNV106(T)

3TNV82A 3,4TNV84(T) 3,4TNV88 4TNV94L 4TNV98(T) 4TNV106(T) 3TNV82A 3,4TNV84(T) 3,4TNV88 4TNV94L 4TNV98(T) 4TNV106(T) Hole inside diameter Pin outside diameter Tolerance Hole inside diameter Pin outside diameter Tolerance Hole inside diameter Pin outside diameter Tolerance Hole inside diameter Pin outside diameter Tolerance

51-200

Standard value 81.950 ÷ 81.980 83.945 ÷ 83.975 87.945 ÷ 87.975 93.945 ÷ 93.955 97.940 ÷ 97.950 105.930 ÷ 105.960 16 24 24 22 22 30 23.000 ÷ 23.009 22.995 ÷ 23.000 0.000 ÷ 0.014 26.000 ÷ 26.009 25.995 ÷ 26.000 0.000 ÷ 0.014 0.000 ÷ 30.009 29.989 ÷ 30.000 0.000 ÷ 0.020 37.000 ÷ 37.011 36.989 ÷ 37.000 0.000 ÷ 0.022

mm Limit value 81.905 83.900 87.900 93.900 97.895 105.880 23.039 22.965 0.074 26.039 25.965 0.074 30.039 29.959 0.080 37.039 36.959 0.080

51. ENGINE

Piston ring Model Top ring

3TNV82A TNV84

Second ring

Oil ring

Top ring

TNV88

Second ring

Oil ring

Top ring

4TNV94L/98

Second ring

Oil ring

Top ring

4TNV106(T)

Second ring

Oil ring

Inspection item Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance Ring groove width Ring width Side gap End clearance

51-201

mm Limit value 1.950 0.490 2.150 1.950 0.200 0.490 4.130 3.950 0.180 0.490 1.950 0.490 2.140 1.950 0.190 0.490 4.130 3.950 0.180 0.490 1.920 0.540 2.195 1.950 0.245 0.730 3.130 2.950 0.180 0.550 2.420 0.540 2.185 1.950 0.235 0.680 3.130 2.950 0.180 0.600

51. ENGINE

5. Link rod mm Inspection item

Standard value 0.2 ÷ 0.4

Thrust clearance

Limit value -

Rod small end mm Model 3TNV82A

TNV84-88

4TNV94L·98

4TNV106(T)

Inspection item Bushing inside diameter Pin outside diameter Tolerance Bushing inside diameter Pin outside diameter Tolerance Bushing inside diameter Pin outside diameter Tolerance Bushing inside diameter Pin outside diameter Tolerance

Standard value 23.025 ÷ 23.038 22.995 ÷ 23.000) 0.025 ÷ 0.043 26.025 ÷ 26.038 25.995 ÷ 26.000 0.025 ÷ 0.043 30.025 ÷ 30.038 29.987 ÷ 30.000 0.025 ÷ 0.051 37.025 ÷ 37.038 36.989 ÷ 37.000 0.025 ÷ 0.049

Limit value 23.068 22.967 0.101 26.068 25.967 0.101 30.068 29.959 0.109 37.068 36.961 0.107

6. Tappet mm Inspection item Tappet hole (block) inside diameter TNV84-88 Tappet stem outside diameter Tolerance Tappet hole (block) inside diameter 4TNV94L·9 Tappet stem outside diameter 8 Tolerance Tappet hole (block) inside diameter 4TNV106(T) Tappet stem outside diameter Tolerance

Standard value 12.000 ÷ 12.025 11.975 ÷ 11.990 0.010 ÷ 0.050 12.000 ÷ 12.018 11.975 ÷ 11.990 0.010 ÷ 0.043 14.000 ÷ 14.018 13.966 ÷ 13.984 0.015 ÷ 0.052

51-202

Limit value 12.045 11.955 0.090 12.038 11.955 0.083 14.038 13.946 0.092

51. ENGINE 51.12.2.4 Lubricating oil system (trochoid pump) 1.

Outside clearance of outer rotor mm Model

3TNV82A~88 4TNV94L/98 4TNV106(T)

Standard value 0.12 ÷ 0.21 0.100 ÷ 0.155 0.100 ÷ 0.165

Limit value 0.30 0.25 0.25

Standard value 0.02 ÷ 0.07 0.05 ÷ 0.10 0.03 ÷ 0.12

Limit value 0.12 0.15 0.17

2. Side clearance of outer rotor mm Model 3TNV82A~88 4TNV94L/98 4TNV106(T)

3. Inside clearance of inner rotor

Piece

Items Inside clearance of inner Gear hub diameter rotor Rotor diameter Width across flats of gear Width across flat hub clearance of inner rotor Width across flats of rotor

Standard value 53.05 ÷ 53.15 53.45 ÷ 53.5 5 49.45 ÷ 49.75

Standard value

mm Limit value

0.3 ÷ 0.5

0.6

0.2 ÷ 0.6

0.7

49.95 ÷ 50.05

4. Rotor shaft clearance

Model 4TNV94L/98

4TNV106(T)

Inspection item Gear case bearing inner diameter Rotor shaft outer diameter Rotor clearance Gear case bearing inner diameter Rotor shaft outer diameter Rotor clearance

Standard value 12.980 ÷ 13.02 12.955 ÷ 12.975 0.035 ÷ 0.065 13.00 ÷ 13.02 12.955 ÷ 12.965 0.035 ÷ -0.065

51-203

mm Limit value 13.05 12.945 0.105 13.05 12.945 0.105

51. ENGINE

51.13 TIGHTENING TORQUE for BOLTS and NUTS 51.13.1

TIGHTENING TORQUES FOR MAIN BOLTS AND NUTS

Part and engine model

Cylinder head screws

Connecting rod bolt

Flywheel set bolt

Bearing cap set bolt

Crankshaft pulley set bolt Fuel nozzle setscrew Fuel pump drive gear set nut Fuel injection pipe set bolt Fuel return pipe joint bolt Rocker arm cover set bolt EPA flange setscrew

3TNV82A TNV84~88 4TNV94L·98 4TNV106(T) 3TNV82A TNV84~88 4TNV94L·98 4TNV106(T) TNV82A~88 4TNV94L·98·106(T) 3TNV82A TNV84~88 4TNV94L·98 4TNV106(T) TNV82A~88 4TNV94L·98·106(T) TNV82A~88 4TNV94L·98·106(T) TNV82A~88 4TNV94L·98·106(T) TNV82A~88 4TNV94L·98·106(T) 4TNV94L·98·106(T) 4TNV106(T) 4TNV106(T)

Thread diameter Lubricating oil application Tightening torque x pitch (thread portion, and seat Nm mm surface) M9x1.25 61.7 ÷ 65.7 M10x1.25 85.3 ÷ 91.1 Applied M11x1.25 103.1 ÷ 112.9 M13x1.5 188.0 ÷ 197.8 M8x1.0 37.2 ÷ 41.2 M9x1.0 44.1 ÷ 49.0 Applied M10x1.0 53.9 ÷ 58.8 M11x1.0 78.5 ÷ 83.4 M10x1.25 83.3 ÷ 88.2 Applied M14x1.5 186.2 ÷ 205.8 M10x1.25 76.4 ÷ 80.4 M12x1.5 93.2 ÷ 98.1 Applied M11x1.25 108.1 ÷ 117.9 M14x1.5 186.2 ÷ 205.8 M14x1.5 112.7 ÷ 122.7 Applied M14x1.5 107.9 ÷ 127.5 M8x1.25 24.4 ÷ 28.4 Not applied M8x1.25 22.6 ÷ 28.4 M14x1.5 78 ÷ 88 Not applied M18x1.5 113 ÷ 123 M12x1.5 29.4 ÷ 34.3 Not applied M12x1.5 19.6 ÷ 24.5 M6x1.0 7.8 ÷ 9.8 Not applied M8x1.25 16.7 ÷ 22.5 Not applied M18x1.5 113 ÷ 123 Not applied

51-204

51. ENGINE 51.13.2

TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS

Piece

Hexagon bolt (7T) and nut

PT plug

Pipe joint bolt

Nominal thread diameter x pitch mm M6x1 M8x1.25 M10x1.5 M12x1.75 M14x1.5 M16x1.5 1/8 1/4 3/8 1/2 M8 M10 M12 M14 M16

Tightening torque Nm 9.8 ÷ 11.8 22.6 ÷ 28.4 44.1 ÷ 53.9 78.4 ÷ 98.0 127.5 ÷ 147.1 215.7 ÷ 235.4 9.8 19.6 29.4 58.8 12.7 ÷ 16.7 19.6 ÷ 25.4 24.5 ÷ 34.3 39.2 ÷ 49.0 49.0 ÷ 58.8

NOTA: lubricating oil is not applied to threaded portion and seat surface.

51-205

Observations Use 80% of the value at left when the tightening part is aluminum. Use 60% of the value at left for 4T bolts and lock nuts.

51. ENGINE [NOTES]

51-206

61. AIR CONDITIONING SYSTEM INDEX 61.1 DESCRIPTION AND OPERATION - AIR CONDITIONING SYSTEM.............. 61-1 61.1.1

AIR CONDITIONING SYSTEM COMPONENTS .................................... 61-1

61.1.2

OPERATING ........................................................................................... 61-2

61.2 AIR CONDITIONING SYSTEM POSITIONING SCHEME .............................. 61-3 61.3 AIR CONDITIONING REFRIGERANT CHECK AND FILLING ...................... 61-11 61.4 HYDRAULIC CIRCUIT ................................................................................... 61-16 61.5 ELECTRICAL DIAGRAM ............................................................................... 61-17 61.6 TROUBLESHOOTING ................................................................................... 61-19

61. AIR CONDITIONING SYSTEM

61.1

DESCRIPTION AND OPERATION - AIR CONDITIONING SYSTEM

61.1.1

AIR CONDITIONING SYSTEM COMPONENTS

1. 2. 3. 4.

5. 6. 7. 8.

Compressor Flexible hose Condenser Flexible hose

The components installed in cabin activate the A/C system. They are: 1. A/C main power switch 2. Temperature control dial 3. Air flow control dial I = low II = medium III = high

61-1

Receiver (dryer) Flexible hose Cooler unit/Evaporator Flexible hose

61. AIR CONDITIONING SYSTEM 4. Air intake control lever (fresh or recirculated air selector). To activate the air conditioning, press the switch (1), and turn the air flow control dial (3) and the temperature control dial (2) to the desired position.

61.1.2

OPERATING

In the cooling process, the refrigerant that flows through the cooling circuit changes its phases from liquid to gas and viceversa during which process heat is transferred from the low temperature part (cabin) to the high temperature part (outside of the vehicle). Refrigerant used is the R134a. The quantity of refrigerant R134a present in the system is 700 Âą 50 g. The portion of system that cools the air of cabin is the evaporator. The air is cooled through the refrigerant that 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. 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. The compressor performs the function of suction, pumping and compressive.

61-2

61. AIR CONDITIONING SYSTEM

61.2

AIR CONDITIONING SYSTEM POSITIONING SCHEME

SAFETY PRECAUTIONS DURING DISASSEMBLY/ASSEMBLY

WARNING To avoid burns: •

Do not touch the hot areas (exhaust tube etc.)

To avoid fire: •

If an abnormality is detected, stop operating immediately and contact our service shop for checking and repair. The operation in abnormal condition could cause fire.

•

The disassembling by other than experts is not allowed. The imperfect repairing may cause injury due to abnormal operation and fire.

•

Be careful not to splash water on interior parts like control panel and so on because it is not waterproofed, it could cause trouble and fire.

To avoid injury: •

Do not insert tools or hand into air vent hole. Since the fan is rotating inside of casing, it may cause injury.

•

Do not touch fan, compressor belt and so on when the engine is running. It may cause injury.

•

Before cleaning, maintenance and checking, turn the cooler control switch off to stop operating.

•

Do not loosen parts of refrigerating circuit. if the refrigerant for cooler gets in eyes and splashed on hands, it causes loss of sight and frostbite.

61-3

61. AIR CONDITIONING SYSTEM

Fig. 61-1 (1/9) Q. F. P. D. H.

Compressor Flexible hose assy Condenser Tube assy Bracket

G. C. J. E.

61-4

Receiver/Dryer Flexible hose assy Cooler unit/Evaporator Flexible hose assy

61. AIR CONDITIONING SYSTEM

Fig. 61-1 (2/9) 1. 7. 19. 32.

Grommet Washer 8x17x1.6 Lock washer D=8 Screw M8x100. Tightening torque 23 Â± 2.3 Nm

61-5

61. AIR CONDITIONING SYSTEM

Fig. 61-1 (3/9) A. B. Q. R. T. 5. 6. 7. 17. 19. 32. 33. 37. 39. 45. 48.

Tube assy (compressor --> condenser) Tube assy (cooler unit --> compressor) Compressor Screw M8x35 Tightening torque 22.5 ± 2.3 Nm Screw M8x20. Tightening torque 23 ± 2.3 Nm Cover assy (5 attaching places) Washer 8x17x1.6 Screw M10x30. Tightening torque 46.5 ± 4.6 Nm (4 places) Lock washer D=8 Screw M8x100. Tightening torque 23 ± 2.3 Nm Washer 10x25x3 Clip Screw M8x20 Screw M8x25 Washer 8x17x3 (only right back side)

61-6

61. AIR CONDITIONING SYSTEM

Fig. 61-1 (4/9) S. Air conditioning control panel

Fig. 61-1 (5/9) F. P. 4. 5. 7. 9. 11. 12. 13. 19.

Flexible hose Condenser Cover assy Screw M8x20. Tightening torque 23 ± 2.3 Nm (4 places) Washer 8x17x1.6 Bracket Washer 10x21x2 Lock washer D=10 Screw M10x25. Tightening torque 46.5 ± 4.6 Nm (3 places) Lock washer D=8

61-7

61. AIR CONDITIONING SYSTEM

Fig. 61-1 (6/9) E. J. K. L. M. N. 11. 12. 13. 14. 36. 37. 40. 41. 42. 50.

Flexible hose assy. Tightening torque 31.9 Nm Cooler unit Tee Flexible hose (L=270) Flexible hose (L=55) Flexible hose (L=1600) Washer 10x21x2 Lock washer D=10 Screw M10x25. Tightening torque 46.5 ± 4.6 Nm Clip Rubber Clip Clip. Tightening torque 2.9 ± 0.5 Nm Flexible hose – drain Flexible hose – drain Clip (3 places)

61-8

61. AIR CONDITIONING SYSTEM

Fig. 61-1 (7/9) 7. 12. 16. 17. 18. 19. 20. 21. 22. 23.

Washer 8x17x1.6 Lock washer D=10 Pulley Screw M10x30. Tightening torque 46.5 ± 4.6 Nm (3 places) V-belt. Adjust belt tension applying a force of 19 N with max. 4 mm arrow. Lock washer D=8 Screw M8x50. Tightening torque 23 ± 2.3 Nm Plate Screw M8x100. Tightening torque 23 ± 2.3 Nm Bracket

Fig. 61-1 (8/9) C. D. G. U. 5. 7. 19. 38. 44. 47. 49.

Flexible hose assy (tightening torque 13.7 ± 1 Nm) Tube assy Receiver/Dryer Tightening torque 7.8 ÷ 11.8 Nm Screw M8x20. Tightening torque 23 ± 2.3 Nm (2 places) Washer 8x17x1.6 Lock washer D=8 Screw M6x20. Tightening torque 49 ± 1 Nm (2 places) Screw M6x25 Washer 6x12x1.6 Lock washer D=6

61-9

61. AIR CONDITIONING SYSTEM

Fig. 61-1 (9/9) 7. 19. 27. 28. 29. 30. 31.

Washer 8x17x1.6 Lock washer D=8 Grommet. Fix with adhesive Grille Duct Strip Screw M8x16. Tightening torque 22.5 Â± 1 Nm (4 places)

61-10

61. AIR CONDITIONING SYSTEM

61.3

AIR CONDITIONING REFRIGERANT CHECK AND FILLING

WARNING Refrigerant with safety characteristics. This means that this refrigerant is non-flammable, non-explosive, nontoxic, non-irritating, tasteless and colourless. Nevertheless, it is necessary to take some precautions. Avoid any contact with the refrigerant. In case of skin contact with the refrigerant, immediately treat the skin. Wear the safety glasses to protect your eyes. If although these measures the coolant comes in contact with your eyes, rinse them immediately with cold and clean water and then obtain medical attention immediately. Empty the system before carrying out repairs on it. Do not let the refrigerant release in the surrounding areas. To suck it, only use duly approved aspirators. Regardless of the system being full of refrigerant or empty, heat determines a remarkable overpressure, which could not only damage the system, but also cause explosions. Never expose the air conditioning components to a flame or a too hot heat source, to prevent fire or explosion hazard, with following emission of toxic gas. Empty refrigerant cylinders must not be discarded. When full, refrigerant cylinders must not be exposed to sun rays or other heat sources for a long time. The maximum allowed temperature for a full refrigerant cylinder must not exceed 40 Â°C. The lack of refrigerant causes low efficiency of cooling. Run the engine at high idling and rotate the cooler at high speed. Then remove the rubber cap (1), and inspect the flowing refrigerant condition from the sight glass (2) of the receiver dryer (3).

61-11

61. AIR CONDITIONING SYSTEM A. No bubbles: proper B. Bubbles appeared (Bubbles appear continuously): insufficient C. Transparent: over charged or no refrigerant If bubbles or transparent are detected, the system recharging must be performed. Replace of refrigerant in the air conditioner requires a vacuum generation procedure and a gas charging procedure. The vacuum generation procedure consists in removing moisture from the air conditioner circuit. In the event even a small quantity of moisture remains in the system, it would freeze in the small orifices of the expansion valve when in operation. This causes a clogging of the circuit or the formation of rust, with a series of operational troubles. Prior to filling the circuit with refrigerant, apply the vacuum and cause the boiling and vaporization of the moisture. In this manner, moisture is eliminated from the system.

Vacuum making operation 5 min.

more than 30 min.

Vacuum pump activation Lower than -750 mm Hg

Check air-tightness

Vacuum pump stop Gauge indicates abnormality

Refrigerant filling procedure

Tighten joints correctly

The gas charging procedure consists in the filing the circuit with refrigerant, after applying a vacuum. The filling of the gas is not only depending upon the cooling performance of the air conditioner, but it influences also the useful working life of the circuit components. An excessive overloading increases considerably the pressure of the system and damages the cooling performance. On the contrary, a too low charging, results in an insufficient circulation of lubricant oil in the compressor, causing the wear of the moving parts of the compressor.

WARNING The gas filling operation involves the handling of highly compressed gases; it is dangerous to handle the gas without complying strictly with the relevant procedures. the procedures and the protections described in this manual for the filling of refrigerant gas must be strictly adhered to.

61-12

61. AIR CONDITIONING SYSTEM

Refrigerant filling procedure

Fill in refrigerant

Check for gas leak

Charge refrigerant gas to a gauge pressure 0.1 MPa

PROCEDURE FOR THE VACCUM GENERATION Close high pressure valve (3) and low pressure valve (1) on gauge manifold (2). Connect the red charging pipe (5) and the blue one (6) to compressor service valves (8) "D" and "S" as described in the figure.

WARNING Never exchange by mistake the high pressure pipe with the low pressure pipe when connecting them. install the pipe firmly until a click noise is heard. Connect the quick release joint of the charging pipe with the service valve of the compressor. If the charging pipe is connected in the opposite direction, mini-valve (9) of the compressor fails to open. Connect the central valve of the gauge manifold with charging pipe (4) of the vacuum pump (7). IMPORTANT: some types of manifold are not equipped with an open/close valve in the central part. Open high pressure valve (3) and low pressure valve (1) of gauge manifold (2). Start the vacuum pump and let it operate 30 minutes to generate the vacuum. At the end of the vacuum phase for the prescribed time (vacuum value: lower than 750 mm Hg) close the high pressure valve (3) and the low pressure valve (1) of the gauge manifold (2). Cut-off the vacuum pump. With the high pressure valve (3) and the low pressure valve (1) closed, check, after five minutes, that the pressure gauge dial does not return to zero. NOTE: in the event the pressure gauge moves toward zero, this indicates the presence of a leakage. Tighten again the connecting joints and apply the vacuum again, verifying that there are no further leakages.

61-13

Fill in refrigerant

61. AIR CONDITIONING SYSTEM PROCEDURE FOR THE CHARGING OF THE GAS After applying the vacuum repeatedly, exchange charging pipe (4) of the gauge manifold (2), from the vacuum pump to the service can (9). Open the valve of service can (10). Close the high and low pressure valves of the gauge manifold. Press central bleeding valve (11) of the side service opening on the low pressure side of the gauge manifold using a screwdriver in order to let out the air in the charging pipe by the pressure of the refrigerant. Proceed with this operation until a whistle is heard coming from the bleeder. Open high pressure valve (3) of the gauge manifold and charge the refrigerant to a pressure of 0.1 MPa. Once the charge is completed, close high pressure valve (3) of the gauge manifold and service valve (10).

WARNING Never start operating the compressor during this work. the starting of the compressor causes the blowing of the service can. Check that there are no leakages of gas in the cycle, using a gas leakage tester. Retighten and eliminate all points of leakage. IMPORTANT: to check for gas leakages, always use a tester for R134a. Do not use one for flon gas service as it provides poor sensitivity. Make sure that high pressure valve (3) and low pressure valve (1) of the manifold and service valve can (10) are closed. Start the engine running it at 1500 Âą 100 rpm and open fully the door and windows of the cab. Activate the air conditioner, setting it at maximum ventilation speed and at lowest temperature. During the charging of the gas, set the discharge pressure of the compressor to 1.4 Ăˇ 1.6 MPa.

61-14

61. AIR CONDITIONING SYSTEM Open low pressure valve (1) of the gauge manifold and service valve can (10) and fill with refrigerant until all air bubbles in sight window (12) of the dryer disappear. Once the refrigerant change operation is terminated, close low pressure valve (1) of the gauge manifold and the service valve can (10).

CAUTION Do not open the high pressure valve of the manifold under any circumstance nor place the service can upside down. The level of refrigerant is correct only once the air conditioner is activated and through the inspection sight window, just a few air bubbles are seen and, afterward, a white colour slightly milky is seen. IMPORTANT: when the air conditioner operates with an insufficient quantity of refrigerant, this has a negative effect on the compressor; on the contrary, when the refrigerant is charged with an excessive quantity, the cooling performance is lost. Also, the pressure of the system increases abnormally. Disassemble the manifold disconnecting the charging pipes from the compressor, as indicated here below: -

press the quick release coupling of the charging pipe on the low pressure side against the service valve of the compressor so that the refrigerant doers not escape leaking when loosening the connection. As soon as the nut has been removed, disconnect the charging pipe from the service valve;

wait for the pressure in the high pressure site to decrease, indicated on the pressure gauge, to a value of 1.0 MPa.;

disconnect the red charging pipe from the high pressure side, in the same manner as described for the low pressure.

61-15

A. Correct quantity of gas B. Incorrect quantity of gas C. Overcharged system

61. AIR CONDITIONING SYSTEM

61.4

HYDRAULIC CIRCUIT NO.

NAME

PUMP ASSY

HYDRAULIC OIL TANK

SOLENOID TANK

61-16

61. AIR CONDITIONING SYSTEM

61.5

ELECTRIC DIAGRAM NO.

NAME

E-17

CONDENSER MOTOR

E-18

COMPRESSOR

SV-5

POWER SHIFT SOLENOID

61-17

61. AIR CONDITIONING SYSTEM

61-18

61. AIR CONDITIONING SYSTEM

61.6

TROUBLESHOOTING

Cabin air temperature does not low

Is A/C main power switch pressed and is the air flow dial to I position?

Press the A/C switch and set the air flow and temperature dials to the desired position.

YES

Is system correctly charged?

YES Is V-belt tightened correctly (refer to indicated values)?

Fill the system with the correct quantity of gas.

Check V-belt tension.

YES

Are tubes tightened to the correct tightening torque?

Tighten to the correct tightening torque.

YES

Is the compressor operative?

Replace the compressor.

YES Is the compressor relay operative?

Replace the compressor relay.

YES Is the voltage between blue/red wiring of air flow dial and earth > 0V?

Replace the amplifier.

YES Is A/C switch operative?

YES Check thermistor and, if necessary, replace it.

61-19

Replace A/C switch.

61. AIR CONDITIONING SYSTEM

[NOTES]

61-20

62. OBJECT HANDLING SYSTEM INDEX 62.1 DESCRIPTION AND OPERATION - OBJECT HANDLING SYSTEM ............. 61-1 62.1.1 BOOM CYLINDER HOLDING VALVE .................................................... 62-3 62.1.2 DIGGING CYLINDER HOLDING VALVE ................................................ 62-4 62.2 LIFTABLE LOADS TABLES ............................................................................. 62-5 62.3 REMOVAL AND INSTALLATION OF OBJECT HANDLING SYSTEM COMPONENTS................................................................................................ 62-8 62.3.1 SWITCH FOR ACTIVATION OF ANTI-TIPPING SENSOR .................... 62-8 62.3.2 ACOUSTIC ALARM (BUZZER) .............................................................. 62-9 62.3.3 BOOM HOLDING VALVE AND PRESSURE SWITCH......................... 62-10 62.3.4 DIGGING HOLDING VALVE................................................................. 62-14 62.3.5 TIGHTENING TORQUE........................................................................ 62-18 62.4 HYDRAULIC CIRCUIT ................................................................................... 62-19 62.5 ELECTRICAL DIAGRAM ............................................................................... 62-21 62.6 TROUBLESHOOTING ................................................................................... 62-22 62.6.1 62.6.2

MALFUNCTIONING OF BUZZER ........................................................ 62-22 MALFUNCTIONING OF OBJECT HANDLING SYSTEM HYDRAULIC CIRCUIT .......................................................................... 62-23

62. OBJECT HANDLING SYSTEM

62.1

DESCRIPTION AND OPERATION - OBJECT HANDLING SYSTEM

DESCRIPTION

The object handling system (optional) is composed of: - switch for activation of anti-tipping sensor (installed in cabin) (1) - overload buzzer (installed in cabin) (2) - boom holding valve (3) - digging holding valve (4) - overload pressure switch (5) - loading hook (installed on connecting rod of bucket linkage) (6) - liftable loads tables (located in cabin). When one of the components is missing or damaged, the machine cannot be used to handle hanging loads.

62-1

62. OBJECT HANDLING SYSTEM OPERATION

WARNING The machine has been specially designed for digging/ loading operations. The moving of hanging loads to complete the working cycle digging and/or loading, is always allowed, only if the machine is equipped with specified optional equipment. Carry out the handling of hanging loads by strictly following the national law concerning the prescribed safety rules, the national safety rules, the rules listed herebelow and those described on chapter safety rules. Before any lifting operation, press the switch (1) to activate the anti-tipping sensor. This sensor activates the buzzer (acoustic alarm) when safety limit load is reached.

Load must be fastened by means of the appropriate hook (2) installed on the connecting rod of the bucket linkage, using hooking devices and chains suitable for the load to be lifted.

62-2

62. OBJECT HANDLING SYSTEM 62.1.1

BOOM CYLINDER HOLDING VALVE

TECHNICAL DATA

DESCRIPTION Anti-burst valve is a safety valve flanged directly to the boom cylinder. This valve is a check valve hydraulically controlled, with a spring load (1) for lock/meter the oil flow. Oil pressure in the cylinders loads the valve, without leakage. Overload or pressure peaks in the port C2 is detected by relief valve (2), that let the spool opening to discharge cylinder pressure and discharge into the tank. Valve (1) is provided of a device (E) to lower the boom in emergency. Once the emergency boom lowering is completed, the screw (E) must be restored to its original position and locked.

62-3

62. OBJECT HANDLING SYSTEM 62.1.2

DIGGING CYLINDER HOLDING VALVE

TECHNICAL DATA Valve operation is same as boom cylinder holding valve. (it is not provided of emergency device).

62-4

62. OBJECT HANDLING SYSTEM

62.2

LIFTABLE LOADS TABLES

E45B SR - CANOPY VERSION

E45B SR - CABIN VERSION

NOTE: the indicated values are calculated by using a 600 mm bucket, weighing 107 kg. 1. 2. 3. 4.

Boom length Digging boom lenght (LD) (alternative) Bucket width Distance between load and slew centre

5. Max. liftable load (ton.), to roll-over limit, according to standard ISO 10567 6. Counterweight 7. Setting pressure of main overpressure relief valve / safety valves of hydraulic system

62-5

62. OBJECT HANDLING SYSTEM E50B SR - CANOPY VERSION

E50B SR - CABIN VERSION

NOTE: the indicated values are calculated by using a 650 mm bucket, weighing 112 kg. 1. 2. 3. 4.

Boom lenght Digging boom lenght (LD) (alternative) Bucket width Distance between load and slew centre

5. Max. liftable load (ton.), to roll-over limit, according to standard ISO 10567 6. Counterweight 7. Setting pressure of main overpressure relief valve / safety valves of hydraulic system

62-6

62. OBJECT HANDLING SYSTEM E55B - CABIN VERSION

1.01 0.81 0.66 0.54 0.49 0.49 5.27 1.311.37 1.41 1.47 1.10 0.87 0.71 0.59 0.50 0.46 0.46 5.38 2.24 2.52 1.83 1.47 1.10 0.87 0.71 0.59 0.57 4.66

928

MX0012

NOTE: the indicated values are calculated by using a 650 mm bucket, weighing 112 kg. 1. 2. 3. 4.

Boom lenght Digging boom lenght (LD) (alternative) Bucket width Distance between load and slew centre

5. Max. liftable load (ton.), to roll-over limit, according to standard ISO 10567 6. Counterweight 7. Setting pressure of main overpressure relief valve / safety valves of hydraulic system

62-7

62. OBJECT HANDLING SYSTEM

62.3

REMOVAL AND INSTALLATION OF OBJECT HANDLING SYSTEM COMPONENTS

62.3.1

SWITCH FOR ACTIVATON OF ANTI-TIPPING SENSOR

1. Stop the engine and remove the starter switch key. Check that all control levers are in neutral position and that the safety lever (red lever) and the safety lock lever are in locked position.

2. Remove all the screws (K). Raise the control panel (J) and remove the switch (20).

3. From the upper part of the control panel (J), remove the switch (20). From the lower part, disconnect the electric cable (21) on one side to the switch (20) and on the other side to the cabâ&#x20AC;&#x2122;s electric wiring harness (W).

4. Install the new switch (20) and connect the electric cable (21). 5. Install the control panel (J) with the new switch (20) and attach it by means of the screws (K).

62-8

62. OBJECT HANDLING SYSTEM 62.3.2

ACOUSTIC ALARM (BUZZER)

1. Stop the engine and remove the starter switch key. Check that all control levers are in neutral position and that the safety lever (red lever) and the safety lock lever are in locked position. 2. Remove the protection caps (X), loosen the fastening screws and disassemble the two half caps (AA) of the left-hand control lever.

3. Remove the buzzer (18), disconnect the electric cable and remove screws, washers and nuts. Install the new buzzer (18) and fasten it by means of the hex. M4x20 screws (15), the D=4 washers (16) and (17) and the M4 nuts (19).

4. Connect the electric cable (22) to the buzzer (18).

5. Install the two half caps (AA) of the left-hand control lever and install the protection caps (X).

62-9

62. OBJECT HANDLING SYSTEM 62.3.3 BOOM HOLDING VALVE AND PRESSURE SWITCH 1. Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity. Lower the dozer to the ground. Place the working attachment in front of the machine and extend the arms, so that they can be accessed. Place the bucket on the ground. Release hydraulic pressure and drain the hydraulic oil tank by following the instructions contained in the Operator’s Manual. Stop the engine and remove the starter switch key. Check that all control levers are in neutral position and that the safety lever (red lever) and the safety lock lever are in locked position.

WARNING During these operations, pay attention to further hydraulic oil leaks; protect the machine and, if necessary, carry out the appropriate cleaning operations. 2. Remove the 1/2” hose (54) connected to the fitting (AP) and to the 1/2” straight fitting (56) available in port V2 of the valve (60).

3. Disconnect the 3/8” draining hose (6) coming from the machine to the 1/4”-3/8” 90°-fitting (58) installed on port T of the valve (60).

62-10

62. OBJECT HANDLING SYSTEM 4. Disconnect the 1/4” pilot control hose (10) coming from the machine to the 1/4” 90°-fitting (64) installed on port P2 of the valve (60).

5. Disconnect the electric cable (12), coming from the machine, to the pressure switch (69) by means of the screw (AY) in the connector.

6. Remove the pressure switch (69) from 3/8”-1/4” straight fitting (68).

7. Disconnect rigid pipe (70) from valve (60).

62-11

62. OBJECT HANDLING SYSTEM 8. Remove the valve (60) with the fittings from bracket (49) of cover (AJ), by removing screws (62) and washers (61).

9. Preassemble the valve (60) of the boom cylinder: - in port C2, install the 1/2” straight fitting (65), the 1/ 2” union tee (66) and the 3/8”-1/2” 90°-fitting (67), and do not tighten to facilitate a subsequent orientation of the pressure switch; - in port V2, screw on the 1/2” straight fitting (56); - in port T, install the 1/4” union tee (59), the 3/8”-1/4” 90°-fitting (58) and the 1/4” straight fitting (57); - in port P2, tighten the 1/4” straight fitting (63) and the 1/4” 90°-fitting (64). Make sure that the fittings screwed in port P2 are turned clockwise (outwards) by 10° (see figure). 10. Assemble the new valve (60) together with the fittings onto the bracket (49) and fasten it by means of the hex. M8x50 screws (62) and the relevant D=8 washers (61). Apply some Loctite 262 and tighten the hex. M8x50 screws (62) to a tightening torque of 33 Nm. Reassemble the cover (AJ) of the boom cylinder.

11. Direct the brackets and the valve by turning them clockwise (outwards) by 30° (as shown in the figure). Connect the union tee 1/2” (65) on port C2 of valve (60) to the rigid pipe (70). Fix the final position of the valve, apply some Loctite 262 and tighten the hex. M10x30 screws (52) to a tightening torque of 31.5 Nm.

62-12

62. OBJECT HANDLING SYSTEM 12. Screw on the 3/8”-1/4” straight fitting (68) on the pressure switch (69) and apply some Loctite 577 between them. Assemble the pressure switch together with fitting on the 3/8”-1/2” 90°-fitting (67) in port C2 of the valve (60). Before tightening, direct the pressure switch (69) by turning it clockwise (outwards) by 30° (as shown in the figure to the side). Check that the pressure switch does not interfere with other machine parts during the various movements of the front attachment. 13. Connect the electric cable (12), coming from the machine, to the pressure switch (69) by means of the screw (AY) in the connector.

14. Connect the 1/4” pilot control hose (10) coming from the machine to the 1/4” 90°-fitting (64) installed on port P2 of the valve (60).

15. Connect the 3/8” draining hose (6) coming from the machine to the 1/4”-3/8” 90°-fitting (58) installed on port T of the valve (60).

62-13

62. OBJECT HANDLING SYSTEM 16. Install the 1/2” hose (54) and connect it to the fitting (AP) and to the 1/2” straight fitting (56) available in port V2 of the valve (60).

62.3.4 DIGGING HOLDING VALVE 1. Move the machine to a level and firm ground, away from any soft ground, excavations or poorly shored cavity. Lower the dozer to the ground. Place the working attachment in front of the machine and extend the arms, so that they can be accessed. Place the bucket on the ground. Release hydraulic pressure and drain the hydraulic oil tank by following the instructions contained in the Operator’s Manual. Stop the engine and remove the starter switch key. Check that all control levers are in neutral position and that the safety lever (red lever) and the safety lock lever are in locked position.

WARNING During these operations, pay attention to further hydraulic oil leaks; protect the machine and, if necessary, carry out the appropriate cleaning operations. 2. Disconnect the 1/2” hose (42) connected to one side to the 1/2” straight fitting (35) available in port V2 of the valve (34) and, to the other side, to the rigid pipe (AU) available on the intermediate portion of the boom.

62-14

62. OBJECT HANDLING SYSTEM 3. Disconnect the 3/8” draining hose (41) connected to one side to the 3/8”-1/4” 45°-fitting (40) available in port T of the valve (34) and, to the other side, to the 3/8” 90°-fitting (43) available on the first portion of the boom.

4. Disconnect the 1/4” pilot control hose (38) connected it to one side to the 1/4” 90°-fitting (37) available in port Pil of the valve (34) and, to the other side, to the 1/4” 90°-fitting (37) available on the first portion of the boom.

5. Disconnect the rigid pipe (23) from straight fitting 1/2” (35) on port C2 of valve (34).

6. Remove the valve (34) with the fittings from bracket (33) removing the screws (39) and the relevant washers D=8 (28).

62-15

62. OBJECT HANDLING SYSTEM 7. Preassemble the valve (34): - in port C2, install the 1/2” straight fitting (35); - in port V2, tighten the 1/2” straight fitting (35); - in port T, install the 3/8”-1/4” 45°-fitting (33); - in port Pil, tighten the 1/4” straight fitting (36) and the 1/4” 90°-fitting (37).

8. Assemble the valve (34) together with the fittings onto the bracket (33) and fasten it by means of the hex. M8x50 screws (39) and the relevant D=8 washers (28). Fix the final position of the valve, apply some Loctite 262 and tighten the hex. M10x30 screws (23) to a tightening torque of 31.5 Nm.

9. Now it is possible to define the final position of the valve (34). Direct the brackets and the valve (as shown in the figure). Connect the straight fitting 1/2” (35) on port C2 of valve (34) to the rigid pipe (23). Fix the final position of the valve, apply some Loctite 262 and tighten the hex. M10x30 screws (24) to a tightening torque of 31.5 Nm.

10. Install the 1/4” pilot control hose (38) by connecting it on one side to the 1/4” 90°-fitting (37) available in port Pil of the valve (34) and, on the other side, to the 1/ 4” 90°-fitting (37) available on the first portion of the boom.

62-16

62. OBJECT HANDLING SYSTEM 11. Install the 3/8” draining hose (41) by connecting it on one side to the 3/8”-1/4” 45°-fitting (40) available in port T of the valve (34) and, on the other side, to the 3/8” 90°-fitting (43) available on the first portion of the boom.

12. Install the 1/2” hose (42) by connecting it on one side to the 1/2” straight fitting (35) available in port V2 of the valve (34) and, on the other side, to the rigid pipe (AU) available on the intermediate portion of the boom.

13. Direct and route between the “ears” of the boom all various hydraulic hoses: 1/4” hose (38), 3/8” hose (41) and 1/2” hose (42) just installed.

62-17

62. OBJECT HANDLING SYSTEM 62.3.5 TIGHTENING TORQUE Please refer to the following data for the installation of all various fittings and hydraulic hoses: -

Fittings 1/4 G O-ring type joint: 36.3 ± 2 Nm 1/4 G 30° flare joint: 29.4 ± 5 Nm 3/8 G O-ring type joint: 73.5 ± 5 Nm 3/8 G 30° flare joint: 49 ± 5 Nm 1/2 G O-ring type joint: 108 ± 10 Nm

Flexible hoses 1/4 G: 29.4 ± 5 Nm 3/8 G: 49 ± 5 Nm 1/2 G: 78.5 ± 5

M-threads M8: 33.3 ± 3.4 Nm M10: 31.5 ± 6

62-18

62. OBJECT HANDLING SYSTEM

62.1

HYDRAULIC CIRCUIT NO.

NAME

PUMP ASSY

CONTROL VALVE

BOOM CONTROL VALVE SECTION

DIGGING CONTROL VALVE SECTION

HYDRAULIC OIL TANK

BOOM CYLINDER HOLDING VALVE

DIGGING CYLINDER HOLDING VALVE

PRESSURE SWITCH SE22

62-19

62. OBJECT HANDLING SYSTEM

N00014

62-20

62. OBJECT HANDLING SYSTEM

62.5

ELECTRICAL DIAGRAM NO. E-11

NAME Overload buzzer

SW-39

Overload pressure switch

SW-40

Overload switch

62-21

62. OBJECT HANDLING SYSTEM

62.6

TROUBLESHOOTING

62.6.1

MALFUNCTIONING OF BUZZER

Is fuse (2) operative?

Replace the fuse.

YES

Is switch SW-40 operative?

Replace the switch

YES

Is pressure switch SW-39 operative?

YES

Replace the buzzer E-11.

62-22

Replace the pressure switch

62. OBJECT HANDLING SYSTEM 62.6.2

MALFUNCTIONING OF OBJECT HANDLING SYSTEM HYDRAULIC CIRCUIT

Are pipes tightened to the correct tightening torque?

Tightening to the correct tightening torque.

YES

Are seals not damaged?

Replace the seals.

YES

Are holding valves operative?

Replace the holding valves.

YES

Cylinders defective. Replace the defective cylinder.

62-23

62. OBJECT HANDLING SYSTEM

[NOTES]

62-24

71. SUPPORTING DATA TABLE OF CONTENTS 71.1 HYDRAULIC CIRCUIT DIAGRAM .................................................................. 71-2 71.1.1

STANDARD SPECIFICATION ............................................................... 71-3

71.1.2

HYDRAULIC CIRCUIT OPERATION ..................................................... 71-4

71.1.3

SCHEMATIC PIPING FOR HYDRAULIC SYSTEM ............................. 71-15

71.2 ELECTRIC CIRCUIT DIAGRAM ................................................................... 71-16

71. SUPPORTING DATA

This page is blank because of editing convenience.

71-1

71. SUPPORTING DATA

71.1

HYDRAULIC CIRCUIT DIAGRAM

No.

NAME

PUMP ASSY

CONTROL VALVE

2-3

SLEWING CONTROL VALVE SECTION

2-4L

LEFT TRAVEL MOTOR CONTROL VALVE SECTION

2-4R

RIGHT TRAVEL MOTOR CONTROL VALVE SECTION

2-5

BOOM CONTROL VALVE SECTION

2-6

ARM CONTROL VALVE SECTION

2-7

BUCKET CONTROL VALVE SECTION

2-8

SWING CONTROL VALVE SECTION

2-9

DOZER CONTROL VALVE SECTION

2-10

AUXILIARY CONTROL VALVE SECTION

SWING MOTOR

TRAVEL LEFT MOTOR

TRAVEL RIGHT MOTOR

BOOM CYLINDER

ARM CYLINDER

BUCKET CYLINDER

SWING CYLINDER

DOZER BLADE CYLINDER

ROTARY CONTROL VALVE

ATTACHMENT CONTROL VALVE

TRAVEL CONTROL VALVE

SOLENOID VALVE

13-1 14

PILOT RELIEF VALVE DOZER CONTROL VALVE

SHUTTLE VALVE

AUXILIARY CONTROL VALVE

RETURN FILTER

SUCTION STRAINER

PILOT VALVE FILTER

CHECK VALVE

STOP VALVE

SELECTOR VALVE

OIL COOLER

HYDRAULIC OIL TANK

TRAVEL 1-2 SPEED CHANGE OVER

LEVER LOCK

201

MAIN PRESSURE RELIEF VALVE P1, P2

202

MAIN PRESSURE RELIEF VALVE P3

203

OVER LOAD RELIEF VALVE

204

OVER LOAD RELIEF VALVE

304

SLEW RELIEF VALVE

71-2

71. SUPPORTING DATA 71.1.1

STANDARD SPECIFICATION

401 R1

404

A1G A1 A2 A2G A4 A3

406

407

407 408

403 402

406

A 405

302

6 22

402

301

407

407 D1

403

405

401

404

408

21.0MPa

B PP

304 21.0MPa

304

303

305

DR B

BD PG A C F E

23 20 147kPa {21psi}

2-8

2-10 2

150kPa {22psi}

2-5 B9

18 17

Pa9

Pb8' Dr B8 A8 Pa8

2-3

2-4L A7 Pa7

Pa6 A6 B6

A5 B5 Pa4

Pa3 A3

2-7

A2 Pa2

P3 B2

A1Pa1

2-9

2-6

206

25.5MPa

204 27.5MPa

203

25.5MPa

27.5MPa

25.5MPa

202

204

203

MRV3

23.0MPa

25.5MPa

23.0MPa

25.5MPa

201 MRV

204

25.5MPa

204 T2

Pb9

Pb8

Pb7

2-4R

Pb6

Pb4

Pb3

Pb2

Pb1

26 25 A2

13-1 P1

3.5MPa

A2 A1

Pp1

13 19

A1 P

T 2

T 1

P P2 MX0010

Fig. 71-1

71-3

71. SUPPORTING DATA 71.1.2

HYDRAULIC CIRCUIT OPERATION

(1) NEUTRAL CIRCUIT

401 R1

404

A1G A1 A2 A2G A4 A3

406

407

407 408

402

406

A 405

302

6 22

402

301

407

407 D1

403

405

401

404

408

RED

403

21.0MPa

B PP

304 21.0MPa

304

303

305

DR B

BD PG A C F E

23 20 147kPa {21psi}

2-8

2-10 2

150kPa {22psi}

2-5 B9

18 17

Pa9

Pb8' Dr B8 A8 Pa8

2-3

2-4L A7 Pa7

Pa6 A6 B6

A5 B5 Pa4

Pa3 A3

2-7

A2 Pa2

P3 B2

A1Pa1

2-9

2-6

206

25.5MPa

204 27.5MPa

203

25.5MPa

27.5MPa

25.5MPa

202

204

203

MRV3

23.0MPa

25.5MPa

23.0MPa

25.5MPa

201 MRV

204

25.5MPa

204 T2

Pb9

Pb8

Pb7

Pb6

Pb4

Pb3

Pb2

2-4R

Pb1

Pp1

A2 A1

13-1 P1

3.5MPa

26 25

13 19

T 1

P P2 MX0052

71-4

Fig. 71-2

71. SUPPORTING DATA (2) TRAVEL CIRCUIT: travel forward operation at travel 2nd speed

401 R1

404

A1G A1 A2 A2G A4 A3

406

407

407 408

402

406

302

6 22

402

301

407

407 D1

403

405

401

404

408

RED

403

21.0MPa

B PP

304 21.0MPa

304

303

305

DR B

BD PG A C F E

23 20 147kPa {21psi}

2-8

2-10 2

150kPa {22psi}

2-5 B9

18 17

Pa9

Pb8' Dr B8 A8 Pa8

2-3

2-4L A7 Pa7

Pa6 A6 B6

A5 B5 Pa4

Pa3 A3

2-7

A2 Pa2

P3 B2

A1Pa1

2-9

2-6

206

25.5MPa

204 27.5MPa

203

25.5MPa

27.5MPa

25.5MPa

202

204

203

MRV3

23.0MPa

25.5MPa

23.0MPa

25.5MPa

201 MRV

204

25.5MPa

204 T2

Pb9

Pb8

Pb7

2-4R

Pb6

Pb4

Pb3

Pb2

Pb1

26 25 A2

13-1 P1

3.5MPa

A2 A1

Pp1

13 19

T 1

P P2 MX0053

Fig. 71-3

71-5

71. SUPPORTING DATA (3) SLEWING CIRCUIT: Slewing left operation

401 R1

404

A1G A1 A2 A2G A4 A3

406

407

407 408

402

406

A 405

302

6 22

402

301

407

407 D1

403

405

401

404

408

RED

403

21.0MPa

B PP

304 21.0MPa

304

303

305

DR B

BD PG A C F E

23 20 147kPa {21psi}

2-8

2-10 2

2-5

150kPa {22psi} B9

18 17

Pa9

Pb8' Dr B8 A8 Pa8

2-3

2-4L A7 Pa7

Pa6 A6 B6

A5 B5 Pa4

Pa3 A3

2-7

A2 Pa2

P3 B2

A1Pa1

2-9

2-6

206

25.5MPa

204 27.5MPa

203

25.5MPa

27.5MPa

25.5MPa

202

204

203

MRV3

23.0MPa

25.5MPa

23.0MPa

25.5MPa

201 MRV

204

25.5MPa

204 T2

Pb9

Pb8

Pb7

2-4R

Pb6

Pb4

Pb3

Pb2

Pb1

26 25 A2

13-1 P1

3.5MPa

A2 A1

Pp1

13 19

T 1

P P2 MX0013

71-6

Fig. 71-4

71. SUPPORTING DATA (4) BUCKET CIRCUIT: Bucket digging operation

401 R1

404

A1G A1 A2 A2G A4 A3

406

407

407 408

402

406

302

6 22

402

301

407

407 D1

403

405

401

404

408

RED

403

21.0MPa

B PP

304 21.0MPa

304

303

305

DR B

BD PG A C F E

23 20 147kPa {21psi}

2-8

2-10 2

150kPa {22psi}

2-5 B9

18 17

Pa9

Pb8' Dr B8 A8 Pa8

2-3

2-4L A7 Pa7

Pa6 A6 B6

A5 B5 Pa4

Pa3 A3

2-7

A2 Pa2

P3 B2

A1Pa1

2-9

2-6

206

25.5MPa

204 27.5MPa

203

25.5MPa

27.5MPa

25.5MPa

202

204

203

MRV3

23.0MPa

25.5MPa

23.0MPa

25.5MPa

201 MRV

204

25.5MPa

204 T2

Pb9

Pb8

Pb7

2-4R

Pb6

Pb4

Pb3

Pb2

Pb1

26 25 A2

13-1 P1

3.5MPa

A2 A1

Pp1

13 19

T 1

P P2 MX0014

Fig. 71-5

71-7

71. SUPPORTING DATA (5) BOOM CIRCUIT: boom up operation

401 R1

404

A1G A1 A2 A2G A4 A3

406

407

407 408

402

302

6 22

402

301

407

407 D1

403

405

404

408

401

RED

403

406

21.0MPa

B PP

304 21.0MPa

304

303

305

DR B

BD PG A C F E

23 20 147kPa {21psi}

2-8

2-10 2

150kPa {22psi}

2-5 B9

18 17

Pa9

Pb8' Dr B8 A8 Pa8

2-3

2-4L A7 Pa7

Pa6 A6 B6

A5 B5 Pa4

Pa3 A3

2-7

A2 Pa2

P3 B2

A1Pa1

2-9

2-6

206

25.5MPa

204 27.5MPa

203

25.5MPa

27.5MPa

25.5MPa

202

204

203

MRV3

23.0MPa

25.5MPa

23.0MPa

25.5MPa

201 MRV

204

25.5MPa

204 T2

Pb9

Pb8

Pb7

2-4R

Pb6

Pb4

Pb3

Pb2

Pb1

26 25 A2

13-1 P1

3.5MPa

A2 A1

Pp1

13 19

T 1

P P2 MX0015

71-8

Fig. 71-6

71. SUPPORTING DATA (6) ARM CIRCUIT: arm in operation

401 R1

404

A1G A1 A2 A2G A4 A3

406

407

407 408

402

302

6 22

402

301

407

407 D1

403

405

404

408

401

RED

403

406

21.0MPa

B PP

304 21.0MPa

304

303

305

DR B

BD PG A C F E

23 20 147kPa {21psi}

2-8

2-10 2

150kPa {22psi}

2-5 B9

18 17

Pa9

Pb8' Dr B8 A8 Pa8

LEFT RIGHT

2-4L A7 Pa7

Pa6 A6 B6

2-3

A5 B5 Pa4

Pa3 A3

2-7

A2 Pa2

P3 B2

A1Pa1

2-9

2-6

206

25.5MPa

204 27.5MPa

203

25.5MPa

27.5MPa

25.5MPa

202

204

203

MRV3

23.0MPa

25.5MPa

23.0MPa

25.5MPa

201 MRV

204

25.5MPa

204 T2

Pb9

Pb8

Pb7

Pb6

Pb4

Pb3

Pb2

2-4R

Pb1

26 25 A2

13-1 P1

3.5MPa

A2 A1

Pp1

13 19

T 1

P P2 MX0016

Fig. 71-7

71-9

71. SUPPORTING DATA (7) SWING CIRCUIT: boom swing left operation

401 R1

404

A1G A1 A2 A2G A4 A3

406

407

407 408

402

406

302

6 22

402

301

407

407 D1

403

405

401

404

408

RED

403

21.0MPa

B PP

304 21.0MPa

304

303

305

DR B

BD PG A C F E

23 20 147kPa {21psi}

2-8

2-10 2

150kPa {22psi}

2-5 B9

18 17

Pa9

Pb8' Dr B8 A8 Pa8

2-3

2-4L A7 Pa7

Pa6 A6 B6

A5 B5 Pa4

Pa3 A3

2-7

A2 Pa2

P3 B2

A1Pa1

2-9

2-6

206

25.5MPa

204 27.5MPa

203

25.5MPa

27.5MPa

25.5MPa

202

204

203

MRV3

23.0MPa

25.5MPa

23.0MPa

25.5MPa

201 MRV

204

25.5MPa

204 T2

Pb9

Pb8

Pb7

Pb6

Pb4

Pb3

Pb2

2-4R

Pb1

26 25 A2

13-1 P1

3.5MPa

A2 A1

Pp1

13 19

T 1

P P2 MX0017

71-10

Fig. 71-8

71. SUPPORTING DATA (8) DOZER CIRCUIT: dozer down operation

401 R1

404

A1G A1 A2 A2G A4 A3

406

407

407 408

402

406

302

6 22

402

301

407

407 D1

403

405

401

404

408

RED

403

21.0MPa

B PP

304 21.0MPa

304

303

305

DR B LEFT

A RIGHT

BD PG A C F E

23 20 147kPa {21psi}

2-8

2-10 2

150kPa {22psi}

2-5 B9

18 17

Pa9

Pb8' Dr B8 A8 Pa8

2-3

2-4L A7 Pa7

Pa6 A6 B6

A5 B5 Pa4

Pa3 A3

2-7

A2 Pa2

P3 B2

A1Pa1

2-9

2-6

206

25.5MPa

204 27.5MPa

203

25.5MPa

27.5MPa

25.5MPa

202

204

203

MRV3

23.0MPa

25.5MPa

23.0MPa

25.5MPa

201 MRV

204

25.5MPa

204 T2

Pb9

Pb8

Pb7

Pb6

Pb4

Pb3

Pb2

2-4R

Pb1

Pp1

26 25 A2

13-1 P1

3.5MPa

A2 A1

13 19

T 1

P P2 MX0018

Fig. 71-9

71-11

71. SUPPORTING DATA (9) COMBINED OPERATION CIRCUIT: travel (forward) 1st speed / dozer down operation

401 R1

404

A1G A1 A2 A2G A4 A3

406

407

407 408

403 402

406

A 405

302

6 22

402

301

407

407 D1

403

405

401

404

408

21.0MPa

B PP

304 21.0MPa

304

303

305

DR B

BD PG A C F E

23 20 147kPa {21psi}

2-8

2-10 2

150kPa {22psi}

2-5 B9

18 17

Pa9

Pb8' Dr B8 A8 Pa8

2-3

2-4L A7 Pa7

Pa6 A6 B6

A5 B5 Pa4

Pa3 A3

2-7

A2 Pa2

P3 B2

A1Pa1

2-9

2-6

206

25.5MPa

204 27.5MPa

203

25.5MPa

27.5MPa

25.5MPa

202

204

203

MRV3

23.0MPa

25.5MPa

23.0MPa

25.5MPa

201 MRV

204

25.5MPa

204 T2

Pb9

Pb8

Pb7

2-4R

Pb6

Pb4

Pb3

Pb2

Pb1

26 25 A2

13-1 P1

3.5MPa

A2 A1

Pp1

13 19

A1 P

T 2

T 1

P P2 MX0019

71-12

Fig. 71-10

71. SUPPORTING DATA (10) COMBINED OPERATION CIRCUIT: travel (forward) 1st speed / boom up operation

401 R1

404

A1G A1 A2 A2G A4 A3

406

407

407 408

402

A 405

302

6 22

402

301

407

407 D1

403

405

404

408

401

RED

403

406

21.0MPa

B PP

304 21.0MPa

304

303

305

DR B

BD PG A C F E

23 20 147kPa {21psi}

2-8

2-10 2

150kPa {22psi}

2-5 B9

18 17

Pa9

Pb8' Dr B8 A8 Pa8

2-3

2-4L A7 Pa7

Pa6 A6 B6

A5 B5 Pa4

Pa3 A3

2-7

A2 Pa2

P3 B2

A1Pa1

2-9

2-6

206

25.5MPa

204 27.5MPa

203

25.5MPa

27.5MPa

25.5MPa

202

204

203

MRV3

23.0MPa

25.5MPa

23.0MPa

25.5MPa

201 MRV

204

25.5MPa

204 T2

Pb9

Pb8

Pb7

2-4R

Pb6

Pb4

Pb3

Pb2

Pb1

26 25 A2

13-1 P1

3.5MPa

A2 A1

Pp1

13 19

T 1

P P2 MX0020

Fig. 71-11

71-13

71. SUPPORTING DATA (11) NIBBLER AND BREAKER OPERATION CIRCUIT: nibbler open operation

401 R1

404

A1G A1 A2 A2G A4 A3

406

407

407 408

403 402

406

A 405

302

6 22

402

301

407

407 D1

403

405

401

404

408

21.0MPa

B PP

304 21.0MPa

304

303

305

DR B

BD PG A C F E

23 20 147kPa {21psi}

2-8

2-10 2

150kPa {22psi}

2-5 B9

18 17

Pa9

Pb8' Dr B8 A8 Pa8

2-3

2-4L A7 Pa7

Pa6 A6 B6

A5 B5 Pa4

Pa3 A3

2-7

A2 Pa2

P3 B2

A1Pa1

2-9

2-6

206

25.5MPa

204 27.5MPa

203

25.5MPa

27.5MPa

25.5MPa

202

204

203

MRV3

23.0MPa

25.5MPa

23.0MPa

25.5MPa

201 MRV

204

25.5MPa

204 T2

Pb9

Pb8

Pb7

2-4R

Pb6

Pb4

Pb3

Pb2

Pb1

Pp1

26 25 A2

13-1 P1

3.5MPa

A2 A1

13 19

A1 P

T 2

T 1

P P2 MX0021

71-14

Fig. 71-12

71. SUPPORTING DATA 71.1.3

SCHEMATIC PIPING FOR HYDRAULIC SYSTEM

Pilot circuit Main circuit Supply/return (drain) circuit N00037

Fig. 71-13

71-15

71. SUPPORTING DATA

71.2

ELECTRIC CIRCUIT DIAGRAM Group

Diode

Electrical system Fittings

Lights

Engine

Relay

Sensors

Solenoid

71-16

Code D-1 D-2 D-3 D-4 D-12 D-13 D-14 D-18 E-1 E-2 E-3 E-4 E-6 E-7 E-8 E-10 E-12 E-13 E-14 E-15 E-16 E-17 E-18 E-23 E-26 L-1 L-2 L-5 M-1 M-2 M-3 M-4 M-6 R-1 R-2 R-3 R-6 R-7 R-8 R-9 R-14 SE-1 SE-2 SV-1 SV-2 SV-3 SV-5

Part Name DIODE DIODE DIODE DIODE DIODE DIODE DIODE DIODE FUSE BOX GENERATOR (ALTERNATOR) HORN FUSIBLE LINK (45A) GAUGE CLUSTER POWER SOCKET AIR HEATER RADIO (OPT) HEATER (OPT) BATTERY SEQUENCE BOX FUSE BOX FOR COOLER (OPT) RADIATOR ENGINE CONDENSER COMPRESSOR ANTENNA HOUR COUNTER ROOM LAMP BOOM WORKING LIGHT CAB / CANOPY WORKING LIGHT STARTER MOTOR WIPER MOTOR (CAB) WASHER MOTOR (CAB) DECELERATION MOTOR FUEL PUMP BATTERY RELAY SAFETY RELAY DECELERATION RELAY TIMER UNIT ENGINE STOP RELAY CHARGE INDICATOR RELAY CAB / CANOPY WORKING LIGHT RELAY SLEW / SWING SELECT RELAY FUEL SENSOR ENGINE THERMO SENSOR LEVER LOCK SOLENOID 2-SPEED SELECT SOLENOID ENGINE STOP SOLENOID POWER SHIFTING SOLENOID (Radiator specifications)

Group Solenoid

Switch

Code PSV-D PSV-E SW-1 SW-2 SW-3 SW-4 SW-5 SW-6 SW-7 SW-9 SW-10 SW-11 SW-15 SW-16 SW-35

Part Name NIBBLER OPEN PROPORTIONAL SOLENOID (RIGHT SLIDE) NIBBLER CLOSE PROPORTIONAL SOLENOID (LEFT SLIDE) KEY SWITCH WORKING LIGHTS SWITCH 2nd SPEED SELECTOR SWITCH WIPER WASHER SWITCH ENGINE COOLANT TEMPERATURE SWITCH ENGINE OIL PRESSURE SWITCH HORN SWITCH LEVER LOCK SWITCH HEATER SWITCH (OPT) DECELERATION SWITCH HIGH AND LOW PRESSURE SWITCH CONDENSER SPEED SHIFT SWITCH HYDRAULIC NIBBLER ACTIVATION SLIDER

71. SUPPORTING DATA

MX0022

Fig. 71-14 (1/3)

71-17

71. SUPPORTING DATA

MX0023

71-18

Fig. 71-14 (2/3)

71. SUPPORTING DATA

MX0024

Fig. 71-14 (3/3)

71-19

71. SUPPORTING DATA

[NOTES]

71-20