New Holland EH35 Compact Excavator Service Manual (6-75740NA) by www.heydownloads.com

SERVICE MANUAL EH35 Compact Excavator

CONSTRUCTION 6-75740NA

SERVICE MANUAL

Section 1 SPECIFICATIONS

EH35 CONSTRUCTION

HYDRAULIC EXCAVATOR

Section 2 MAINTENANCE

Section 1 - SPECIFICATION Section 2 - MAINTENANCE

Section 3 SYSTEM

Section 3 - SYSTEM Section 4 - DISASSEMBLY Section 5 - TROUBLESHOOTING

Section 4 DISASSEMBLY and ASSEMBLY

Section 6 - ENGINE Section 5 TROUBLESHOOTING

Section 7 - MISCELLANEOUS

Section 6 ENGINE

NEW HOLLAND Form Number - 6-75740

Source Code No. S5PW0002E-02

00 -0-1 ➁

Section 7 MISCELLANEOUS

Any use of editorial or pictorial content is strictly prohibited without express written permission from New Holland Construction, LLC. Carol Stream, IL 60188 U.S.A. Copyright ÂŠ 2003 New Holland Construction, LLC. All Rights Reserved.

00 -0-2 â&#x17E;

TABLE OF CONTENTS Book Code No. and Distribution Month/Year

S5PW0202E-00 Jan 2001

S5PW0202E-00 Nov 2001

S5PW0202E-00 Dec 2002

S5PW0302E-00 Jan 2001

S5PW0302E-00 Nov 2001

S5PW0302E-00 Dec 2002

S5PW0402E-00 Jan 2001

S5PW0402E-00 Nov 2001

Section

Chapter Title

Chapter Number

Preliminary Remarks

S5PW0102E

Specifications

S5PW0202E

S5PW0402E-00 Dec 2002

Attachment Dimensions

S5PW0302E

S5PW1102E-00 Jan 2001

S5PW1102E-01 Dec 2002

Tools

S5PW1102E

S5PW1202E-00 Jan 2001

S5PW1202E-01 Dec 2002

Standard Maintenance Time Table

S5PW1202E

Section 1 SPECIFICATIONS

Section 2 MAINTENANCE

S5PW1302E-00 Jan 2001

S5PW1302E-01 Nov 2001

S5PW1302E-02 Dec 2002

Maintenance Standard and Test Procedures

S5PW1302E

S5PW2202E-00 Jan 2001

S5PW2202E-01 Nov 2001

S5PW2202E-02 Dec 2002

Hydraulic Systems

S5PW2202E

S5PW2302E-00 Jan 2001

S5PW2302E-01 Nov 2001

S5PW2302E-02 Dec 2002

Electric System

S5PW2312E

S5PW2402E-00 Jan 2001

S5PW2402E-01 Nov 2001

S5PW2402E-02 Dec 2002

Components System

S5PW2402E

S5PW3102E-01 Dec 2002

Disassembling and Assembling

S5PW3102E

Attachments

S5PW3202E

Upper Structure

S5PW3302E

Travel System

S5PW3402E

Troubleshooting (Hydraulic)

S5PW4202E

S5PW3102E-00 Jan 2001 S5PW3202E-00 Jan 2001

S5PW3202E-01 Nov 2001

S5PW3202E-02 Dec 2002

S5PW3302E-00 Jan 2001

S5PW3302E-01 Nov 2001

S5PW3302E-02 Dec 2002

S5PW3402E-00 Jan 2001

S5PW3402E-01 Nov 2001

S5PW3402E-02 Dec 2002

Section 3 SYSTEM

Section 4 DISASSEMBLY and ASSEMBLY

Section 5 TROUBLESHOOTING

S5PW4202E-00 Jan 2001

S5PW4202E-01 Dec 2002

S5PW4302E-00 Jan 2001

S5PW4302E-01 Dec 2002

Troubleshooting (Electrical)

S5PW4302E

S5PW4402E-00 Jan 2001

S5PW4402E-01 Dec 2002

Troubleshooting (Engine)

S5PW4402E

S5PW5102E-00 Jan 2001

S5PW5102E-01 Dec 2002

Engine

S5PW5102E

Section 6 ENGINE Section 7 MISCELLANEOUS

00 -1-1 â&#x17E;

SAFETY PRECAUTIONS 1.1 GENERAL SAFETY INFORMATION

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

CAUTION – Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against possible damage to the machine and its components and is represented as follows:

Do Not operate or perform any maintenance on this machine until all instructions found in the OPERATOR'S MANUAL 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 the operator’s seat pocket. If it is missing or damaged, place an order with an authorized Distributor for a replacement. If you have any questions, please consult an authorized Distributor.

Most accidents, which occur during operation, are due to neglect of precautionary measures and safety rules. Sufficient care should be taken to avoid these accidents. Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death of personnel. Therefore all p r e c a u t i o n a r y m e a s u r e s, N OT E S , 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. Operation, inspection, and maintenance should be carefully carried out, and safety must be given the first priority. Messages of safety are indicated with marks. The safety information contained in this manual is intended only to supplement safety codes, insurance requirements, local laws, rules and regulations. Messages of safety appear in this manual and on the machine. All messages of safety are identified by the words DANGER, WARNING and CAUTION. a.

DANGER – Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury and is represented as follows:

It is very difficult to forecast every danger that may occur during operation. However, safety can be ensured by fully understanding proper operating procedures for this machine according to methods recommended by the manufacturer.

While operating the machine, be sure to perform work with great care, so as not to damage the machine, or allow accidents to occur.

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

The proper and safe lubrication and maintenance for this machine, recommended by the manufacturer, is outlined in the OPERATOR’S MANUAL for this machine. Improper performance of lubrication or maintenance procedures are dangerous and could result in injury or death. Read and understand the OPERATOR’S MANUAL before performing any lubrication or maintenance.

00 -1-2

SAFETY PRECAUTIONS 1.2

SAFETY PRECAUTIONS

The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work. A knowledge of the system and or components is important before the removal or disassembly of any component. 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 for SK40SR-2 / SK45SR-2 is shown in page 02-1-7, 8 of chapter SPECIFICATIONS in this manual.

Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.

Lower the bucket, blade 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.

Use steps and grab handles when mounting or dismounting a machine. Clean any mud, grease, oil or debris from steps, walkways or work platforms before using. 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.

To avoid back injury, use a hoist when lifting components which weigh 23 kg (50 lbs) 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.

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 jewelry, confine long hair and loose clothing before working on this machinery.

Disconnect the battery and hang a “Do Not Operate” tag in the operator’s compartment. remove ignition keys.

If possible, make all repairs with the machine parked on a level, hard surface. Block the machine so it does not roll while working on or under the machine. Hang a “Do Not Operate” tag in the operator’s compartment.

Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or jack stands, capable of supporting the machine, before performing any disassembly.

Do not operate this machine unless you have read and understand the instructions in the OPERATOR’S MANUAL. Improper machine operation is dangerous and could result in injury or death.

10. To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and components. 11. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and carefully pry cover loose to relieve any spring or other pressure, before removing the last two bolts or nuts completely. 12. Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot. 13. Always use the proper tools that are in good condition and that are suited for the job at hand. Be sure you understand how to use them before performing any service work. 14. Reinstall all fasteners with the same part number. Do not use a lesser quality fastener if replacements are necessary.

00 -1-3

SAFETY PRECAUTIONS 15. Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of the parent metal. Make sure to disconnect battery before any welding procedures are attempted. 16. Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will be damaged in operation of the machine by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid. 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.

20. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure must be installed correctly. 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. 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 are disengaged from the sprockets. Block the machine to prevent it from moving.

18. The maintenance and repair work while holding the bucket raised is dangerous due to the possibility of a falling attachment. Donâ&#x20AC;&#x2122;t fail to lower the attachment and place the bucket to the ground before starting the work. 19. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Very small (pin hole) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use cardboard or paper to locate pin hole leaks.

00 -1-4

Book Code No.

PW0102E ➁

NEW HOLLAND EH35 Model Cross-reference: SK35SR-2 is NEW HOLLAND Model EH35

PRELIMINARY REMARKS TABLE OF CONTENTS 1. GENERAL PRECAUTIONS FOR REPAIRS ........................................... 1-1 2. ESCAPING PROCEDURE IN CASE OF EMERGENCY ........................ 1-4 3. INTERNATIONAL UNIT CONVERSION SYSTEM ................................. 1-5

01-0-1 ➁

PW01

Revision First edition First revision Second revision

Date of Issue January, 2001 November, 2001 December, 2002

Remarks S5PW0102E A S5PW0102E ➀ A S5PW0102E ➁ A

Any use of editorial or pictorial content is strictly prohibited without express written permission from New Holland Construction, LLC. Carol Stream, IL 60188 U.S.A. Copyright © 2003 New Holland Construction, LLC. All Rights Reserved.

01-0-2 ➁

1. GENERAL PRECAUTIONS FOR REPAIRS 1.1 PREPARATION BEFORE DISASSEMBLING (1) Understanding operating procedure Read OPERATION & MAINTENANCE MANUAL carefully to understand the operating procedure. (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. (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. (4) Recording Record the following items for communication and prevention of recurring malfunction. 1) Inspection date and place 2) Model name, applicable machine number, and hour meter read 3) Trouble condition, place and cause, if any 4) Visible oil leakage, water leakage and damage 5) Clogging of filters, oil level, oil quality, oil contamination and loosening of connections 6) Result of consideration if any problem exists based on the operation rate per month calculated from hour meter indication after the last inspection date. (5) 1) 2) 3)

Arrangement and cleaning in service shop Tools required for repair work. Prepare space to place the disassembled parts. Prepare oil containers for spilling oil etc.

1.2 SAFETY IN DISASSEMBLING AND ASSEMBLING 1) Wear appropriate clothes with long sleeves, safety shoes, safety helmet and protective glasses. 2) Suspend warning tag "DO NOT OPERATE" from the doorknob or the operating lever, and have a preliminary meeting before starting work.

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

1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT (1) Removing hydraulic equipment 1) Before disconnecting pipes, release the hydraulic pressure of the system, or open the return side cover and take out the filter. 2) Carefully drain oil of the removed pipes into a containers without spilling on the floor. 3) Apply plugs or caps on the pipe ends to avoid oil spillage and dust intrusion. 4) Clean off the external surface of the equipment before disassembling, and drain hydraulic and gear oil before placing it on the workbench. (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 reassembling. 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. 3) Provide matching marks to facilitate reassembling work. 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. 5) Use the special jig and tools without fail if they are specified.

01-1-1

If it is hard to remove a part according to the procedure, do not try it by force but investigate the cause. 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) Inspecting parts 1) Ensure that the disassembled parts are free from seizure, interference and uneven contact. 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. (4) Reassembling hydraulic equipment 1) Turn ON the ventilation fan or open windows to maintain good ventilation prior to starting the cleaning of parts. 2) Perform rough and finish cleaning before assembling. 3) Remove washing oil by air and apply clean hydraulic or gear oil for assembling. 4) Always replace the removed O-rings, backup rings and oil seals with new ones by applying grease in advance. 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. 7) Fit bearings, bushings and oil seals using special jigs. 8) Assemble the parts utilizing matching marks. 9) Ensure all the parts are completely assembled after the work. (5) Installing hydraulic equipment 1) Ensure hydraulic oil and lubricant are properly supplied. 2) Perform air bleeding when: a. Hydraulic oil changed b. Parts of suction side piping replaced c. Hydraulic pump installed d. Slewing motor installed e. Travel motor installed f. Hydraulic cylinder installed Operation of the hydraulic equipment without filling hydraulic oil or lubricant or without performing air bleeding will result in damage to the equipment.

Perform air bleeding of the hydraulic pump and slewing motor after loosening the upper drain plug, starting the engine and keep it in low idle condition. Complete the air bleeding when seeping of hydraulic oil is recognized, and tightly plug. Perform air bleeding of the travel motor and the hydraulic cylinders by running the engine for more than 5 minutes at low speed without load. Do not allow the hydraulic cylinder to bottom on the stroke end just after the maintenance.

5) 6)

Perform air bleeding of pilot line by performing a series of digging, slewing and travel. Check hydraulic oil level after placing the attachment to the oil check position, and replenish oil if necessary.

Checking hydraulic oil level Level gauge

Oil level lines (Level located between the two lines shows appropriate amount of oil)

1.4 ELECTRICAL EQUIPMENT (1) Do not disassemble electrical equipment. (2) Handle it carefully not to drop and give a shock. (3) Turn the key OFF prior to connecting and disconnecting work. (4) Disconnect the connector by holding it and pressing the lock. Do not pull the wire to apply force to the caulking portion. (5) Connect the connector and ensure it is completely locked. (6) Turn the key OFF prior to touching the terminal of starter or generator. (7) Remove the ground (earth) terminal of battery when handling tools around the battery or its relay. (8) Do not splash water on the electrical equipment and connectors during machine washing. (9) Check for moisture adhesion inside the waterproof connector after pulling it out, since it is hard to remove moisture from the connector. If moisture adhesion is found, dry it completely before the connection.

01-1-2

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 the exposure occurs, take the following emergency measures and seek the advice of a medical specialist. ! 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.

1.5 HYDRAULIC PARTS 1) ! !

! ! 2)

O-ring Ensure O-rings have elasticity and are not damaged before use. Use the appropriate O-rings. O-rings are made of various kinds of materials having different hardness to apply to a variety of parts, such as the part for moving or fixed portion, subjected to high pressure, and exposed to corrosive fluid, even if the size is same. Fit the O-rings without distortion and bend. Always handle floating seals as a pair.

Flexible hose (F hose) ! 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.

1.6 WELDING REPAIR (1) Refer repair welding to qualified personnel according to the appropriate procedure. (2) Disconnect the ground (earth) cable of the battery before starting the repair. Failure to do so will cause damage to the electrical equipment. (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.

1.7 ENVIRONMENTAL MEASURE (1) Run the engine at the place that is sufficiently ventilated. (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: ! 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 genuine replacement parts and lubricants.

01-1-3

2. ESCAPING PROCEDURE IN CASE OF EMERGENCY 2.1 WHEN CAB DOOR DOES NOT OPEN (CAB spec. only) (1) Escape from the front window. (2) Escape from skylight. (3) When front window and skylight do not open ; The life hammer is always reserved on the rear left side of cab. Break the glass on the rear side of cab, and escape from there. Break the window glass with care to protect eyes, and don't fail to break the window on which label "Emergency exit" is stuck. (4) In addition, the life hammer is equipped with a cutter on the lever side to cut the seat belt, etc.

Fig. 2-1 LIFE HAMMER AND "EMERGENCY EXIT" SEAL

2.2 TOWING THE MACHINE 1. If the machine should become stuck in soft soil areas it may be necessary to tow the machine. Attach a wire rope or chain, with the capacity to pull the machine out, to the lower frame axles. 2. Attach other end to the vehicle used to pull the machine. Operate the Machineâ&#x20AC;&#x2122;s Travel Lever in the proper direction while pulling with the other vehicle.

! While towing, do not enter between the machine and towing vehicle. ! Do not apply a shock load onto the towing rope. ! Do not use eyes on machine lower frame to tow machine. ! Keep the wire rope horizontally, and perpendicularly to the crawler frame. ! Tow the machine slowly at low speed mode. ! For the towing of the machine body, provide pads to be applied to the corner of crawler frame to prevent the wire rope and crawler frame from any damages.

NOTE Do not pull machine utilizing the brackets welded on the lower plates of the carbody. These brackets are provided for pulling lightweight objects. See figure for better reference. Fig. 2-2 TOW MACHINE PROPERLY

01-1-4

3. INTERNATIONAL UNIT CONVERSION SYSTEM (Based on MARKS´ STANDARD HANDBOOK FOR MECHANICAL ENGINEERS) Introduction 2. Construction of SI Unit System Although this manual uses the gravitational unit system,

if you need SI unit, refer to the

Base units Table 3-1

following international system of units. are related to this manual : 1. Etymology of SI Units French :Le System International d´ Units

Supplementary units Table 3-2

SI units

SI unit system

Derived units bearing peculiar designations Table 3-4

Derived units

English :International System of Units

Derived units of base units Table 3-3

Prefixes of SI (n-th power of 10, where n is an integer) Table 3- 5

Given hereinafter is an excerpt of the units that

(1) Base Units [ Table 3-1 ] QUANTITY UNIT

SYMBOL

Length

metre

Mass Time

kilogram second

kg s

Electric current

ampere

Thermodynamic temperature

kelvin

Amount of substance mol Luminous intensity candela

mol cd

(2) Supplementary Units [ Table 3-2 ] QUANTITY Plane angle

UNIT radian

Solid angle

steradian

(3) Derived Units [ Table 3-3 ] QUANTITY UNIT

SYMBOL rad sr

(4) Derived Units bearing Peculiar Designations [ Table 3-4 ] QUANTITY Frequency Force Pressure and Stress Energy, Work and Quantity of heat Power Quantity of electricity Electric potential difference, Voltage, and Electromotive force Quantity of static electricity and Electric capacitance Electric resistance Celsius temperature Illuminance

UNIT hertz newton pascal joule

SYMBOL Hz N Pa J

FORMULA 1/s kg · m/s 2 N/m2 N·m

watt coulomb

W C

J/s A·s

volt

W/A

farad

C/V

ohm

‰

V/A

celsius degree or degree lux

°C

(t+273.15)K

l m/m2

SYMBOL

Area

square metre

Volume Velocity

cubic metre metre per second

m3 m/s

Acceleration

metre per second squared

m/s2

Density

kilogram per cubic metre

kg/m3 Continued on next page.

01-1-5

(5) Prefixes of SI [ Table 3-5 ] PREFIX giga mega kilo hecto deca deci centi milli micro nano pico

SYMBOL

MULTIPLICATION FACTORS

G M k h da d c m µ n p

10 9 10 6 10 3 10 2 10 10-1 10-2 10-3 10-6 10-9 10-12

(6) Unit Conversion [ Table 3-6 ] QUANTITY Gravitational SI CONVERSION FACTOR Weight kgf Mass kg 1 kgf=1 kg Force kgf N 1 kgf=9.807 N Torque kgf · m N·m 1 kgf·m=9.807 N¥m Pressure kgf/cm2 MPa 1 kgf/cm2=0.09807 MPa Motive power PS kW 1 PS=0.7355 kW Revolution rpm min-1 r/min 1

* 1 Units that are allowed to use

(7) Unit conversion logarithmic chart

FORCE

1 N=0.10197 kgf

100

500

1,000

100

5,000 10,000 500

20,000 N

1,000 2,000 kgf

1 kgf=9.807 N

TORQUE

1 N • m=0.102 kgf • m

100

5,000

10,000 20,000 N • m

500

1,000 2,000 kgf • m

1 kgf ¥ m=9.807 N ¥ m

PRESSURE

1 MPa=10.197 kgf/cm 2

0.1

100

1,000

1 kgf/cm2=0.09807 MPa

01-1-6

MPa kgf/cm2

Book Code No.

PW02 02E ➀

NEW HOLLAND EH35 Model Cross-reference: SK35SR-2 is NEW HOLLAND Model EH35

SPECIFICATIONS TABLE OF CONTENTS 1. COMPONENTS NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 2. MACHINE DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 3. SPECIFICATIONS AND PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . 1-6 4. MACHINE AND COMPONENTS WEIGHT (DRY) . . . . . . . . . . . . . . . . . . 1-7 5. TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 6. TYPE OF CRAWLER SHOES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 7. TYPE OF BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 8. MACHINE LIFTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 9. WORKING RANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 10. LIFTING CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 11. ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

02 -0-1 ➀

PW02

Revision First edition First revision Second revision

Date of Issue January, 2001 November, 2001 December, 2002

Remarks S5PW0202E A S5PW0202E ➀ A S5PW0202E ➁ A

Any use of editorial or pictorial content is strictly prohibited without express written permission from New Holland Construction, LLC. Carol Stream, IL 60188 U.S.A. Copyright © 2003 New Holland Construction, LLC. All Rights Reserved.

02-0-2 ➀

1. CONPONENTS NAME

â&#x20AC;¢ The figure shows standard machine. (after BU)

02 -1-1

2. MACHINE DIMENSIONS 2.1 SK30SR-2 [EU • OCEANIA] CANOPY

Unit : mm (ft·in)

CAB

02 -1-2

2.2 SK35SR-2 [EU • OCEANIA] CANOPY

Unit : mm (ft·in)

CAB

02 -1-3

2.3 SK30SR-2 (USA) CANOPY

Unit : mm (ft·in)

CAB

02 -1-4

2.4 SK35SR-2 (USA) CANOPY

Unit : mm (ft·in)

CAB

02 -1-5

3. SPCIFICATIONS AND PERFORMANCE SPEED AND GRADEABILITY Model Item Slewing Speed

Shoe Type

Travel Speed km/h (mph) Gradeability

USA

SK30SR-2 SK35SR-2 Rubber shoe Steel shoe (OPT) Rubber shoe Steel shoe (OPT) 9.0 rpm 8.6 rpm Low (1st) High (2nd) Low (1st) High (2nd) Low (1st) High (2nd) Low (1st) High (2nd) 2.5 4.4 2.5 4.5 2.5 4.3 2.6 4.5 (1.6) (2.7) (1.6) (2.8) (1.6) (2.7) (1.6) (2.8) 2.3 4.0 2.3 4.1 (1.4) (2.5) (1.4) (2.5) 58 % (30ß)

58 % (30ß)

Boom swing by hydraulic cylinder 60ß CANOPY:80ß / CAB:70ß 305 / 390 (12.0 / 15.4)

Boom swing by hydraulic cylinder 60ß CANOPY:80ß / CAB:70ß 330 / 390 (13.0 / 15.4)

% (degree)

SIDE DIGGING & DOZER Type Right Left Stroke of Dozer(above/below) mm(in) Boom Swing Angle

ENGINE Model YANMAR 3TNE82A - YBD YANMAR 3TNE82A - YBC Type Water-cooled, 4-cycle type Swirl chamber type diesel engine Number of cylinders-Bore x Stroke 3 - 82mm X 84mm (3.23in X 3.31in) Total Displacement 1.33 liters (81.1 cu.in) Output Rating 23PS / 2,300rpm {16.9kW / 2,300min-1} 24PS / 2,400rpm {17.7kW / 2,400min-1} Maximum Torque 8.1kgf¥m / 1,400rpm {59lbf¥ft/1,400rpm} 8.1kgf¥m / 1,500rpm {59lbf¥ft/1,500rpm} Starting Motor 12V / 1.2 kW Generator 12V / 40 A

HYDRAULIC COMPONENTS Hydraulic Pump Hydraulic Motor Hydraulic Motor w/Reducer (Travel) Control Valve Cylinder (Boom, Arm, Swing, Bucket, Dozer, Frame width) Return Filter

Variable displacement axial piston + gear pump Axial piston 2-Axial piston, 2-Speed motor 10-spool multiple control valve Double action cylinder Safety valve containing/Filter Type (30 )

02 -1-6

4. MACHINE&COMPONENTS WEIGHT (DRY) MODEL COMPLETE MACHINE UPPER FRAME ASSEMBLY (ASSY OF FOLLOWINGS)

CANOPY / CAB

[EU • OCEANIA] 1,660 (3,660) 1,770 (3,900) 1,900 (4,190) 2,010 (4,430) 1,710 (3,770) 1,770 (3,900) 1,950 (4,300) 2,010 (4,430) USA [EU • OCEANIA]

BUCKET ARM CYLINDER BUCKET CYLINDER BUCKET LINK IDLER LINK FLUIDS HYDRAULIC OIL COOLING WATER FUEL

84 (185) 129 (284)

USA

UPPER FRAME ENGINE RADIATOR HYDRAULIC PUMP HYDRAULIC TANK FUEL TANK CONTROL VALVE SLEWING MOTOR SWING BRACKET SWING CYLINDER COUNTER WEIGHT GUARD • BONNET BOOM CYLINDER LOWER FRAME ASSEMBLY (ASSY OF FOLLOWINGS) LOWER FRAME SWIVEL JOINT SLEWING BEARING RUBBER CRAWLER SHOE TRAVEL MOTOR LOWER ROLLER FROMT IDLER SPROCKET IDLER ADJUSTER DOZER DOZER CYLINDER HOE ATTACHMENT BOOM ARM

Unit ; kg (lb)

SK35SR-2 SK30SR-2 CANOPY CAB CANOPY CAB [EU • OCEANIA] 3,000 (6,620) 3,110 (6,860) 3,510 (7,740) 3,620 (7,980) 3,060 (6,750) 3,130 (6,900) 3,570 (7,870) 3,640 (8,030) USA

194 (428) 194 (428)

360 (794) 150 (331) 11 (24) 38 (84) 30 (66) 24 (53) 25 (55) 38 (84) 66 (146) 34 (75) 330 (728) 82 (181) 36 (79) 1,110 (2,450) 320 (706) 22 (49) 43 (95) 145 X 2 (320 X 2) 42 X 2 (93 X 2) 8 X 8 (18 X 2) 27 X 2 (60 X 2) 14 X 2 (31 X 2) 16 X 2 (35 X 2) 124 (273) 21 (46) [EU • OCEANIA] 400 (882) [USA] 415 (915) 100 (221) [EU • OCEANIA] 56 (123) [USA] 71 (157) 88 (194) 31 (68) 21 (46) 9 (20) 3X2 (7 X 2) 82 (181) 43 (95) 4 (9) 32 (71)

Note : Bucket weight is shown with Japanese standard bucket weight.

02 -1-7

84 (185) 129 (284)

194 (428) 194 (428)

(794) 360 (331) 150 (24) 11 (84) 38 (66) 30 (53) 24 (55) 25 (84) 38 (146) 66 (75) 34 560 (1,230) (181) 82 (88) 40 1,180 (2,600) (772) 350 (49) 22 (95) 43 150 X 2 (331 X 2) 42 X 2 (93 X 2) 8 X 8 (18 X 8) 27 X 2 (60 X 2) 14 X 2 (31 X 2) 16 X 2 (35 X 2) (309) 140 (51) 23 [EU • OCEANIA] 420 (926) [USA] 435 (959) 130 (287) [EU • OCEANIA] 60 (132) [USA] 75 (165) 90 (198) 36 (79) 21 (46) 9 (20) 3X2 (7 X 2) 82 (181) 43 (95) 4 (9) 32 (71)

5. TRANSPORTATION (1) LOADING MACHINE ON A TRAILER 1) Keep trailer bed clean.Put chocks against truck wheels. 2) Use a ramp or loading dock. 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. Center the machine over the trailer. 4) Lower all attachment. 5) Stop engine. Remove key from switch. 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 arm cylinder fully extended, remove bucket or attachment and extend arm cylinder.

02 -1-8

(2) Transportation Dimention and Weight of Attachment 1) BOOM WITH ARM CYLINDER

Model

SK30SR-2

SK35SR-2

L X H X W mm(ft·in)

2,430 X 820 X 255 (7’11.7") (2’8.3") (10.0")

2,600 X 820 X 255 (8’6.4") (2’8.3") (10.0")

Weight w/Arm cyl. kg(lb)

190 (419)

220 (485)

2) ARM & BUCKET (Japanese standard bucket)

Model

SK30SR-2

SK35SR-2

L X H X W mm(ft·in)

2,190 X 470 X 500 (7’2.2") (1’6.5") (1’7.7")

2,330 X 470 X 600 (7’7.7") (1’6.5") (1’11.6")

Weight kg(lb)

195 (430)

[EU] 200 (441) [USA] 215 (474)

Model

SK30SR-2

SK35SR-2

L X H X W mm(ft·in)

1,550 X 400 X 240 (5’1.0") (1’3.7") (9.4")

1,690 X 400 X 240 (5’6.5") (1’3.7") (9.4")

Weight kg(lb)

105 (232)

[EU] 110 (243) [USA] 125 (276)

3) ARM

4) BUCKET (Japanese standard bucket)

Model Heaped capacity m3(cu·yd) L X H X W mm(in) Weight kg(lb)

SK30SR-2 0.09 (0.12)

SK35SR-2 0.11 (0.14)

640 X 620 X 500 640 X 620 X 600 (2’1.2") (2’0.4") (1’7.7") (2’1.2") (2’0.4") (1’11.6") 88 (194)

91 (201)

SK30SR-2

SK35SR-2

5) DOZER w/o cylinder weight

Model L X H X W ; Ret/Exp mm(in) Weight kg(lb)

1,060 X 320 X 1,550 1,190 X 320 X 1,700 (3’5.7") (1’0.6") (5’1.0") (3’10.9") (1’0.6") (5’6.9") 124 (273)

142 (313)

02 -1-9

6. TYPE OF CRAWLER SHOES

Type

Model

Shoe width Total Crawler width mm(ft·in) mm (in)

Number of Link

Ground pressure kgf/cm2 (psi)

CANOPY

CAB

Rubber shoe SK30SR-2

300 (11.8")

1,550 (5’1.0")

0.29 (4.1)

0.31 (4.4)

SK35SR-2

300 (11.8")

1,700 (5’6.9")

0.31 (4.4)

0.32 (4.6)

SK30SR-2

300 (11.8")

1,550 (5’1.0")

0.31 (4.4)

0.32 (4.6)

SK35SR-2

300 (11.8")

1,700 (5’6.9")

0.33 (4.7)

0.34 (4.8)

Steel shoe(option)

7. TYPE OF BUCKET (Japanese standard bucket)

Type

Model

Heaped capacity m3(cu.yd)

Outer width mm(in) with side without side cutter cutter

Number of tooth

Weight Remarks kg(lb)

Back hoe bucket SK30SR-2 0.09 (0.118)

500

430

(1’7.7")

(1’4.9")

88 (194) Standard size

SK35SR-2 0.11 (0.144)

600

530

(1’11.6")

(1’8.9")

02 -1-10

91 (201)

8. MACHINE LIFTING PROCEDURE WEIGHT kg(lb) EU • OCEANIA USA A : SK30SR-2 3,000 (6,620) 3,060 (6,750) B : SK35SR-2 3,510 (7,740) 3,570 (7,870) MODEL

• The wire ropes to be used for lifting the machine should have sufficient strength against the machine weight.

LIFTING ANGLE CABLE fl14 A : 2300 mm x 1 Q ’ TY B : 2200 mm x 1 Q ’ TY

• Improper lifting method and/or roping manner might cause for a movement or slip of the machine while it is lifted up, resulting serious injury or damages on the machine.

A: B: 18 … 23 …

… 17 … 19 B:

CABLE fl14 A, B : 4400 mm x 2 Q ’ TY

A, B : 4700 mm

LIFTING PROCEDURES FOR THE MACHINE COMPLETE

(D)

• Do not impose a load suddenly on the wire ropes and slings. • When the lifting work is carried out in cooperation with plural persons, make sure to ensure every situations with exchanging signals with each other. (C)

• During the lifting work, keep any persons away from around the lifting machine, especially under the machine A: 50 mm B: 23 mm

[1] Manipulate each operating lever to take the machine a position as shown in the figure.

WEIGHT kg(lb) EU • OCEANIA USA A : SK30SR-2 3,110 (6,860) 3,130 (6,900) B : SK35SR-2 3,620 (7,980) 3,640 (8,030) MODEL

[2] Operate the boom swing pedal [EU • OCEANIA] or slew/swing lever [USA] to face the boom direct front.

LIFTING ANGLE A: B: 15… 23 …

[3] Stop the engine, and make the safety lock lever to “LOCKED” position. Then take off the machine after ensuring for no abnormalities around the operators seat.

CABLE fl14 A : 2600 mm x 1 Q’TY B : 2200 mm x 1 Q’TY

… 16 … 19 : B CABLE fl14 A : 4800 mm x 2 Q’TY B : 4400 mm x 2 Q’TY

(D)

A: 5100 mm B: 4700 mm

Carry out the lifting work at a level ground.

[4] Install shackles to both bores (C) provided at both ends of the dozer blade, and put the wire ropes on them. [5] Put the wire ropes on the (D) portion of the boom. (C)

[6] If any portions of the wire ropes directly get touch with the machine when the wire ropes are put up, protect the machine from damages by means of applying a wooden piece or rag between them. [7] Slightly lift the machine to ensure the balance, then lift up the machine.

A: 50 mm B: 23 mm

Note : This figure is calculated with Japanese standard bucket. Bucket weight SK30SR-2 : 88kg (194 lb) SK35SR-2 : 91kg (201 lb)

02 -1-11

9. WORKING RANGES

[

CANOPY EU, USA OCEANIA

]

A A’ G

[Note] Figure shows the case of

Y X

H D

standard canopy spec.

F J

Unit ; mm (ft·in) Model Attachment Item

A A’ B C D E F G H J K L X Y

SK30SR-2

SK35SR-2

1,200 (3’ 11.2")

1,320 (4’ 4.0")

0.09m3 (0.118 cu.yd) 4,920 (16’ 1.7")

0.11m3 (0.144 cu.yd) 5,180 (16’ 11.9")

Max. digging reach at ground level

4,790 (15’ 8.6")

5,060 (16’ 7.2")

Max. digging depth

2,830 (9’ 3.4")

3,100 (10’ 2.0")

Max. digging height

4,500 (14’ 9.2")

4,530 (14’ 10.3")

Max. dumping clearance

3,160 (10’ 4.4")

3,220 (10’ 6.8")

Min. dumping clearance

1,260 (4’ 1.6")

1,230

(4’ 0.4")

Max. vertical wall digging depth

2,170 (7’ 1.4")

2,320

(7’ 7.3")

Min. front slew radius

2,140 (7’ 0.3")

2,310

(7’ 6.9")

Height at min. slew radius

3,450 (11’ 3.8")

3,540 (11’ 7.4")

8-feet level digging depth

2,320 (7’ 7.3")

2,610

Stroke Horizontal digging stroke at ground level Minimum

2,150 (7’ 0.6")

2,390 (7’ 10.1")

1,640 (5’ 4.6")

1,660

(5’ 5.4")

Above

305 (1’ 0.0")

330

(1’ 1.0")

Below

390 (1’ 3.4")

390

(1’ 3.4")

Arm

Bucket Max. digging reach

Dozer strokes

Note : Japanese domestic specification.

02 -1-12

(8’ 6.8")

WORKING RANGES CANOPY [NEW ZELAND] A A’ G

Y X

H D

[Note] Figure shows the case of standard canopy spec.

F J

Unit ; mm (ft·in) Model Attachment Item

A A’ B C D E F G H J K L X Y

SK30SR-2

SK35SR-2

1,200 (3’ 11.2")

1,320 (4’ 4.0")

0.09m3 (0.118 cu.yd) 4,920 (16’ 1.7")

0.11m3 (0.144 cu.yd) 5,180 (16’ 11.9")

Max. digging reach at ground level

4,790 (15’ 8.6")

5,060 (16’ 7.2")

Max. digging depth

2,830 (9’ 3.4")

3,100 (10’ 2.0")

Max. digging height

4,770 (15’ 7.8")

4,900 (16’ 0.9")

Max. dumping clearance

3,410 (11’ 2.3")

3,550 (11’ 7.8")

Min. dumping clearance

1,390 (4’ 6.7")

1,390

(4’ 6.7")

Max. vertical wall digging depth

2,170 (7’ 1.4")

2,320

(7’ 7.3")

Min. front slew radius

1,870 (6’ 1.6")

1,980

(6’ 6.0")

Height at min. slew radius

3,590 (11’ 9.3")

3,720 (12’ 2.5")

8-feet level digging depth

2,320 (7’ 7.3")

2,610

Stroke Horizontal digging stroke at ground level Minimum

2,150 (7’ 0.6")

2,390 (7’ 10.1")

1,640 (5’ 4.6")

1,660

(5’ 5.4")

Above

305 (1’ 0.0")

330

(1’ 1.0")

Below

390 (1’ 3.4")

390

(1’ 3.4")

Arm

Bucket Max. digging reach

Dozer strokes

Note : Japanese domestic specification.

02 -1-12-(1)

(8’ 6.8")

WORKING RANGES

[

]

CAB EU, USA OCEANIA

Unit ; mm (ft¥in) Model Attachment Item

A A’ B C D E F G H J K L X Y

SK30SR-2

SK35SR-2

1,200 (3’ 11.2")

1,320 (4’ 4.0")

0.09m3 (0.118 cu.yd) 4,920 (16’ 1.7")

0.11m3 (0.144 cu.yd) 5,180 (16’ 11.9")

Max. digging reach at ground level

4,790 (15’ 8.6")

5,060 (16’ 7.2")

Max. digging depth

2,830 (9’ 3.4")

3,100 (10’ 2.0")

Max. digging height

4,500 (14’ 9.2")

4,530 (14’ 10.3")

Max. dumping clearance

3,160 (10’ 4.4")

3,220 (10’ 6.8")

Min. dumping clearance

1,260 (4’ 1.6")

1,230

(4’ 0.4")

Max. vertical wall digging depth

2,170 (7’ 1.4")

2,320

(7’ 7.3")

Min. front slew radius

2,140 (7’ 0.3")

2,310

(7’ 6.9")

Height at min. slew radius

3,450 (11’ 3.8")

3,540 (11’ 7.4")

8-feet level digging depth

2,320 (7’ 7.3")

2,610

Stroke Horizontal digging stroke at ground level Minimum

2,150 (7’ 0.6")

2,390 (7’ 10.1")

1,640 (5’ 4.6")

1,660

(5’ 5.4")

Above

305 (1’ 0.0")

330

(1’ 1.0")

Below

390 (1’ 3.4")

390

(1’ 3.4")

Arm

Bucket Max. digging reach

Dozer strokes

Note : Japanese domestic specification.

02 -1-12-(2)

(8’ 6.8")

10. LIFTING CAPACITIES (1) Conditions of calculation

1) The lifting load shows the lower value either 87% of lifting capacity by hydraulic pressure, or 75% of tipping load. 2) The load point is on the bucket lift point, and the bucket cylinder is extended (bucket IN). 3) Weight of hooks, slings, and all other lifting equipment shall be considered a part of the load. 4) The values in the upper rows show the lifting capacity at a machine facing sideways, and values in the lower rows show a machine facing longitudinally. 5) Crawler : 300mm (11.8 in), Rubber crawler shoe. 6) Set hydraulic pressure 230 kgf / cm2 (3270 psi)

(2) Reference No. list of lifting diagram

MODEL

FIGURE No. CANOPY

CAB

SK30SR-2 (EU)

[1]

[2]

SK35SR-2 (EU)

[3]

[4]

SK30SR-2 (USA)

[5]

[6]

SK35SR-2 (USA)

[7]

[8]

SK30SR-2 (OCEANIA)

[9]

[10]

SK35SR-2 (OCEANIA)

[11]

[12]

02 -1-13

Unit : ton

[1] SK30SR-2 CANOPY (EU) • Arm length : 1.20 m (3’11”) • Dozer blade : Up and Front • With Japanese standard bucket. Bucket weight : 88 kg (194 lb) Bucket capacity : 0.09 m3 (0.12 cu•yd)

Unit : ton

[2] SK30SR-2 CAB (EU) • Arm length : 1.20 m (3’11”) • Dozer blade : Up and Front • With Japanese standard bucket. Bucket weight : 88 kg (194 lb) Bucket capacity : 0.09 m3 (0.12 cu•yd)

02 -1-14

Unit : ton

[3] SK35SR-2 CANOPY (EU) • Arm length : 1.32 m (4’4.0”) • Dozer blade : Up and Front • With Japanese standard bucket. Bucket weight : 91 kg (201 lb) Bucket capacity : 0.11 m3 (0.14 cu•yd)

Unit : ton

[4] SK35SR-2 CAB (EU) • Arm length : 1.32 m (4’4.0”) • Dozer blade : Up and Front • With Japanese standard bucket. Bucket weight : 91 kg (201 lb) Bucket capacity : 0.11 m3 (0.14 cu•yd)

02 -1-15

[5] SK30SR-2 CANOPY (USA)

Based on machine equipped with Arm 1200 mm (3' 11") arm Shoe 300 mm (11.8") Rubber Shoe Dozer blade up With Japanese standard bucket. Bucket weight : 91kg (201 lb)

[6] SK30SR-2 CAB (USA)

Based on machine equipped with Arm 1200 mm (3' 11") arm Shoe 300 mm (11.8") Rubber Shoe Dozer blade up With Japanese standard bucket. Bucket weight : 91kg (201 lb)

02 -1-16

[7] SK35SR-2 CANOPY (USA)

Based on machine equipped with Arm 1320 mm (4' 4") arm Shoe 300 mm (11.8") Rubber Shoe Dozer blade up With Japanese standard bucket. Bucket weight : 91kg (201 lb)

[8] SK35SR-2 CAB (USA)

Based on machine equipped with Arm 1320 mm (4' 4") arm Shoe 300 mm (11.8") Rubber Shoe Dozer blade up With Japanese standard bucket. Bucket weight : 91kg (201 lb)

02 -1-17

Unit : ton

[9] SK30SR-2 CANOPY (OCEANIA) • Arm length : 1.20 m (3’11”) • Dozer blade : Up and Front • With Japanese standard bucket. Bucket weight : 88 kg (194 lb) Bucket capacity : 0.09 m3 (0.12 cu•yd)

Unit : ton

[10] SK30SR-2 CAB (OCEANIA) • Arm length : 1.20 m (3’11”) • Dozer blade : Up and Front • With Japanese standard bucket. Bucket weight : 88 kg (194 lb) Bucket capacity : 0.09 m3 (0.12 cu•yd)

02 -1-17-(1)

Unit : ton

[11] SK35SR-2 CANOPY (OCEANIA) • Arm length : 1.32 m (4’4.0”) • Dozer blade : Up and Front • With Japanese standard bucket. Bucket weight : 91 kg (201 lb) Bucket capacity : 0.11 m3 (0.14 cu•yd)

Unit : ton

[12] SK35SR-2 CAB (OCEANIA) • Arm length : 1.32 m (4’4.0”) • Dozer blade : Up and Front • With Japanese standard bucket. Bucket weight : 91 kg (201 lb) Bucket capacity : 0.11 m3 (0.14 cu•yd)

02 -1-17-(2)

11. ENGINE SPECIFICATIONS 11.1 SPECIFICATIONS SK30SR-2 Model

Item

SK30SR-2

Engine Model

3TNE82A-YBC

Type

Vertical, 4-cycle water-cooled diesel engine

No. of cylinders - Bore X Stroke

3 - 82mm (3.23 in) X 84 mm (3.31 in)

Total displacement

1.33 liter (81.2 cu·in)

Compression ratio

Rated output

23 PS (16.9 kW) at 2300 rpm

Maximum torque

8.1 ~ 8.5 kgf·m (58.6 ~ 61.5 lbf·ft) at 1400 rpm

Low idling

1200 ± 25 rpm

High idling

2500 ± 25 rpm

Fuel consumption rate

Less than 175 g / PS·h

Allowable tilting angles

Back and forth, left and right 25° (momentary 30°)

Rotating direction

Counterclockwise as seen from flywheel side

Firing order

1-3-2-1

Fuel injection timing (FID, b.T.D.C.)

12 ± 1°

Fuel injection pressure

Valve action

Valve clearance

200 +100 kgf / cm2 (2840 +1400 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 (0.008 in) in cold condition

Exhaust valve

0.2 mm (0.008 in) in cold condition

Thermostat action

Start 71 ± 1.5°C (160 ± 3°F) / Full open 85°C (185°F)

Compression pressure

35 ± 1 kgf / cm2 (500 ± 14 psi) at 250 rpm

Lubrication oil pressure

3.7 kgf / cm2 (53 psi) at 2300 rpm

Dimensions L X W X H

566 X 509 X 551 mm (22.3 X 20.0 X 21.7 in)

Dry weight

130 kg (290 lb)

Governor

Mechanical centrifugal governor (All speed type)

Lubrication system

Forced lubrication with trochoid pump

Cooling system

Liquid cooling / Radiator

Starter capacity

12 V X 1.2 kW

Generator capacity

12 V X 40 A

Cooling water capacity : Max / Engine

2.5 / 1.8 liter (0.66 / 0.48 gal)

Engine oil volume : Max / Effective

3.9 / 1.2 liter (1.03 / 0.32 gal)

02 -1-18

SK35SR-2 Model

Item

SK35SR-2

Engine Model

3TNE82A-YBD

Type

Vertical, 4-cycle water-cooled diesel engine 3 - 82mm (3.23 in) X 84 mm (3.31 in)

No. of cylinders - Bore X Stroke Total displacement

1.33 liter (81.2 cu·in)

Compression ratio

Rated output

24 PS (17.7 kW) at 2400 rpm

Maximum torque

8.1 ~ 8.5 kgf·m (58.6 ~ 61.5 lbf·ft) at 1500 rpm

Low idling

1200 ± 25 rpm

High idling

2590 ± 25 rpm

Fuel consumption rate

Less than 175 g / PS·h

Allowable tilting angles

Back and forth, left and right 25° (momentary 30°)

Rotating direction

Counterclockwise as seen from flywheel side

Firing order

1-3-2-1

Fuel injection timing (FID, b.T.D.C.)

14 ± 1°

Fuel injection pressure

Valve action

Valve clearance

200 +100 kgf / cm2 (2840 +1400 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 (0.008 in) in cold condition

Exhaust valve

0.2 mm (0.008 in) in cold condition

Thermostat action

Start 71 ± 1.5°C (160 ± 3°F) / Full open 85°C (185°F)

Compression pressure

35 ± 1 kgf / cm2 (500 ± 14 psi) at 250 rpm

Lubrication oil pressure

3.7 kgf / cm2 (53 psi) at 2400 rpm

Dimensions L X W X H

566 X 509 X 551 mm (22.3 X 20.0 X 21.7 in)

Dry weight

130 kg (290 lb)

Governor

Mechanical centrifugal governor (All speed type)

Lubrication system

Forced lubrication with trochoid pump

Cooling system

Liquid cooling / Radiator

Starter capacity

12 V X 1.2 kW

Generator capacity

12 V X 40 A

Cooling water capacity : Max / Engine

2.5 / 1.8 liter (0.66 / 0.48 gal)

Engine oil volume : Max / Effective

3.9 / 1.2 liter (1.03 / 0.32 gal)

02 -1-19

11.2 ENGINE PERFORMANCE CURVE SK30SR-2 Model : 3TNE82A-YBC Rated Output : 23 PS / 2,300 rpm (16.9 kW / 2300min-1)

SMOKE : Bosch

[ Sd ]

{kgf•m} N•m SHAFT TORQUE

[T]

{PS}

POWER OUTPUT

[PS]

g/kW•h {g/PS•h}

Engine speed rpm X 100

Fuel consumption volume =

F X1000

XPX

FUEL CONSUMPTION RATE

[F]

F : Fuel consumption rate (g / PS·h) P : Shaft output (ps) : Specific gravity

175

X 23 X 0.835 X 1000

: Standard load factor (0.60 ~ 0.70) Fuel consumption in normal operation ;

= 4.82

2.89 ~ 3.37 / h (load factor : (0.60 ~ 0.70))

02 -1-20

SK35SR-2 Model : 3TNE82A-YBD Rated Output : 24 PS / 2,400 rpm (17.7 kW / 2400min-1)

SMOKE : Bosch

[ Sd ]

{kgf•m} N•m SHAFT TORQUE

[T]

{PS}

POWER OUTPUT

[PS]

Engine speed rpm X 100

Fuel consumption volume =

F X1000

XPX

F : Fuel consumption rate (g / PS·h) P : Shaft output (ps) : Specific gravity

175

X 24 X 0.835 X 1000

: Standard load factor (0.60 ~ 0.70) Fuel consumption in normal operation ;

= 5.03

3.02 ~ 3.52 / h (load factor : (0.60 ~ 0.70))

02 -1-21

FUEL CONSUMPTION RATE

g/kW•h {g/PS•h} [F]

NOTES

02 -1-22

Book Code No.

PW03 02E ➁

NEW HOLLAND EH35 Model Cross-reference: SK35SR-2 is NEW HOLLAND Model EH35

ATTACHMENT DIMENSIONS TABLE OF CONTENTS 1. BOOM 1.1 Boom dimensional drawings ........................................................... 1-1 1.2 Boom maintenance standards ......................................................... 1-2 2. ARM 2.1 Arm dimensional drawings .............................................................. 1-6 2.2 Arm maintenance standards ............................................................ 1-8 3. BUCKET 3.1 Bucket dimensional drawings ......................................................... 1-12 3.2 Detail dimensional drawings of lug section .................................... 1-13 3.3 Detail dimensional drawings of boss section .................................. 1-14 4. DOZER 4.1 Dozer dimensional drawings .......................................................... 1-15 4.2 Dozer maintenance standards ....................................................... 1-16 5. SWING 5.1 Swing bracket dimensional drawings ............................................. 1-18 5.2 Swing portion maintenance standards ........................................... 1-19

03 -0-1 ➁

PW03

Revision First edition First revision Second revision

Date of Issue January, 2001 November, 2001 December, 2002

Remarks S5PW0302E A S5PW0302E ➀ A S5PW0302E ➁ A

Any use of editorial or pictorial content is strictly prohibited without express written permission from New Holland Construction, LLC. Carol Stream, IL 60188 U.S.A. Copyright © 2003 New Holland Construction, LLC. All Rights Reserved.

3-0-2 ➁

1. BOOM 1.1 BOOM DIMENSIONAL DRAWINGS

Fig. 1-1 Boom dimensional drawings

Table 1-1 No. A B C D E F G H J K d1 d2 d3 d4

Unit : mm (ft•in)

DIMENSIONS SK30SR-2 SK35SR-2 Boom length 2330 (7’7.73”) 2500 (8’2.43”) Distance between pins of boss R1140 (3’8.88”) R1177 (3’10.34”) Distance between pins of bracket R1136 (3’8.72”) R1157 (3’9.55”) Height of boom cylinder rod pin 387.7 (1’3.26”) 398.5 (1’3.69”) Height of arm cylinder (head side) pin 725.5 (2’4.56”) 708 (2’3.87”) Boom foot width 178 (7.01”) Inner width of bracket for boom cylinder (rod side) mounting 61 (2.40”) Boom end inner width 150 (5.91”) Boom end outer width 235 (9.25”) Inner width of bracket for arm cylinder (head side) 56 (2.20”) 61 (2.40”) Boom foot pin dia. [Bushing outer dia.] ø45 (1.77”) [ø55(2.17”] Boom cylinder (head side) pin dia. ø45 (1.77”) Pin dia. of arm end ø45 (1.77”) Arm cylinder (head side) pin dia. ø45 (1.77”) NAME

03-1-1

1.2 BOOM MAINTENANCE STANDARDS (1)

Clearance of pin and bushing on boom section D

B Fig. 1-2 Clearance of pin and bushing on boom section

Table 1-2 Å° Å°

SK30SR-2 Applicable machines : PW08-20001 ~ 20594 SK35SR-2 Applicable machines : PX09-08001 ~ 08414

Pos.

A B C D

Item

Boom foot Boom cylinder (Head side) Boom cylinder (Rod side) Arm cylinder (Head side)

Pin part No.

Standard dimensions Clearance Tolerance Tolerance Standard Standard Serviceab- Remedy Pin dia. on bushing value on pin dia. bore dia. value for repair ility limit

PW02B01221P1 PW02B01256P2

PW02B01220P2

Unit : mm (in)

(

-0.02 -0.05 -0.0008 -0.0020

)(

+0.10 +0.05 +0.0039 +0.0020

ø45

-0.02

+0.25

(1.7717)

-0.08

+0.05

)(

( )( )

0.07~ 0.15 0.0028~ 0.0059

0.07~

) 0.7

1.0

Replace

0.33 (0.028) (0.039) bushing

-0.0008 +0.0098 (0.0028~ -0.0031 +0.0020 0.0130)

or pin

03-1-2

Table 1-3 Å° Å°

SK30SR-2 Applicable machines : PW08-20595 ~, PW10-22001~ SK35SR-2 Applicable machines : PX09-08415 ~, PX11-08901~

Pos.

A B C D

Item

Boom foot Boom cylinder (Head side) Boom cylinder (Rod side) Arm cylinder (Head side)

Pin part No.

Standard dimensions Clearance Tolerance Tolerance Standard Standard Serviceab- Remedy Pin dia. on bushing value on pin dia. bore dia. value for repair ility limit

PW02B01221P1 PW02B01256P2

PW02B01220P2

Unit : mm (in)

(

-0.02 -0.05 -0.0008 -0.0020

)(

+0.06 0 +0.0024 0

ø45

-0.02

+0.25

(1.7717)

-0.08

+0.05

)(

( )( )

0.02~ 0.11 0.0008~ 0.0043

0.07~

) 0.7

1.0

Replace

0.33 (0.028) (0.039) bushing

-0.0008 +0.0098 (0.0028~ -0.0031 +0.0020 0.0130)

or pin

03-1-3

(2)

Clearance in thrust direction on boom and cylinder installation section

D D

C C A B

A X

SECTION AA

3 X

SECTION BB

4 X

SECTION CC

SECTION DD

Fig. 1-3 Clearance in thrust direction on boom section

03-1-4

Table 1-3

SK30SR-2

Standard dimensions Pos.

Item No.

Boom A Boom foot Swing bracket Boom cylinder Boom cylinder B (Head side) Swing bracket Boom cylinder Boom cylinder C (Rod side) Boom Arm cylinder Arm cylinder D (Head side) Boom

Dimensions

-0.2 -0.008 178 -0.4 (7.008 -0.016 ) +0.3 +0.012 178 0 (7.008 0 ) 0 0 60 -0.5 (2.362 -0.020 ) L2 +2.0 +0.079 61 0 (2.402 0 ) 0 0 60 -0.5 (2.362 -0.020 ) L3 +1.0 +0.039 61 0 (2.402 0 ) 0 0 55 -0.5 (2.165 -0.020 ) L4 +1.0 +0.039 56 0 (2.205 0 )

1 0.1~0.5 1.0

1.5

0.5~0.9 (0.039) (0.059) (0.020~ 0.035) 0.1~0.5 (0.004~ 0.020)

Item No.

Boom Boom foot Swing bracket Boom cylinder Boom cylinder B (Head side) Swing bracket Boom cylinder Boom cylinder C (Rod side) Boom Arm cylinder Arm cylinder D (Head side) Boom

Dimensions

-0.2 -0.008 178 -0.4 (7.008 -0.016 ) +0.3 +0.012 178 0 (7.008 0 ) 0 0 60 -0.5 (2.362 -0.020 ) L2 +2.0 +0.079 61 0 (2.402 0 ) 0 0 60 -0.5 (2.362 -0.020 ) L3 +1.0 +0.039 61 0 (2.402 0 ) 0 0 60 -0.5 (2.362 -0.020 ) L4 +1.0 +0.039 61 0 (2.402 0 )

Recondi-

tioned 164 3 (6.46) with shim 164 4 (6.46)

Unit : mm (in) Clearance X reconditioned Pin length with shim (total of both sides) Remedy Standard Standard Serviceabvalue No. Dimensions value for repair ility limit

03-1-5

301 (11.85)

196 2 (7.72)

Table 1-4 Standard dimensions

Clearance X reconditioned Pin length with shim (total of both sides) Remedy Standard Standard Serviceabvalue No. Dimensions value for repair ility limit

SK35SR-2

Pos.

Unit : mm (in)

1 0.1~0.5 1.0

1.5

0.5~0.9 (0.039) (0.059) (0.020~ 0.035) 0.1~0.5 (0.004~ 0.020)

301 (11.85)

196 2 (7.72)

Recondi-

tioned 164 3 (6.46) with shim 164 4 (6.46)

2. ARM 2.1 ARM DIMENSIONAL DRAWINGS

SECTION ZZ

SECTION XX SECTION YY Fig. 2-1 Arm dimensional drawings SK30SR-2 No. A B C D E F G H J K L

Unit : mm (ft•in)

Table 2-1 Name

Arm length Distance between pins of boss and bracket Distance between pins of boss and bracket Distance between pins of boss and boss Height between pins of boss and bracket Height between pins of boss and bracket Height between pins of boss and center Boss width Boss width Bracket inner width Bracket inner width

Dimensions

No.

Name

1200 (3’11.24”) M Link dimension R303 (11.93”) N Link dimension R999 (3’3.33”) D1 I.D. of boss R195 (7.68”) D2 I.D. of boss 302.5 (11.91”) D3 I.D. of boss 155 (6.10”) d1 Pin dia. 8 (0.31”) d2 Pin dia. 140 (5.51”) d3 Pin dia. d4 Pin dia. 150 (5.91”) d5 Pin dia. 56 (2.20”) 56 (2.20”)

03-1-6

Dimensions 310 (1’0.20”) 285 (11.22”) ø50 (1.97”) ø50 (1.97”) ø55 (2.17”) ø40 (1.57”) ø40 (1.57”) ø45 (1.77”) ø40 (1.57”) ø45 (1.77”)

SK35SR-2 No. A B C D E F G H J K L

Unit : mm (ft•in)

Table 2-2 Name

Dimensions

No.

1320 (4’3.97”) R312 (1’0.28”) R999 (3’3.33”) R195 (7.68”) 302.5 (11.91”) 141.5 (5.57”) 8 (0.31”) 140 (5.51”) 150 (5.91”) 57 (2.24”) 62 (2.44”)

M N D1 D2 D3 d1 d2 d3 d4 d5

03-1-7

Name Link dimension Link dimension I.D. of boss I.D. of boss I.D. of boss Pin dia. Pin dia. Pin dia. Pin dia. Pin dia.

Dimensions 310 (1’0.20”) 285 (11.22”) ø50 (1.97”) ø50 (1.97”) ø55 (2.17”) ø40 (1.57”) ø40 (1.57”) ø45 (1.77”) ø40 (1.57”) ø45 (1.77”)

2.2 ARM MAINTENANCE STANDARDS (1)

Clearance of pin and bushing E D, DÅf G

C F Fig. 2-2A Clearance of pin and bushing on arm section Table 2-3A SK30SR-2 Applicable machines : PW08-20001 ~ 20596 Pos.

Item

Pin part No.

Unit : mm (in)

Clearance Standard dimensions Tolerance Tolerance Standard Standard Serviceab- Remedy Pin dia. on bushing value on pin dia. bore dia. value for repair ility limit

Arm point A

(Connected part of bucket) Bucket link

(

PW12B01250P1

(

(Bucket side) Idler link

(Connected part of arm) Bucket link

(Idler link side)

(1.5748)

-0.05

( )

(Head side) Arm foot

(Connected part of boom) Arm cylinder

(Rod side)

(

0.05~ 0.12 0.0020~ 0.0047 0.07~ 0.16 0.0028~ 0.0063 0.05~ 0.13 0.0020~ 0.0051 0.06~ 0.13 0.0024~ 0.0051

)(

)

)(

)

)(

)

)(

)

-0.0020

(

PW12B01220P1

PW12B01255P1

(

ø45

(1.7717) -0.02 -0.08 PW12B01219P2 -0.0008 -0.0031

(

)(

+0.25 0.07~ 0.30 +0.05 +0.0098 0.0028~ 0.0118 +0.0020

)(

+0.10 +0.05 +0.0039 +0.0020 +0.25 +0.05 +0.0098 +0.0020

0.7

1.0

(0.028) (0.039)

-0.0008

(Rod side) Bucket cylinder

-0.02

PW12B01253P1

Bucket cylinder D’

(

ø40

+0.07 +0.03 +0.0028 +0.0012 +0.11 +0.05 +0.0043 +0.0020 +0.08 +0.03 +0.0031 +0.0012 +0.08 +0.04 +0.0031 +0.0016

)( )(

0.07~ 0.15 0.0028~ 0.0059 0.07~ 0.33 0.0028~ 0.0130

Replace bushing or pin

) ) )

03-1-8

Table 2-3B SK30SR-2 Applicable machines : PW08-20597 ~, PW10-22001~ Pos.

Item

Pin part No.

Standard dimensions Clearance Tolerance Tolerance Standard Standard Serviceab- Remedy Pin dia. on bushing value on pin dia. bore dia. value for repair ility limit

Arm point A

(

(Connected part of bucket) [PW12B01250P1] Bucket link

PW12B01250P2

(

(Bucket side) Idler link

(Connected part of arm) Bucket link

(Idler link side) Bucket cylinder

D’

(

ø40 [PW12B01253P1] (1.5748) 1 PW12B01253P2

*PW12B01311P1

-0.02 -0.05

( ) -0.0020

(Rod side)

(Head side)

(

(Connected part of boom)

PW12B01255P1

(Rod side)

(

ø45 (1.7717)

Arm cylinder G

0.02~ 0.10 0.0008~ 0.0039 0.07~ 0.16 0.0028~ 0.0063 0.05~ 0.13 0.0020~ 0.0051 0.06~ 0.13 0.0024~ 0.0051

)(

)

)(

)

)(

)

)(

)

0.7

1.0

(0.028) (0.039)

+0.25 0.07~ 0.30 +0.05 +0.0098 0.0028~ 0.0118 +0.0020

)(

Replace bushing or pin

)

PW12B01220P1

Arm foot F

(

+0.05 0 +0.0020 0 +0.11 +0.05 +0.0043 +0.0020 +0.08 +0.03 +0.0031 +0.0012 +0.08 +0.04 +0.0031 +0.0016

-0.0008

Bucket cylinder E

Unit : mm (in)

PW12B01219P2

(

-0.02 -0.08 -0.0008 -0.0031

)(

+0.06 0 +0.0024 0 +0.25 +0.05 +0.0098 +0.0020

)( )(

0.02~ 0.11 0.0008~ 0.0043 0.07~ 0.33 0.0028~ 0.0130

) )

(Note)• The tolerance for bushing inside diameter means the dimension after fitting of it into the place. • The part number for pins may be changed owing to improvement, use them only for reference. • The part numbers in [ ] are applicable to the machine numbers PW08-20001 ~ 20677. 1 is applicable for the following Machine Nos. * 1 : PW08-20678~, PW10-22001~22182

• The part Nos. with the mark

03-1-8-(1)

Clearance of pin and bushing E D, DÅf G

C F Fig. 2-2B Clearance of pin and bushing on arm section Table 2-4A SK35SR-2 Applicable machines : PX09-08001 ~ 08378 Pos.

Item

Pin part No.

Unit : mm (in)

Clearance Standard dimensions Tolerance Tolerance Standard Standard Serviceab- Remedy Pin dia. on bushing value on pin dia. bore dia. value for repair ility limit

Arm point A

(Connected part of bucket) Bucket link

(

PW12B01250P1

(

(Bucket side) Idler link

(Connected part of arm) Bucket link

(Idler link side)

(1.5748)

-0.05

( )

(Head side) Arm foot

(Connected part of boom) Arm cylinder

(Rod side)

(

0.05~ 0.12 0.0020~ 0.0047 0.07~ 0.16 0.0028~ 0.0063 0.05~ 0.13 0.0020~ 0.0051 0.06~ 0.13 0.0024~ 0.0051

)(

)

)(

)

)(

)

)(

)

-0.0020

(

[PW12B01220P1]

0.7

1.0

(0.028) (0.039)

-0.0008

(Rod side) Bucket cylinder

-0.02

PW12B01253P1

Bucket cylinder D’

(

ø40

+0.07 +0.03 +0.0028 +0.0012 +0.11 +0.05 +0.0043 +0.0020 +0.08 +0.03 +0.0031 +0.0012 +0.08 +0.04 +0.0031 +0.0016

+0.25 0.07~ 0.30 +0.05 +0.0098 0.0028~ 0.0118 +0.0020

)(

Replace bushing or pin

)

PX12B01206P1 PW12B01255P1

(

ø45 (1.7717)

PW12B01219P2

(

-0.02 -0.08 -0.0008 -0.0031

)(

+0.10 +0.05 +0.0039 +0.0020 +0.25 +0.05 +0.0098 +0.0020

)( )(

0.07~ 0.15 0.0028~ 0.0059 0.07~ 0.33 0.0028~ 0.0130

) )

03-1-8-(2)

Table 2-4B SK35SR-2 Applicable machines : PX09-08379 ~, PX11-08901~ Pos.

Item

Pin part No.

Standard dimensions Clearance Tolerance Tolerance Standard Standard Serviceab- Remedy Pin dia. on bushing value on pin dia. bore dia. value for repair ility limit

Arm point A

(

(Connected part of bucket) [PW12B01250P1] Bucket link

PW12B01250P2

(

(Bucket side) Idler link

(Connected part of arm) Bucket link

(Idler link side) Bucket cylinder

D’

(Head side)

(

ø40 [PW12B01253P1] (1.5748) 1 PW12B01253P2

*PW12B01311P1

-0.02 -0.05

( ) -0.0020

(

PX12B01206P1

Arm foot F

(Connected part of boom)

PW12B01255P1

(Rod side)

(

ø45 (1.7717)

Arm cylinder G

(

PX12B01205P1

+0.05 0 +0.0020 0 +0.11 +0.05 +0.0043 +0.0020 +0.08 +0.03 +0.0031 +0.0012 +0.08 +0.04 +0.0031 +0.0016

0.02~ 0.10 0.0008~ 0.0039 0.07~ 0.16 0.0028~ 0.0063 0.05~ 0.13 0.0020~ 0.0051 0.06~ 0.13 0.0024~ 0.0051

)(

)

)(

)

)(

)

)(

)

(

-0.02 -0.08 -0.0008 -0.0031

)(

+0.25 0.07~ 0.30 +0.05 +0.0098 0.0028~ 0.0118 +0.0020

)(

+0.06 0 +0.0024 0 +0.25 +0.05 +0.0098 +0.0020

0.7

1.0

(0.028) (0.039)

-0.0008

(Rod side) Bucket cylinder

Unit : mm (in)

)( )(

0.02~ 0.11 0.0008~ 0.0043 0.07~ 0.33 0.0028~ 0.0130

Replace bushing or pin

) ) )

(Note)• The tolerance for bushing inside diameter means the dimension after fitting of it into the place. • The part number for pins may be changed owing to improvement, use them only for reference. • The part numbers in [ ] are applicable to the machine numbers PX09-08001 ~ 08400. 1 is applicable for the following Machine Nos. * 1 : PX09-08401~, PX11-08901~09023

• The part Nos. with the mark

03-1-9

(2)

Clearance in thrust direction on arm and cylinder installation section

SECTION AA

SECTION BB

SECTION CC

7 X

SECTION EE

SECTION DD

SECTION FF 8 L8

SECTION GG Fig 2-3 Clearance in thrust direction on arm section

03-1-10

SK30SR-2 SK35SR-2

Unit : mm (in)

Table 2-5

Clearance X reconditioned Pin length with shim (total of both sides) Remedy Standard Standard Serviceabvalue Dimensions No. Dimensions No. value for repair ility limit Less than 1.0 1.5 140 (5.512 ) 278 L1 0.5 1 (10.94) 141±0.7 (5.551±0.028 ) (0.020) (0.039) (0.059) -0.2 -0.008 278 140 -0.4 (5.512 -0.016 ) 0.5~2.1 L2 (0.020~ See “NOTE” 2 (10.94) 141±0.7 (5.551±0.028 ) 0.083) Standard dimensions

Pos.

Item

Arm point

Bucket link

Idler link C (Connected part of arm) Bucket link D (Rod side) Bucket link (Idler link side) E

Bucket cylinder (Head side) Arm foot

Arm cylinder G (Rod side)

Arm Bucket Link side Bucket Arm

(5.551)

140 L3

Link side Rod side Link side Bucket link Idler link

0.6~1.0 1.5 2.0 (0.024~ 0.039) (0.059) (0.079) 0.1~0.5 (0.004~ 0.020)

203 5 (7.99)

0 (2.165 55 -0.5

L6 Arm L7

Rod side

0 -0.020

) 0.5~0.9 (0.020~ 0.035) +0.039 +1.0 56 0 (2.205 0 ) 1.5 (5.906 -0.0079 ) Less than 1.0 150 -0.2 -0.4 0.5 -) +0.5 (5.906 150 0 (0.020) (0.039) (0.059) 0.0157 0 (2.165 55 -0.5

+0.020 0

)

0 -0.020

L8 Arm

203 (7.99) 3 204.5 (8.05)

55 -0.5 (2.165 -0.020 ) L4 57 (2.244 ) (5.512 +0.008 ) 140 +0.2 -0.016 -0.4 L5 ( ) -

Head side

Arm Boom

(

+1.0 0

[ ]

[-] [-] 0.1~0.5 1.0 1.5 (0.004~ 0.020) (0.039) ) (0.059)

(2.205

)

0.5~0.9 (0.020~ 0.035)

+0.039 0

Reconditioned with shim

153 (6.02) 6 1 157 (6.18)

234.5 (9.23)

153 (6.02) 8 2 157 (6.18)

(Note) • Clearance X shall be reconditioned using shims, if clearance exceeds the standard value for repair. • The dimensions noted by the mark of 1 is to be applicable to the machine number on and after PX09-08350. • The dimensions noted by the mark of 2 is to be applicable to the machine number on and after PX09-08379. • The dimensions in [ ] are applicable for the following Machine Nos. SK30SR-2 : PW08-20001~, PW10-22001~22182 SK35SR-2 : PX09-08001~, PX11-08901-09023

* *

03-1-11

3. BUCKET 3.1 BUCKET DIMENSIONAL DRAWINGS

Fig. 3-1 Bucket dimensional drawings

Unit : mm (ft•in)

Table 3-1 Model No. Name A B C D E F G H I Io d1 d2

SK30SR-2 Heaped Capacity m3 (cu.yd)

Distance between pin and bracket Distance between bucket pin and tooth end Inner width of bucket top end Inner width of lug Inner width of bracket Outer width of side cutter Outer width of bucket bottom plate Outer tooth distance Pitch between teeth Pitch between teeth Pin dia. Pin dia.

Note : Japanese standard bucket.

03-1-12

0.09 (0.118) 192 (7.56”) R690 (2’3.17”) 428 (1’4.85”) 193 (7.60”) 141 (5.55”) 500 (1’7.69”) 388 (1’3.28”) 367 (1’2.45”) 122 (4.80”) 123 (4.84”) ø40 (1.57”) ø40 (1.57”)

SK35SR-2 0.11 (0.144)

528 (1’8.79”)

600 (1’11.62”) 488 (1’7.21”) 467 (1’6.39”) 155.5 (6.12”) 156 (6.14”)

3.2 DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION

Fig. 3-2 Dimension of lug section Unit : mm (in)

Table 3-2

øE

øF

ø40 +0.15 0

ø50

ø8

ø95

SK35SR-2 (1.578

+0.0059 0

) (0.551) (1.77)

(1.97) (0.315) (3.74)

Note : Japanese standard bucket.

03-1-13

Capscrew P.C.D.

øD

Boss thickness

Plate outer dia.

Boss outer dia.

Spring pin dia.

Plate thickness

Bore dia.

øA

Screw size

Bushing length

SK30SR-2

Lug plate thickness

Model

Pin bore dia.

Portion

øJ

øN

ø85

ø75

(0.35)

(3.35)

M10

(1.02) (2.95)

3.3 DETAIL DIMENSIONAL DRAWINGS OF BOSS SECTION

Fig. 3-3 Dimension of boss section

Unit : mm (in)

Table 3-3 Portion

øA

øB

øC

øD

øG

SK30SR-2

SK35SR-2

(2.56)

(1.69)

(2.36)

(2.48)

(0.472)

(0.945)

(0.433)

Model

03-1-14

4. DOZER 4.1 DOZER DIMENSIONAL DRAWINGS

WITH CUTTING EDGE (OPT)

STANDARD

Fig. 4-1 Dozer dimensional drawings Table 4-1 No. A A1 A2 B C D E F G d1 d2

SK30SR-2 With cutting edge Blade width (OPT) – Blade width with (left•right) 400 (1’3.75”) – Blade width with cutting edge (center) 746 (2’5.37”) 320 (1’0.60”) Blade height Distance from dozer attaching pin center to cutting edge end R1017 (3’4.04”) R1027 (3’4.43”) 500 (1’7.69”) Inner width of dozer attaching bracket 60 (2.36”) Width of dozer attaching bracket R692 (2’3.24”) Distance from dozer attaching pin center to attaching pin on dozer cylinder head side 52 (2.05”) Attaching bracket inner width on dozer cylinder head side ø40 (1.57”) Dozer attaching pin dia. ø45 (1.77”) Attaching pin dia. on dozer cylinder head side NAME

Standard 1550 (5’1.02”)

03- 1-15

Unit : mm (ft•in) SK35SR-2 With cutting edge Standard (OPT) 1700 (5’6.93”) – 400 (1’3.75”) – 895 (2’11.24”) 320 (1’0.60”) R1142 (3’8.96”) R1152–(3’9.35”) 500 (1’7.69”) 60 (2.36”) R723 (2’4.46”) 52 (2.05”) ø40 (1.57”) ø45 (1.77”)

4.2 DOZER MAINTENANCE STANDARDS

1~1.5 (0.04”~0.06”)

PIN A PORTION

(0.04”~0.06”)

1~1.5

0.5~1 (0.02”~0.04”)

PIN C PORTION

Fig. 4-2 Dozer maintenance standards

(1) Clearance of pin and bushing SK30SR-2 SK35SR-2 Pos.

A B

Item

Table 4-2 Pin part No.

Dozer blade cylinder (Rod side) PW51B01029P1 Dozer blade cylinder (Head side)

Standard dimension Clearance Tolerance Tolerance Standard Standard Serviceab- Remedy on bushing value Pin dia. on pin dia. bore dia. value for repair ility limit ø45 (1.7717)

-0.06 -0.09

( ) -0.0024

Dozer blade foot

PW51B01028P1

Unit : mm (in)

ø40 (1.5748)

-0.0035

+0.25 0.11~ 0.34 +0.05 (0.0043~ +0.0098 +0.0020 0.0134)

(

)

+0.22 0.18~ 0.31 +0.12 +0.0087 (0.0071~ +0.0047 0.0122)

(

0.7

1.0

(0.028) (0.039)

Replace bushing or pin

)

03-1-16

(2) Clearance in thrust direction on the dozer and cylinder installation section SK30SR-2 SK35SR-2

Table 4-3

Unit : mm (in)

Standard dimensions Pos.

Item No.

Dimensions

Pin length

Clearance X reconditioned No. Dimensions with shim (total of both sides)

0 0 Rod side 50 -0.4 (1.969 -0.020 ) L1 +1.0 +0.039 Lower frame 52 0 (2.047 0 ) 0 0 Head side 50 -0.5 (1.969 -0.020 ) L2 +0.039 +1.0 Dozer brade 52 0 (2.047 0 ) Dozer brade 60±1.0 (2.362 ±0.039) L3 C Dozer blade foot +1.0 +0.039 Lower frame 63 0 (2.480 0 )

Dozer blade cylinder (Rod side) Dozer blade cylinder B (Head side) A

2.0~3.5 (0.079~0.035) 2.7~4.3 (0.106~0.169)

Remedy

122 (4.80)

122 2 (4.80)

Recondi-

127 3 (5.0)

with shim

tioned

(Note)• Clearance X shall be reconditioned using shims, if clearance exceeds the standard value for repair.

03-1-17

5. SWING 5.1 SWING BRACKET DIMENSIONAL DRAWINGS

Fig.5-1 Swing bracket dimensional drawings Table 5-1 No.

NAME

A B C D E F F1 F2 G H J d1 d2 d3 d4

Distance between swing center pin and boom foot pin Distance between boom foot pin and boom cylinder pin - ditto Distance between swing center pin and swing cylinder pin - ditto Inside width of swing center - ditto - ditto Inside width of boom foot Inside width for installing boom cylinder Inside width for installing swing cylinder Pin dia. of swing center Pin dia. of boom foot Pin dia. of boom cylinder Pin dia. of swing cylinder

03-1-18

Unit : mm (in) DIMENSION SK30SR-2 SK35SR-2 96 (3.78) 168.8 (6.65) 176.4 (6.94) 243.1 (9.57) 252.4 (9.94) R260 (10.24) 253.3 (9.97) 276 (10.87) 78 (3.07) 73.5 (2.89) 178 (7.01) 61 (2.40) 67 (2.64) ø65 (2.56) ø45 (1.77”) ø45 (1.77”) ø45 (1.77”)

5.2 SWING PORTION MAINTENANCE STANDARDS (1) Clearance of pin and bushing

X VIEW X Fig.5-2 Clearance of pin and bushing on swing portion

SK30SR-2 Table 5-2

SK35SR-2 Pos.

A B C D

Item Swing cylinder (Rod side) Swing cylinder (Head side) Swing center (Upper side) Swing center (Lower side)

Pin part No.

PW02B01229P1 PW02B01252P1 PW02B01230P2 PW02B01231P1

Unit : mm (in)

Standard dimension Clearance Tolerance Tolerance Standard Standard Serviceab- Remedy Pin dia. on bushing value on pin dia. bore dia. value for repair ility limit 0.02~ +0.15 0.20 0 ø45 -0.02 +0.0059 (+0.0008~ Replace 0.0079) 0 -0.05 1.0 0.7 bushing 0.04~ (0.028) (0.039) -0.0008 +0.07 or pin 0.12 -0.0020 +0.02 ø65 +0.0028 (+0.0016~ +0.0008 0.0047)

( )

03-1-19

(2) Crearance in thrust direction on swing bracket and cylinder installation section.

SECTION AA

SECTION BB WASHER To be instal the groove to the lower side. [t=2.3 (0.091”)] WASHER [t=2.3 (0.091”)]

SECTION C, D Fig.5-3 Clearance in thrust direction on swing portion SK30SR-2 Table 5-3

SK35SR-2

Unit : mm (in)

Clearance X reconditioned Pin length with shim (total of both sides) Remedy Standard Standard Serviceabvalue Dimensions No. Dimensions value for repair ility limit 0 0 1.5 65 -0.5 (2.559 -0.020 ) 0.5~0.9 138 (0.020~ 1 +2 +0.079 Recondi(5.43) (0.059) 67 0 (2.638 0 ) 0.035) 0 0 tioned 1.0 139 65 -0.5 (2.559 -0.020 ) 0.1~0.5 2 (5.47) +1 +0.039 (0.004~ 67 0 (2.638 0 ) 0.020) (0.039) with shim Replace 152 71±0.5 (2.795±0.020) 3 (5.98) washer 78±1(3.071±0.039)

Standard dimension Pos.

Item No.

Swing cylinder (Rod side) Swing cylinder B (Head side) Swing center C (Upper side) Swing center D (Lower side) A

Cylinder Bracket Cylinder Upper frame Upper frame Bracket Upper frame Bracket

L1 L2 L3 L4

71.5±0.5(2.815±0.020) 73.5±1 (2.894±0.039)

03-1-20

145 4 (5.71)

Reconditioned with shim

Book Code No.

PW11 02E ➀

NEW HOLLAND EH35 Model Cross-reference: SK35SR-2 is NEW HOLLAND Model EH35

PW11

TOOLS TABLE OF CONTENTS 1. TORQUE SPECIFICATIONS FOR CAPSCREWS AND NUTS . . . . . . . . 1-1 2. SCREW SIZES TO TOOL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 3. TORQUE SPECIFICATIONS FOR JOINTS AND HOSES . . . . . . . . . . . . 1-2 4. TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS . . . 1-3 5. PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 7. APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS . 1-6 8. COUNTERWEIGHT LIFTING JIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

11 -0-1 ➀

Revision First edition --------Second revision

Date of Issue January, 2001 December, 2002

Remarks S5PW1102E A S5PW1102E ➀ A

Any use of editorial or pictorial content is strictly prohibited without express written permission from New Holland Construction, LLC. Carol Stream, IL 60188 U.S.A. Copyright © 2003 New Holland Construction, LLC. All Rights Reserved.

11-0-2 ➀

1. TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS The following Torque Specifications are provided for use when actual torque value of a fastener is not known. 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 as the 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. • In case that the tightening torque is specified in the manual, use such torque values regardless to the table below.

11-1-1

• 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, M 5 or less.

2. SCREW SIZES TO TOOL SIZES 1) Capscrew

2) Socket bolt

Table 2-1

Table 2-2

Nominal B mm screw size (d) Tool size M6 10 M8 13 M10 17 M12 19 M16 24 M20 30 M24 36 M30 46 M36 55

Nominal B mm screw size Tool size ((d)) 5 M6 6 M8 8 M10 10 M12 12 M14 14 M16 14 ((M18)) 17 M20 19 M24 22 M30 27 M36

3. TORQUE SPECIFICATIONS A FOR JOINTS AND HOSES A. JOINTS FOR PIPING (O-RING SEALING TYPE) Nominal screw size (PF) Spanner size (mm)

Tightening torque kg•m(lbf•ft)

1/8

1.7 + -- 0.2 (12 + -- 1)

1/4

3.7 + --

3/8

1/2

11.0 --

3/4

16.5 + -- 1.0 (119 + -- 7)

26.0 + -- 1.0 (188 + -- 7)

-- 7)

º Nominal screw size (PF) Spanner size (mm)

Tightening torque kg• (lbf•ft)

1/8

1.5 + -- 0.2 (11 + -- 1)

1/4

3.0 + -- 0.5 (22 + -- 4)

3/8

5.0 + --

+ --

1/2

8.0 + --

+ --

3/4

12.0 + --

14.0 + -- 1.5 (101 + -- 11)

+ -- 7)

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

11-1-2

4. TORQUE SPECIFICATIONS A FOR SLEEVE TYPE TUBE FITTINGS A. SLEEVE TYPE TUBE FITTINGS Tube size OD X Thickness(mm)

Spanner size (mm)

Tightening Torque kg•m(lbf•ft)

1.5

4.5 + -- 0.5 (33 + -- 4)

2.0

15 + --

2.5

22 28 35

+ -- 14)

X X

4.0

5.0

45 + --

+ -- 33)

B. PART NO. SLEEVE

Tube size ød 6 8 10 12 15 18 22 28 32 35 38

NUT

Part NO. Ihara Koatu Nippon A.M.C ZF93S06000 ZF93S08000 ZA93S10000 ZF93S10000 ZF93S12000 ZA93S15000 ZF93S15000 ZA93S18000 ZF93S18000 ZA93S22000 ZF93S22000 ZA93S28000 ZF93S28000 ZF93S32000 ZA93S35000 ZF93S35000 ZF93S38000

Tube size ød 6 8 10 12 15 18 22 28 32 35 38

11-1-3

Opposing flats(HEX) B

14 17 19 22 27 32 36 41 50 55 60

Part NO. Ihara Koatu Nippon A.M.C ZF93N06000 ZF93N08000 ZA93N10000 ZF93N10000 ZF93N12000 ZA93N15000 ZF93N15000 ZA93N18000 ZF93N18000 ZA93N22000 ZF93N22000 ZA93N28000 ZF93N28000 ZF93N32000 ZA93N35000 ZF93N35000 ZF93N38000

5. PLUGS (1) Plug for hydraulic pipe joint

Table 5-1

1) Cap nut (Joint plug)

Applicable tube O. D : A 6 8 10 12 15 18 22 28

screw

2) Plug (Tube plug)

Sleeve Type joint body

T screw

ZF83H06000 ZF83H08000 ZF83H10000 ZF83H12000 ZF83H15000 ZF83H18000 ZF83H22000 ZF83H28000

M12 X 1.5 M14 X 1.5 M16 X 1.5 M18 X 1.5 M22 X 1.5 M26 X 1.5 M30 X 1.5 M36 X 1.5

Opposing flat

H1 14 17 17 19 24 27 32 38

H 14 17 19 22 27 32 36 41

Table 5-2

Nut

Applicable tube O. D : A

Plug parts No.

6 8 10 12 15 18 22 28

ZF83P06000 ZF83P08000 ZF83P10000 ZF83P12000 ZF83P15000 ZF83P18000 ZF83P22000 ZF83P28000

3) Nut

D screw

Cap nut parts No.

Table 5-3 Applicable tube O. D : A 6 8 10 12 15 18 22 28 32 35 38

11-1-4

Nut parts No.

D screw

Opposing flat

ZF93N06000 ZF93N08000 ZF83H10000 ZF93N12000 ZF93N15000 ZF93N18000 ZF93N22000 ZF93N28000 ZF93N32000 ZF93N35000 ZF93N38000

M12 X 1.5 M14 X 1.5 M16 X 1.5 M18 X 1.5 M22 X 1.5 M26 X 1.5 M30 X 1.5 M36 X 1.5 M42 X 1.5 M45 X 1.5 M48 X 1.5

14 17 19 22 27 32 36 41 50 55 60

(2) Plug for hydraulic equipment 1) PF screw

O ring

Table 5-4 PF screw Plug parts No. B mm O ring parts No. Nominal O ring 19 PF1/4 ZE72X04000 ZD12P01100 1B P11 22 PF3/8 ZE72X06000 ZD12P01400 1B P14 27 PF1/2 ZE72X08000 ZD12P01800 1B P18 36 PF3/4 ZE72X12000 ZD12P02400 1B P24 41 PF1 ZE72X16000 ZD12P02900 1B P29

PF screw

2) PT screw

Table 5-5 PT screw Plug parts No. ZE82T02000 PT1/8 ZE82T04000 PT1/4 ZE82T06000 PT3/8 ZE82T08000 PT1/2 ZE82T12000 PT3/4 ZE82T16000 PT1 ZE82T20000 PT1 1/4 ZE82T24000 PT1 1/2

PT screw

(3) Plug for (F) flare hose PF screw

B mm 5 6 8 10 14 17 22 22

Table 5-6 PF screw Plug parts No. 2444Z2728D1 PF1/4 2444Z2728D2 PF3/8 2444Z2728D3 PF1/2 2444Z2728D4 PF3/4 Opposing 2444Z2728D5 PF1 flat B

B mm 14 17 22 27 36

Table 5-7

PF screw Opposing flat F

Opposing flat E

PF screw PF1/4 PF3/8 PF1/2 PF3/4 PF1 PF1 1/4

Plug parts No. 2444Z2729D1 2444Z2729D2 2444Z2729D3 2444Z2729D4 2444Z2729D5 2444Z2729D6

11-1-5

E mm 14 17 23 27 36 40

F mm 19 22 27 36 41 50

6. SPECIAL SPANNERS P FOR TUBES Table 6-1 Applicable tube diameter mm (in)

Part No.

HEX mm

Dimensions of a special spanner mm (in) 70 (2.76)

15 (0.591)

2421T160

16 (0.630)

22 (0.866)

012 004

40 (1.57)

)

70 (2.76)

18 (0.709)

2421T138

22 (0.866)

19 (0.748)

+0.012 12.7 +0.3 -0.1 (0.50 -0.004 )

70 (2.76)

22 (0.866)

2421T130

22 (0.866)

23 (0.906)

12.7 +0.3 -0.1

-0

)

109 (4.29)

28 (1.102)

2421T115

22 (0.866)

29 (1.142) 12.7 +0.3 -0.1

+0.012 -0

7. APPLICATION A OF SCREW LOCKING AND SEALING COMPOUNDS Table 7-1 Manufacturer Service

Screw locking compound

Sealing compound

Features Loctite

Three-Bond

#242

1360K

Low strength

#262

1374

Middle strength

#271

1305

High strength

#515

1215

Sealing

11-1-6

)

8. COUNTERWEIGHT LIFTING JIG

(For left)

(For right) Qâ&#x20AC;&#x2122;ty:1set Material:Steel

Fig. 8-1 Counterweight lifting jig

11-1-7

NOTES

11-1-8

Book Code No.

PW12 02E ➀

NEW HOLLAND EH35 Model Cross-reference: SK35SR-2 is NEW HOLLAND Model EH35

STANDARD MAINTENANCE TIME TABLE TABLE OF CONTENTS 1. STANDARD WORKING TIME TABLE FOR MAINTENANCE OF EXCAVATOR ................................ 1-1 01 Attachment ....................................................................................... 1-1 02 Canopy & Guard .............................................................................. 1-2 03 Upper structure ................................................................................ 1-3 04 Upper carriage ................................................................................. 1-6

12 -0-1 ➀

PW12

PREFACE (1) Working Conditions 1) Technicians : One or more technicians qualified by the manufacturer as a first class service technician

2) Facilities :

(with five years or more of field experience and having completed the training in the operation of vehicle type construction machinery) to be provided. General jigs, tools, apparatus, testers to be provided. The maintenance workshop to be equipped with a good enough capacity of building with crane and inspection instruments necessary for specific self inspection activities. The workshop to be located on a flat land at which the work is able to perform and to

3) Place :

which a service car or truck crane is accessible. (2) Applicable Range of Standard Maintenance Time 1) Standard maintenance time : Direct maintenance time plus spare time. 2) Direct maintenance time : Net time actually spent for maintenance. 3) Spare time : Time for transportation of the machine for maintenance, preparation for safety work, meeting for the work and physiological time for the needs of body. (3) Excluded Time (not included in the standard maintenance time) 1) Repairing time :Time for machining, sheet metal processing, welding, gas cutting, removing broken screw, taking care of parts and painting. 2) Items excluded from maintenance time because of uncertainty in time :Receiving the vehicle into shop, transportation, delivery, final inspection and investigation of causes for trouble, diagnosis and inspection. 3) Indirect time : Time for field work, preparation of required parts, etc., before starting work, going to and from the site, waiting due to user's convenience at the site and paper work for reports, bills, etc. 4) Special time :

Working time at early morning, at mid night and on holidays shall be separately calculated.

5) Separate calculation : The cost for service cars, trucks with crane and truck cranes shall be separately calculated. (4) 1)

Applicable Machine for Estimation of Standard Maintenance Time Standard machine.

A well maintained machine combined with standard attachments which has operated in a normal circumstances.

Revision First edition --------Second revision

Date of Issue January, 2001 December, 2002

Remarks S5PW1202E A S5PW1202E â&#x17E;&#x20AC; A

12-0-2 â&#x17E;&#x20AC;

1. STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR

(1) Standard maintenance time table 1) Units of working time : 6 minutes = 0.1 hour 2) Calculating method of standard maintenance time : Maintenance time = Working time X Number of workers (Working time = Maintenance time / Number of workers)

5) Abbreviations in the table. ASSY ; Assembly F hose ATT ; Attachment Inst. BRG ; Bearing O/H C/V ; Control valve SOL Cyl ; Cylinder SW E/G ; Engine V

; Flexible hose ; Installation ; Overhaul ; Solenoid ; Switch ; Valve

(2) Classification of work code

No. 01 02 03 04

3) When more than one work are done, a) Add each standard maintenance time b) A net time (readily starting) is given except covers easily removed by hand. c) Assy works include the following works marked with black dot •

GROUP REMARK Attachment To indicate removing, Canopy and Guard installing, replacement Upper Structure and overhaul. Under carriage

4) O / H : The removing and installing time are not included.

01 Attachment

GROUP No. 00 01 02 03 04 05 06 07 10 11 12 13 14 15 16 17 18 20 21 22 23 24 25 26

EQUIPMENT PORTION Bucket portion Bucket ASSY • Bucket removing/ installing position • Bucket installing pin • Bucket drive pin • Bucket sling and transfer Bucket (Single) • Bushing Arm portion Arm ASSY • Bucket cylinder removing/ installing position and piping • Bucket cylinder rod pin • Bucket cylinder head pin • Bucket cylinder assy • Arm cylinder rod pin • Boom top pin • Arm sling and transfer Boom portion Boom ASSY • Boom removing/ installing position • Boom cylinder temporary slinging • Boom cylinder rod pin • Boom cylinder piping • Arm & Bucket piping

WORK TO BE UNIT DONE

REMARK

Refer to 32-I item2 Removal/Inst. 1 pc. Include adjustment Preparation 1 pc. Removal/Inst. 1 pc. Include stopper pin. 1 pc. - ditto Preparation 1 pc. 1 pc. Not include removal / inst. O/H 1 pc. Replace Refer to 32-I item 3 Removal/Inst. 1 pc. Preparation 1 pc. 1 pc. Include stopper pin. 1 pc. Include stopper pin. 1 pc. 1 pc. Include stopper pin. 1 pc. 1 pc. Refer to 32-I item 4 Removal/Inst. 1 pc. Preparation 1 pc. — ditto — 1 pc. Removal/Inst. 1 pc. Include stopper pin. — ditto — 1 pc. — ditto — 1 pc.

Removal/Inst. — ditto — — ditto — — ditto — — ditto — — ditto —

12 -1-1

UNIT : HOUR 0.4 0.1 0.1 0.1 0.1 0.6 0.5 0.8 0.2 0.1 0.1 0.1 0.1 0.1 0.1 1.0 0.1 0.1 0.1 0.1 0.2

02 Canopy & Guard

01 Attachment

GROUP No.

EQUIPMENT PORTION

WORK TO BE UNIT DONE

27 28 29 30 31 32 33 40 41 42 43 50 51 60 61 70 71 80 81 82 83 84 85

• Boom assy temporary slinging • Boom foot pin • Boom assy slinging Arm cylinder removing / installing • Arm cylinder piping • Arm cylinder head pin • Arm cylinder slinging Boom cylinder removing / installing • Boom cylinder piping • Boom cylinder head pin • Boom cylinder slinging Bucket cylinder • Pin bushing Arm cylinder • Pin bushing Boom cylinder • Pin bushing Swing portion Swing bracket assy • Swing cylinder rod pin • Swing bracket slinging • Swing center pin Swing cylinder removing / installing

86 87 88 89 90 91 92 93 94 95 96 00

• Swing cylinder hose • Swing cylinder head pin Swing cylinder • Pin bushing Other necessary works Dozer portion Dozer ASSY • Dozer cylinder hose • Dozer cylinder rod pin • Dozer installing pin Dozer cylinder • Pin bushing Canopy portion

01 02 10

Canopy assy Hand rail Cab portion

Removal / Inst. 1 pc. — ditto — 1 pc.

11 12 20 21 22 23 24

Cab assy Harness Bonnet & Guard Cover assy (1) Pannel assy (2) Pannel assy (3) Bonnet assy (4)

Removal / Inst. 1 pc. — ditto — 1 pc.

Removal / Inst. — ditto — — ditto — — ditto — — ditto — — ditto — — ditto — — ditto — — ditto — — ditto — — ditto — O/H Replace O/H Replace O/H Replace

1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 set 1 pc. 1 set 1 pc. 1 set

REMARK Include stopper pin.

Include stopper pin.

Include seal. Include seal.

Include seal. Refer to 32-I item 5 Removal / Inst. 1 pc. After removing boom. — ditto — 1 pc. — ditto — 1 pc. — ditto — 1 pc. — ditto — 1 pc. After removing swing bracket. Removal / Inst. 2 pcs. — ditto — 1 pc. 1 pc. O/H 1 pc. Include seal. Replace Removal / Inst. 1 set Pannel assy (3) Refer to 32-I item 6 Removal / Inst. 1 pc. — ditto — 2 pcs. — ditto — 1 pc. — ditto — 2 pcs. 1 pc. O/H 1 set Include seal. Replace Refer to 33-I item 1

UNIT : HOUR 0.1 0.1 0.1 0.3 0.1 0.1 0.1 0.3 0.1 0.1 0.1 2.5 1.0 2.5 1.0 2.5 1.0 0.4 0.1 0.1 0.1 0.3 0.2 0.1 2.5 1.0 0.1 0.6 0.2 0.1 0.2 2.5 1.0

0.2 0.1 Refer to 33-I item 1 0.4 0.1 Refer to 33-I item 2

Removal / Inst. — ditto — — ditto — — ditto —

12 -1-2

1 pc. 1 pc. 1 pc. 1 pc.

0.1 0.1 0.1 0.1

02 Canopy & Guard

GROUP No. 25 26 27 --29 30 31 32 40 41 50 51 52 53 54

03 Upper structure

00 01 02 03 04 05 10 11 12 13 14 20 21 22 23 20 21 22 22 23

26 27 28 29

EQUIPMENT PORTION Bonnet assy (5) Cover assy (6) Cover assy (7) ----Cover (36) Bracket assy (9) Cover assy (17) Suport (10) Floor plate portion Floor plate assy Othen necessary works Counter weight portion Counter weight ASSY • Lifting tools • Slinging • Counter weight fixing bolt Othen necessary works Control portion E / G control cable Dozer yoke Dozer cable Swing yoke (EU) Swing cable (EU) Other necessary works Intake portion Air cleaner ASSY • Hose (1) • Hose (2) • Element Exhaust portion Muffler ASSY • Muffler attaching nuts (9) • Clamp Other necessary works E / G Accessory portion Dynamo • Connector • Dynamo fixing bolt • V-belt Other necessary works Starter • B-terminal • S-terminal connector • Starter fixing bolt Other necessary works

WORK TO BE DONE Removal / Inst. — ditto — — ditto — ----Removal / Inst. — ditto — — ditto — — ditto —

UNIT

REMARK

1 pc. 1 pc. 1 pc. ----1 pc. 1 pc. 1 pc. 1 pc.

Refer to 33-1 item3 Removal / Inst. 1 set — ditto — 1 pc. Canopy removal/inst Refer to 33-I item 6 Removal / Inst. 1 pc. Preparation 1set Removal / Inst. 1 pc. — ditto — 1 set — ditto — 3 pcs. Guards Removal / Inst. — ditto — — ditto — — ditto — — ditto — — ditto — Removal / Inst. - ditto - ditto Replace Removal / Inst. — ditto — — ditto — — ditto — Removal / Inst. - ditto - ditto - ditto - ditto - ditto - ditto - ditto - ditto - ditto - ditto - ditto -

12 -1-3

1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 set. Cover and Hose Refer to 33-I item 9 1 pc. 1 pc. 1 pc. 1 pc. Refer to 33-I item 12 1 pc. 3 pcs. 2 pcs. 1 pc. Under cover Refer to 33-I item 10 & 11 1 pc. 1 pc. 2 pcs. 1 pc. Include tension adjusting 1 set Covers 1 pc. Negative terminal of battery 1 pc. 1 pc. 1 pc. 2 pcs. 1 set Cover and Floor plate 1 pc. Negative terminal of battery

UNIT : HOUR 0.1 0.2 0.2 ----0.1 0.1 0.1 0.2 0.5 0.2 0.4 0.1 0.1 0.1 0.3 0.2 0.1 0.1 0.1 0.1 0.4 0.4 0.1 0.1 0.1 0.4 0.1 0.1 0.1 0.6 0.1 0.1 0.3 0.4 0.1 0.5 0.1 0.1 0.2 0.3 0.1

03 Upper structure

GROUP EQUIPMENT PORTION No. 30 Fuel portion 31 Fuel tank ASSY • Fuel 32 • Hose (Supply ; water separator side) 33 • Hose (Return ; filter side) 34 • Level sensor connector 35 36 • Fuel tank top / bottom fixing bolt Other necessary works 40 Hydraulic oil tank portion 41 Hydraulic oil tank ASSY 42 • Pressure releasing 42 • Return filter 43 • Hydraulic oil 44 • Suction hose 45 • Strainer 46 • Pilot return hose 47 • Swivel drain hose 48 • SOL. valve return hose 49 • Slewing, C / V return hose 50 • Tank fixing bolt Other necessary works

60 61

Pump portion Pump ASSY

62 63 64 65 66 67 68 69

• Pressure releasing • Hydraulic oil • Pilot delivery oil hose • Suction hose • Suction tube (pump side) • Main pump delivery hose • Pump fixing bolt Pump ASSY Other necessary works Radiator portion Radiator ASSY • Coolant (LLC) • Coolant density • Reserve tank hose • Radiator hose • Cooler hose • Radiator lifting bolt • Radiator lifing or slinging Other necessary works

70 71 72 73 74 75 76 77 78

WORK TO BE UNIT DONE

REMARK

UNIT : HOUR

Refer to 33-I items 7 Removal / Inst. Replace Removal / Inst. — ditto — — ditto — Removal / Inst. — ditto — Removal / Inst. Preparation Replace — ditto — Removal / Inst. Replace Removal / Inst. — ditto — — ditto — — ditto — — ditto — — ditto — — ditto — Preparation Removal / Inst. Preparation Replace Removal / Inst. — ditto — — ditto — — ditto — — ditto — O/H Removal / Inst. Removal / Inst. Replace Measuring Removal / Inst. — ditto — — ditto — — ditto — — ditto — — ditto — — ditto —

12 -1-4

1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. Guards Refer to 33-I item 8 1 pc. After removing fuel tank ; 1 pc. 1 pc. Include replacing O-ring 1 pc. 1 pc. 1 pc. Include replacing O-ring 1 pc. 1 pc. 1 pc. 2 pcs. 5 pcs. 1 pc. Under cover 1 pc. Fuel tank bracket 1 pc. Hyd. oil tank pressurizing Refer to 33-I item 13 1 pc. After removing cownter weight 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 3 pcs. 2 pcs. 1 pc. 1 pc. Hyd. oil tank pressurizing Refer to 33-I item 14 1 pc. 1 pc. 1 pc. 1 pc. 2 pcs. 2 pcs. 3 pcs. 1 pc. 1 pc. Counter weight 1 pc. Guard and Under cover

0.6 0.2 0.1 0.1 0.1 0.1 0.4 1.6 0.2 0.2 0.2 0.1 0.1 0.1 0.1 0.2 0.2 0.1 0.1 0.1 1.2

0.2 0.1 0.2 0.2 0.23 0.2 3.0 0.1 1.2 0.2 (0.2) 0.3 0.2 0.1 0.1 0.4 0.3

03 Upper structure

GROUP No.

EQUIPMENT PORTION

80 81 82

Engine (E / G) Installing portion Engine ASSY • Fuel hose

83 84 85

• Harness, connector and cable • Engine fixing nut • Engine slinging Other necessary works

90 91 92

Control valve portion Control valve ASSY • Piping connector, hose

93 94 95

• Control cable, Yoke • Fixing bolt Control valve ASSY Other necessary works

100 101 102

Slewing motor portion Slewing motor ASSY • Piping connector, hose

103 104 105 106

• Grease piping hose • Fixing bolt • Greasing Slewing motor ASSY Other necessary works

110 111

Swivel joint portion Swivel joint ASSY • Under cover

112

• Piping connector, hose

113 114 115

• Stopper • Fixing bolt Swivel joint ASSY Other necessary works

WORK TO BE UNIT DONE

REMARK

UNIT : HOUR

Refer to 33-I item 15 Removal / Inst. 1 pc. — ditto — 4 pcs. For injection pump - 2 For feed pump - 2 Removal / Inst. 1 set — ditto — 1 set — ditto — 1 set Removal / Inst. 1 pc. Canopy — ditto — 1 set Guard — ditto — 1 pc. Counter weight — ditto — 1 pc. Air cleaner — ditto — 1 pc. Muffler — ditto — 1 pc. Pump — ditto — 1 pc. Radiator Refer to 33-I item 16 Removal / Inst. 1 pc. — ditto — 1 set Include attaching hose’s tag and plug — ditto — 1 set — ditto — 1 set 1 pc. O/H Removal / Inst. 1 pc. Canopy — ditto — 1 set Floor plate — ditto — 1 set Cover Refer to 33-I item 19 Removal / Inst. 1 pc. — ditto — 5 pcs. Include attaching hose’s tag and plug — ditto — 1 pc. — ditto — 1 pc. 1 pc. Greasing 1 pc. O/H Removal / Inst. 1 set Canopy — ditto — 1 set Floor plate Refer to 33-I item 20 Removal / Inst. 1 pc. After removing slewing motor — ditto — 1 pc. — ditto — — ditto — — ditto — O/H Preparation

12 -1-5

1 set Include attaching hose’s tag and plug 1 pc. 1 set 1 pc. 1 pc. Removal / Inst. position. Secure working space. 1 pc. Canopy removal/inst. (for easy working) 1 set. Floor plate cover (2) removal/inst.

1.0 0.2 0.3 0.2 0.2 0.2 1.5 0.4 0.2 0.4 1.2 1.0 1.6 0.1 0.4 0.1 3.0 0.2 0.5 0.2 1.3 0.4 0.1 0.1 0.1 3.0 0.2 0.5 2.5 0.1

1.5 0.1 0.2 2.0 0.5 0.2 0.1

GROUP EQUIPMENT PORTION No. 120 Upper frame 121 Upper frame ASSY 122 • Fixing bolt 123 • Upper frame slinging 124 • Cleaning Other necessary works

WORK TO BE UNIT DONE

UNIT : HOUR

Refer to 33-I item 21

03 Upper structure 04 Under carriage

REMARK

00 01 02 03 04 10 11 12 20 21 22 30 31 32 33 34 40 41 50 51 52 53

Travel portion Rubber crawler • Rubber shoe removing / inst. position. • Tension adjusting • Crawler shoe Upper roller portion Upper roller ASSY Upper roller Lower roller portion Lower roller ASSY Lower roller Front idler & Idler adjuster portion Idler & Idler adjuster ASSY Idler & Idler adjuster ASSY Idler ASSY Idler adjuster ASSY Sprocket portion Sprocket Travel motor portion Travel motor ASSY • Motor cover • Hydraulic connector, hose

54 55 56 57 60 61 62 63 64

• Motor fixing bolt • Motor slinging Travel motor Travel reduction unit Slewing bearing Slewing bearing ASSY • Slewing bearing fixing bolt • Slewing bearing • Slewing bearing slinging

Removal / Inst. — ditto — — ditto — Cleaning Removal / Inst. — ditto — — ditto — Drain / Feed Removal / Inst. — ditto —

1 pc. 1 set 1 pc. 1 pc. 1 set 1 set 1 pc. 1 pc. 1 set 1 set

Removal / Inst. Preparation Adjusting Removal / Inst.

One side One side One side One side

Removal / Inst. O/H Removal / Inst. O/H Removal / Inst. Disassembly O/H - ditto Replace Removal / Inst. - ditto - ditto - ditto - ditto O/H - ditto Removal / Inst. - ditto Cleaning Removal / Inst.

12 -1-6

Apply sealant

Canopy Guard (Cover, support) Counter weight Hydraulic oil Swivel joint hose Boom, Swing bracket Refer to 34-I item 2

Refer to 34-I item 3 1 pc. After removing crawler shoe 1 pc. Refer to 34-I item 4 1 pc. 1 pc. Refer to 34-I item 5 & 6 One side After removing crawler shoe One side One side One side Refer to 34-I item 7 One side After removing crawler shoe Refer to 34-I item 8 One side After removing crawler shoe One side One side Include attaching hose’s tag and plug One side One side One side One side Refer to 34-I item 9 1 pc. After removing upper flame 1 pc. 1 pc. Degreasing / Replenishment 1 pc.

1.0 0.3 0.3 0.2 0.2 1.5 0.4 0.2 0.5 1.5 0.6 0.1 0.2 0.2 0.2 1.0 0.2 1.0 0.5 0.1 1.0 0.5 0.5 1.0 0.1 0.6 0.3 0.1 3.0 3.0 0.6 0.3 0.1 0.2

Book Code No.

PW13 02E ➁

NEW HOLLAND EH35 Model Cross-reference: SK35SR-2 is NEW HOLLAND Model EH35

MAINTENANCE STANDARDS AND TEST PROCEDURES TABLE OF CONTENTS 1. STANDARD WORKING TIME TABLE FOR MAINTENANCE OF EXCAVATOR ................................ 1-1 01 Attachment ....................................................................................... 1-1 02 Canopy & Guard .............................................................................. 1-2 03 Upper structure ................................................................................ 1-3 04 Upper carriage ................................................................................. 1-6

13 -0-1 ➁

PW13

Revision First edition First revision Second revision

Date of Issue January, 2001 November, 2001

Remarks S5PW1302E A S5PW1302E ➀ A

December, 2002

S5PW1302E ➁ A

Any use of editorial or pictorial content is strictly prohibited without express written permission from New Holland Construction, LLC. Carol Stream, IL 60188 U.S.A. Copyright © 2003 New Holland Construction, LLC. All Rights Reserved.

13-0-2 ➁

1. HOW TO USE MAINTENANCE STANDARDS AND PRECUATIONS (1)Application 1) For Newa 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, Orings, 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. 3) Inspection & 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 & MAINTENANCE MANUAL as well.

13-1-1

2. PERFORMANCE INSPECTION STANDARD TABLE 2.1 STANDARD VALUE TABLE [EU • OCEANIA] Table 1 (1/2) [EU • OCEANIA] Model

SK30SR-2

SK35SR-2

Applicable machines

PW08-20001~

PX09-08001~

Main relief valve Engine speed pressure

Measuring condition

Div.

Unit

Hyd. oil cleanliness

Class

8±1

Hyd. oil temperature (Tank surface) Coolant temperature (Radiator surface)

ºC (ºF)

50~60

(122~140)

60~90

(140~194)

1150 ± 50

230 0 (3270

+70 0

)

+70 (3270 0

)

+70 0

)

+70 -40

)

Low idle

Port (Over load) relief valve pressure

rpm

High idle Deceleration (OPT)

+70 0

230 0 (3270

Boom • Bucket • Travel (LH) P1

Dozer • 1 Slew • Service P3 Pilot Line

Head Rod Head Rod

Boom Arm

(psi)

+70 0

)

+70 0

)

200 0 (2840

+70 -40

)

35 -3 ( 500

Bucket

Head

Dozer

Head

(psi)

LH RH

* 1 Slew

10m (32.8 ft)

280 (3980)

260 (3700)

+31 +440 0 (2130 0 )

160

+44 +630 0 (2280 0 ) +1.7 -1.5

30.8 ± 1.5

32.6

17.8 ± 0.9

18.8 ± 0.9

Low

31.5 ± 1.5

33.3

crawler High

18.2 ± 0.9

19.2 ± 0.9

Rubber Low

14.3 ± 1.1

14.3 ± 0.7

8.3 ± 0.4

14.9 ± 1.2

14.8 ± 0.7

8.7 ± 0.4

8.6 ± 0.4

Travel Speed crawler High

Travel Speed

280 (3980)

150

Rubber Low

(5 rev.)

180 0 (2560 35 -3 ( 500

kgf/cm2

)

+5 230 0

Arm • Swing • Travel (RH) P2 kgf/cm2 230 0 (3270

Pilot relief valve pressure

Travel

Standard value Standard value Standard value Standard value for repair for repair

Item

Steel

crawler High Steel

Low

sec.

crawler High

Travel deviation Drift due to gravity w / P.B.

mm (in)

140

0 0 -140 (5.5 -5.5

)

280 (11.0) -

140

*1 : The pressure for slew is controlled by the relief valve attached to the slew motor. 13-1-2

+1.7 -1.5

0 0 -140 (5.5 -5.5

)

280 (11.0) -

Table 1 (2/2) [EU • OCEANIA]

Slew

Div.

Model

SK30SR-2

SK35SR-2

Applicable machines

PW08-20001~

PX09-08001~

Item

Unit

Slew time per 2-revolution

sec.

Overrun when slewing stops

mm (in)

Cylinder speed Cylinders

+0.4 -1.4 )

+0.12 +3 -2 (0.08 --0.18)

14.3

+1.0 -0.6

+0.4

+10

130 (5.1)

95 -35 (3.7 -1.4 )

7 (0.28)

+0.12 +3 -2 (0.08 --0.18 )

130 (5.1) 7 (0.28)

EU Boom [OCEANIA] Ret.

3.6 [3.5] 3.3 [3.5]

2.8 ± 0.4 [2.5 ± 0.4] 2.6 ± 0.4 [2.5 ± 0.4]

3.6 [3.2] 3.3 [3.2]

Ext.

2.8 ± 0.4

3.6

2.8 ± 0.4

3.6

Ret.

2.6 ± 0.4

3.3

2.6 ± 0.4

3.3

Ext.

3.0 ± 0.4

3.8

3.3 ± 0.3

4.2

3.2 ± 0.5

4.1

3.4 ± 0.5

4.4

Ext.

3.3 ± 0.5

4.2

2.9 ± 0.4

3.7

Ret.

2.4 ± 0.4

3.1

2.1 ± 0.3

2.7

Ext.

6.6 ± 1.0

8.4

6.2 ± 0.9

7.9

Ret.

5.5 ± 0.8

7.0

4.9 ± 0.7

6.3

Ext.

2.8 ± 0.8

3.6

2.4 ± 0.4

3.1

Ret.

2.2

2.8

2.0 ± 0.3

2.6

24 (0.94)

12 -12 (0.47-0.47 )

Arm Ret. Bucket

Swing

Dozer

Cylinder Gravity move

2.8 ± 0.4 [2.7 ± 0.4] 2.6 ± 0.4 [2.7 ± 0.4]

Cab

sec.

6 (0.24)

0 -3

(0.12-0.12 )

6 (0.24)

0 -3

(0.12-0.12 )

300 (12)

0 150-150

0 (0.24-0.24 )

12 (0.47)

0 0 60-40 (2.4 -1.6 )

0 -5

(0.20-0.20 )

Bucket

0 -3

(0.12-0.12 )

0 -3

(0.12-0.12 )

Dozer

mm (in) Slew bearing play Rubber Crawler tension Steel

0 0

mm (in)

0 (0.20-0.20 ) 0

10 (0.39) 6 (0.24) 6 (0.24) 300 (12)

0 (0.24-0.24 )

12 (0.47)

120 (4.7)

0 0 60-40 (2.4 -1.6 )

120 (4.7)

1.4 ± 0.4 (0.06 ± 0.0.2)

2.6 (0.10)

1.4 ± 0.4 (0.06 ± 0.0.2)

2.6 (0.10)

60~70 (2.36~2.76)

118~128 (4.65~5.04)

0 -6

(5.9

0 -5.9

24 (0.94)

)

Swing

Bucket tip play

150-150 (5.9 -5.9 )

Bucket tip

10 (0.39)

5 mm (in)

0 -5

Arm (10min)

• The Values in [

+0.4 - 0.6

12 -12 (0.47-0.47 )

Boom

(5min) Slew bearing

+0.9 -0.6

95 -35 (3.7 2

Ext.

Canopy

Crawler

13.6 +10

Drift due to gravity

(Note)

Standard value Standard value Standard value Standard value for repair for repair

] are applicable for the machines with canopy specification which are delivered for

Oceanian district.

13-1-3

2.2 STANDARD VALUE TABLE [USA] Table 2 (1/2) [USA] Model

SK30SR-2

SK35SR-2

Applicable machines

PW08-20001~

PX09-08001~

Main relief valve Engine speed pressure

Measuring condition

Div.

Unit

Hyd. oil cleanliness

Class

8±1

Hyd. oil temperature (Tank surface) Coolant temperature (Radiator surface)

ºC (ºF)

50~60

(122~140)

60~90

(140~194)

1150 ± 50

230 0 (3270

+70 0

)

+70 (3270 0

)

+70 0

)

+70 -40

)

Low idle

Port (Over load) relief valve pressure

rpm

High idle Deceleration (OPT)

+70 0

230 0 (3270

Boom • Bucket • Travel (LH) P1

Dozer • 1 Slew • Service P3 Pilot Line

Head Rod Head Rod

Boom Arm

(psi)

+70 0

)

+70 0

)

200 0 (2840

+70 -40

)

35 -3 ( 500

180 0 (2560 35 -3 ( 500

kgf/cm2

)

+5 230 0

Arm • Swing • Travel (RH) P2 kgf/cm2 230 0 (3270

Pilot relief valve pressure

280 (3980)

260 (3700)

Bucket

Head

Dozer

Head

260 (3700)

LH RH

+31 +440 150 0 (2130 0 )

+630 160 +44 0 (2280 0 )

30.8 ± 1.5

36.2

17.8 ± 0.9

20.8 ± 0.9

* 1 Slew

(psi)

Rubber Low Travel Speed crawler High (5 rev.)

Travel

Standard value Standard value Standard value Standard value for repair for repair

Item

Travel Speed 10m (32.8 ft)

sec.

+1.8 - 1.4

46 27

+1.8 - 1.4

Low

31.5 ± 1.5

37.0

crawler High

18.2 ± 0.9

21.3 ± 0.9

Rubber Low

14.3 ± 1.1

15.8 ± 0.8

8.3 ± 0.4

9.1 ± 0.5

14.9 ± 1.2

16.3 ± 0.8

8.7 ± 0.3

9.4 ± 0.5

Steel

crawler High Steel

Low

sec.

crawler High

Travel deviation Drift due to gravity w / P.B.

mm (in)

140

0 0 -140 (5.5 -5.5

)

280 (11.0) -

140

0 0 -140 (5.5 -5.5

* 1 : The pressure for slew is controlled by the relief valve attached to the slew motor. 13-1-4

)

280 (11.0) -

Table 2 (2/2) [USA] Model

SK30SR-2

SK35SR-2

Applicable machines

PW08-20001~

PX09-08001~

Slew

Div.

Item

Unit

Slew time per 2-revolution

sec.

Overrun when slewing stops

Boom

Cylinders

Cylinder speed

Cab

Arm

Swing

Cylinder Gravity move

Dozer

mm (in)

Slew bearing Crawler

+0.4 -1.4 )

+3 +0.12 -2 (0.08 --0.18)

130 (5.1) 7 (0.28)

14.3

+1.0 -0.6

+0.4

+10

95 -35 (3.7 -1.4 ) 2

+0.12 +3 -2 (0.08 --0.18 )

130 (5.1) 7 (0.28)

2.8 ± 0.4

3.6

2.8 ± 0.4

3.6

Ret.

2.6 ± 0.4

3.3

2.6 ± 0.4

3.3

Ext.

2.8 ± 0.4

3.6

2.8 ± 0.4

3.6

Ret.

2.6 ± 0.4

3.3

2.6 ± 0.4

3.3

Ext.

3.0 ± 0.4

3.8

3.3 ± 0.3

4.2

3.2 ± 0.5

4.1

3.4 ± 0.5

4.4

Ext.

3.3 ± 0.5

4.2

2.9 ± 0.4

3.7

Ret.

2.4 ± 0.4

3.1

2.1 ± 0.3

2.7

Ext.

6.6 ± 1.0

8.4

6.2 ± 0.9

7.9

Ret.

5.5 ± 0.8

7.0

4.9 ± 0.7

6.3

Ext.

2.8 ± 0.8

3.6

2.4 ± 0.4

3.1

Ret.

2.2

2.8

2.0 ± 0.3

2.6

24 (0.94)

12 -12 (0.47-0.47 )

10 (0.39)

0 -5

(0.20-0.20 )

sec.

+0.4 -0.6

12 -12 (0.47-0.47 )

0 0

24 (0.94)

Arm

0 -5

(0.20-0.20 )

Bucket

0 -3

(0.12-0.12 )

6 (0.24)

0 -3

(0.12-0.12 )

6 (0.24)

0 -3

0 (0.12-0.12 )

6 (0.24)

0 -3

0 (0.12-0.12 )

6 (0.24)

0 0 150-150 (5.9 -5.9 )

300 (12)

0 0 150-150 (5.9 -5.9 )

300 (12)

mm (in)

Dozer Bucket tip (5min)

Ext.

Boom (10min)

+0.9 -0.6

95 -35 (3.7 2

Ret.

Bucket

13.6 +10

Drift due to gravity Canopy

Standard value Standard value Standard value Standard value for repair for repair

Swing

Bucket tip play mm (in) Slew bearing play Rubber Crawler tension Steel

mm (in)

0 -6

0 (0.24-0.24 )

12 (0.47)

0 -6

0 60-40

0 (0.24-0.24 ) 0 -1.6

10 (0.39)

12 (0.47)

0 0 60-40 (2.4 -1.6 )

120 (4.7)

1.4 ± 0.4 (0.06 ± 0.0.2)

2.6 (0.10)

60~70 (2.36~2.76)

118~128 (4.65~5.04)

13-1-5

(2.4

)

120 (4.7)

1.4 ± 0.4 (0.06 ± 0.0.2) 2.6 (0.10)

3. MEASURING ENGINE SPEED 3.1 ENGINE SPEED MEASUREMENT (1) Measuring Instruments 1) Diesel Speedmeter (Measuring engine speed by means of applying a pick-up to one of injection pipes) 2) Surface Thermometer (Measuring the surface temperature getting contact of the probe with the surface of hydraulic oil tank and radiator)

PICK UP SPEED METER

(2) Engine Warming up Operation Start up the engine, and make the coolant temperature within the range of 60 to 90 °C (140 to 194 °F). Check the coolant temperature with the coolant thermometer on the monitor panel. The white color zone shows approx. 67 to 105 RED °C (153 to 221 °F) of temperature range. WHITE Therefore, when the indicator is located at around center of the white zone, it is suitable for the engine operation. BLUE

Fig. 3-1 Engine Speed measurement (The above figue shows concept) 130 (5.12”) 113 (4.45”) Applicable Nos.

(3) Engine Speed Measurement 1) Apply the pick up of speedmeter to one of convenient injection pipes. (Refer to Fig. 3-1)

SK30SR-2 : PW10-22001~ SK35SR-2 : PX11-08901~

(2.76”)

DETAIL "X"

2) Measure the engine speed at idling with no load, and compare it to the figure in the STANDARD VALUE TABLE. (4) Speed Adjustment 1) Low / High Idling Speeds 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 due to improper length of the wire, adjust it with the capscrew (8).

DECELERATION MOTOR (OPT)

• However, if the proper high idling speed is not obtainable, consult it with the engine manufacturer. 133 (5.24”)

133 (5.24”)

24.5½ 2.5½ FULL

24.5½ 2.5½

LOW T= 8.1 kgf•m (58.6 lbf•ft)

DETAIL "Y" [W/DECEL. (OPT)]

VIEW A DETAIL "Y" (STD)

13-1-6

Fig. 3-2 Accelerator wire adjustment

4. MEASURING HYDRAULIC OIL PRESSURE 4.1 STANDARD FOR HYDRAULIC OIL PRESSURE MEASUREMENT (1) Hydraulic Instruments 70 kgf/cm2 (1000 psi) pressure gauge .......1 set 500 kgf/cm2 (7110 psi) pressure gauge .....3 sets Surface Thermometer ................................1 set Pressure Measuring Kit and FRONT OF Oil Analyzing Equipment ......................1 set MACHINE

(2) Measuring cleanliness of hydraulic oil • After releasing air in the hydraulic oil tank, open the cover and sample oil in the hydraulic tank, and measure with the instrument for analysis. If the measured value is over the standard value, replace the return filter and/or change the hydraulic oil. 4.2 PRESSURE MEASUREMENT AND ADJUSTMENT 4.2.1 Main Circuit Pressure (1) Measuring Conditions Engine speed : High idling Hydraulic oil temperature: 50~60 °C (122~140 °F) Coolant temperature (on radiator surface): 60~90 °C (140~194 °F) (2) Pressure Measuring Procedures 1) After releasing pressure in the hydraulic oil tank, and setting a 500 kgf/cm2 (7110 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. 3) If the main relief pressure is lower than the standard range, tighten up the main relief valve by half turn [pressure increase by 80 ~ 90kgf/cm2 (1140 ~ 1280 psi)], then measure the pressure at overload relief valve. 4) After adjustment for the overload relief pressure, return back the main relief pressure within the standard range. Attaching position of overload relief valve

PLUG PLUG

VIEW X

VIEW Y

Remove the PF1/4 plug, and attach a 500 kgf/cm2 (7110 psi) pressure gauge.

Fig. 4-1 Main hydraulic oil pressure measurement (Typical figure)

Operating Circuit OR1 BUCKET DIGGING OR6 SLEW RIGHT OR3 BOOM RISING

OR7 ARM DIGGING

OR4 BOOM LOWERING OR8 ARM DISCHARGE OR5 SLEW LEFT

OR9 DOZER LOWERING

PLUG

Press. Detecting Port Relief Port Location Size Valve

Boom, Bucket & Travel (left)

MR1

Arm, Travel (right) & Swing

PF 1/4 MR2

Dozer, Service & Slew

MR3

13-1-7

(3) Pressure Adjustment (A) Control Valve : Main Relief Valve and Overload Relief Valve

1) Loosen the lock nut (2), and adjust the setting pressure turning the setscrew (1). Roughly with one full turn:

Main relief valve & Overload relief valve : Approx. 125 kgf/cm2 (1780 psi) CW turning ............ Increasing setting pressure CCW turning ......... Decreasing setting pressure

Fig. 4-2 Main relief valve / Overload relief valve

2) After the adjustment, tighten up the lock nut holding the setscrew not to turn around. 3) Again activate the relief valve to check the stable setting pressure. Tightening torque for nut (2): 2 kgf·m (14 lbf·ft) (B) Slewing Motor: Relief Valve 1) Loosen the lock nut (2). Then adjust the setting

OR6

pressure turning the setscrew (1).

Roughly with one full turn : Approx. 100 kgf/cm2 (1400

OR5

psi)

CW turning ............ Increasing setting pressure CCW turning .......... Decreasing setting pressure 2) After the adjustment, tighten up the lock nut hold-

Fig. 4-3 Relief valve (Slewing motor)

ing the setscrew not to turn around. Tightening torque for nut (2): 3.5 kgf·m (25 lbf·ft)

4.2.2 Pilot Circuit Pressure (1) Measuring Conditions PLUG

Engine : High idling Hydraulic oil temp. : 50 ~ 60 °C (122 ~ 140 °F) Coolant temp.

: 60 ~ 90 °C (140 ~ 194 °F) at radiator surface

(2) Measurement Releasing pressure in the hydraulic oil tank of hydraulic system, and setting a 70 kgf / cm2 pressure gauge to the pressure detecting port (G4, PF 1/4 with plug), measure the pilot relief pressure.

Pressure Detecting Port Port Location Size G4 PF1/4

Fig. 4-4 Pilot oil pressure measurement (Typical figure)

Relief Valve PR1

13-1-8

(3) Pressure Adjustment Adjust it with the relief valve attached to the solenoid valve. 1) Loosen the lock nut (2), then turn the setscrew (1) to adjust the set pressure. CW

screwing : Set pressure is increased.

CCW screwing : Set pressure is decreased. 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

Fig. 4-5 Relief valve

: Lock Nut (2) : 0.8 ± 0.1 kgf·m (6 ± 0.7 lbf·ft) : Relief valve (PR1) lbf·ft) : Solenoid Valve(3)

4.5 ± 0.5 kgf·m (33 ± 4

13-1-9

5. MEASURING TRAVEL PERFORMANCES • TEST PROCEDURES Measure 3-time each. Apply average data of the above for judgement. 5.1 Travel (1) Travel Speed (5 Revolutions) • Engine

: High Idle

• Hydraulic Oil Temp.

: 50 ~ 60 °C (122 ~ 140 °F)

Fig. 5-1

• Measurement Posture : 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 (10m) • Engine

: Rated r.p.m.

• Hydraulic Oil Temp.

: 50 ~ 60 °C

START

10m (32.8 ft)

PRELIMINARY RUNNING

MEASUREMENT DISTANCE

Fig. 5-2

(122 ~ 140 °F) • Measurement Posture

5m (16.4 ft)

: Travel Posture

• Set machine in motion. Starting after a running of 5 meters, measure the time required to travel 10 meters. Do this on level and hard ground. • Travel Posture Fully extend the arm and bucket cylinders and

GROUND CLEARANCE 30 ~ 40 cm (12~16 in)

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

Fig. 5-3

the ground.

5.2 Travel Deviation • Engine

: Rated r.p.m.

• Hydraulic Oil Temp.

: 50 ~ 60 °C (122 ~ 140 °F)

• Measurement Posture

: Travel Posture

• Measure the deviation "X" at the point of half of 10m (32.8 ft) travel after 5m preliminary running. Measure on level and hard ground.

13-1-10

10m (32.8 ft)

Fig. 5-4

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 Temp. : 50 ~ 60°C (122 ~ 140 °F) • Gradient

(Approx.1/3.73)

: 15 ° (Approx. 1/3.73) Fig. 5-5 Machine Posture for Measurement

• Machine posture : Fully extending the boom, arm and bucket cylinders, and fully contracting the

FORWARD

dozer cylinder.

5.4 DRAIN RATE ON TRAVEL MOTOR

RIB "A"

(1) Preparation 1) Apply stopper pins for both travel sprockets of left and right.

STOPPER PIN

2) Stop the engine, and release air in the hydraulic

Fig. 5-6 Location of stopper pin applied to travel

oil tank.

sprocket

3) Connect a hose to the drain port of travel motor, (3.94")

and receive the drained oil in a container. 4) Apply a plug to the drain piping at tank side. • Make sure of the rotating direction of travel mo-

(0.47") (2.76")

(0.47")

tor referring to the right sketch. Otherwise, the (2) Measurement: : At rated speed

MARK

øD L 80 SK30SR-2 40 SK35SR-2 (1.57) (3.15)

MODEL

rib "A" may be broken by the stopper pin. • Engine

ROTATING DIRECTION

Fig. 5-7 Stopper pin size

• Hydraulic oil temp. : 50 ~ 60 °C (122 ~ 140 °F) • Machine posture : Locking the traveling, and allowing relief on the travel motor • Measure the drained volume of oil for 30 seconds of relief.

Fig. 5-8 Measure drain

Unit : liter (gal.) /30sec SPEED SHIFT

1 st

13-1-11

DRAIN RATE OF TRAVEL MOTOR Standard value

Standard value Serviceability for repair limit 3 (0.79) or more — 1.5 (0.40) or less

6. MEASURING SLEW PERFORMANCES • TEST PROCEDURES Measure 3-time each. Apply average data of the above for judgement.

BUCKET PIN

6.1 SLEW TIME • Engine : High Idle • Hydraulic Oil Temp. : 50 ~ 60 °C (122 ~ 140 °F) • Measurement Posture : Completely retract the arm cylinder, fully extend the bucket cylinder and place so that boom foot pin and bucket pin 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. 6.2 OVERRUN WHEN SLEWING STOPS • Engine : High Idle • Hydraulic Oil Temp. : 50 ~ 60 °C (122 ~ 140 °F) • Measurement Posture : Same as that for measuring slew 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. At which point return the operating lever to neutral. Measure the distance between the position marks and the point the hoe attachment stops. 6.3 SLEW DRIFT DUE TO GRAVITY • Engine : Stopped • Hydraulic Oil Temp. : 50 ~ 60 °C (122 ~ 140 °F) • Gradient : 15 ° (Approx.1/3.73) • Measurement Posture : Same as that for measuring slew 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 that develops between the marks after 5 minutes. Measure for both RH and LH directions.

13-1-12

BOOM FOOT PIN

Fig. 6-1

Fig. 6-2

Fig. 6-3

6.4 Drain Rate of Travel Motor (1) Preparation 1) Stop the engine, and release air inside 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

Fig. 6-4 Receiving Drain Oil

: At rated speed

• Hydraulic oil temp. : 50 ~ 60 °C

Unit : liter (gal.) /30sec

(122 ~ 140 °F)

DRAIN RATE OF TRAVEL MOTOR

• Machine posture : Pushing a fixture with the side

Model

of bucket, operating the engine.

Standard value

• Measure the drained volume of oil for 30 seconds relieving at full stroke of the slewing opera-

SK30SR-2

4.2 (1.1)

tion.

SK35SR-2

or less

13-1-13

Standard value Serviceability for repair -----

limit 9 (2.4) or more

7. MEASURING ATTACHMENT OPERATING PERFORMANCES • TEST PROCEDURES Measure 3-time each. Apply average data of the above for judgement. 7.1 CYLINDER SPEED (1) Boom Cylinder Speed • Engine : High Idle • Hydraulic Oil Temp. : 50 ~ 60 °C (122 ~ 140 °F) • Measurement Posture : 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 Speed • Engine : High Idle • Hydraulic Oil Temp. : 50 ~ 60 °C (122 ~ 140 °F) • Measurement Posture : 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 Idle • Hydraulic Oil Temp. : 50 ~ 60 °C (122 ~ 140 °F) • Measurement Posture : 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 Idle • Hydraulic Oil Temp. : 50 ~ 60 °C (122 ~ 140 °F) • Measurement Posture : Same as that for measuring slew time. • While swinging the boom left (right) to right (left), measure the time required for a full stroke each way. (Do not include the cushioning time.)

13-1-14

Fig. 7-1

Fig. 7-2 FULLY RETRACTED

Fig. 7-3

Fig. 7-4

(5) Dozer Cylinder Speed • Engine

: High Idle

• Hydraulic Oil Temp. : 50 ~ 60 °C (122 ~ 140 °F) • Measurement Posture : Using the hoe attachment lift up the dozer blade side. • Then, raising and lowering the dozer blade with full stroke, measure the time required per stroke in each direction. Fig. 7-5

7.2 GRAVITY DRIFT OF CYLINDERS (1) Boom, Arm, Bucket, Dozer, Bucket Tip • Engine

: Stopped

• Hydraulic Oil Temp. : 50 ~ 60 °C (122 ~ 140 °F) • Measurement Posture : 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.

Fig. 7-6

(2) Swing Cylinder • Engine

: Stopped

• Hydraulic Oil Temp. : 50 ~ 60 °C (122 ~ 140 °F) • Gradient

: 15 °C (Approx.1/3.73)

• Measurement Posture : Same as that for measuring slew time. • Slew the upper slewing structure and stop at right

(Approx.1/3.73)

angle to the slope, then measure the change in rod length after 5 minutes.

Fig. 7-7

13-1-15

8. MEASURING SLEW BEARING PERFORMANCES • TEST PROCEDURES Measure 3-time each. Apply average data of the above for judgement. 8.1 SLEW BEARING-BUCKET TIP PLAY • Measurement Posture

: 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.

Fig. 8-1

8.2 SLEW BEARING PLAY Raise the crawler on one

3) Then raise the opposite

tom face of the slew bearing's

side off the ground and set

crawler and read the dial

outer-race located in front of

the dial gauge to zero.

gauge.

1) Attach a dial gauge to the bot-

the upper slewing structure.

Fig. 8-2

Fig. 8-3 Fig. 8-4

9. MEASURING CRAWLER TENSION 9.1 CRAWLER TENSION

RUBBER CRAWLER

• Raise the machine completely off the ground using the hoe attachment and dozer blade. Then measure the distance (of droop) between the center point on the crawler frame and top of STEEL CRAWLER

the crawler shoe. • Caution :

In the case of rubber crawlers, measurements should be taken with setting the joint ("M" or "×" mark) in the top center position. Fig. 9-1

13-1-16

Fig. 9-2

Book Code No.

PW22 02E ➁

NEW HOLLAND EH35 Model Cross-reference: SK35SR-2 is NEW HOLLAND Model EH35

HYDRAULIC SYSTEM TABLE OF CONTENTS 1. SUMMARY ............................................................................................ 1-1 2. HYDRAULIC CIRCUITS AND COMPONENT MODELS ....................... 1-2 3. HYDRAULIC CIRCUIT OPERATION 3.1 Color Coding Standard for Hydraulic Circuits .................................. 1-6 3.2 Neutral Circuit ................................................................................. 1-6 3.3 Travel Operating Circuit .................................................................. 1-8 3.4 Slew Operating Circuit .................................................................... 1-10 3.5 Bucket Operating Circuit ................................................................. 1-12 3.6 Boom Operating Circuit ................................................................... 1-14 3.7 Arm Operating Circuit ...................................................................... 1-16 3.8 Swing Operating Circuit .................................................................. 1-18 3.9 Dozer Operating Circuit ................................................................... 1-20 3.10 Travel / Dozer Combined Operating Circuit ................................... 1-22 3.11 Travel / Boom Combined Operating Circuit ................................... 1-24 3.12 Slew Operating Circuit [USA] ....................................................... 1-26 3.13 Swing Operating Circuit [USA] ...................................................... 1-28 4. SCHEMATIC PIPING FOR HYDRAULIC SYSTEM .............................. 1-30

22 -0-1 ➁

PW22

Revision First edition First revision Second revision

Date of Issue January, 2001 November, 2001 December, 2002

Remarks S5PW2202E A S5PW2202E ➀ A S5PW2202E ➁ A

Any use of editorial or pictorial content is strictly prohibited without express written permission from New Holland Construction, LLC. Carol Stream, IL 60188 U.S.A. Copyright © 2003 New Holland Construction, LLC. All Rights Reserved.

22-0-2 ➁

1. SUMMARY 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. Performance

Device

Features

Function • Straight traveling

• Securing straight traveling at combined op-

Travel

erations of travel and other operations • Preventing overrunning of travel motor

• Preventing overrunning on a slope

• Travel lock

• Safety lock lever locks operation of travel le-

Slew

• Parking brake

• Automatic braking at parking

• Slewing (with dozer) independent circuit

• Constant slewing speed when operating in simultaneous operation condition

• Auto slewing parking brake

• Protecting against slewing overrun at slope

• Slewing shockless function

• Smooth feeling when starting and stopping slewing operation

Attachment

Easy Operation and Safety

ver

• Hydraulic pilot control system

• Responsive operability

• Pilot lock system

• Safety lock lever locks pilot circuit

• Dozer (with slewing) independent circuit.

• Secure the travel straight when travelling and working with dozer.

• John Deere multi control valve (USA Only)

• The shift lever is available to change in two control patterns.

• Closed pressurized hydraulic oil tank

• Preventing contamination of hydraulic oil and • Removing dirt of suction side

• Line filter in pilot circuit

• Preventing malfunction in pilot operating circuit

• Return filter

• Preventing contamination of hydraulic oil

• Total power control (Pumps : P1 + P2 + P3)

• Effective use of engine power with variable pump (Two delivery openings) (Power shifting by P3 pump)

Travel

Pump

• Suction strainer

• 2 speeds traveling

Eleclricity Attachment

Low Fuel High Working Performance Consumplion

Others

improving self sucking up efficiency

• Recirculation of return oil at light load digging • Speed-up for light load digging with arm

• Improving working efficiency with 2 travel speeds shifting

with arm • Push button deceleration

• When waiting for dump truck, the engine speed is repeatedly changed and the fuel consumption and noise are reduced

22-1-1

2. HYDRAULIC CIRCUITS AND COMPONENT MODELS Applicable Machine Nos. PW08-20001~ SK30SR-2 [EU • OCEANIA] No.

NAME

PART No.

PUMP ASSY

PW10V00013F1

CONTROL VALVE

PW30V00022F3

SLEWING MOTOR

TRAVEL MOTOR

BOOM CYLINDER

ARM CYLINDER

PW01V00051F2

BUCKET CYLINDER

Applicable Machine Nos. PW10-22001~

PART No.

MODEL No.

Applicable Machine Nos. PX09-08001~ SK35SR-2 [EU • OCEANIA] No.

NAME

PART No.

Applicable Machine Nos. PX11-08901~

PART No.

MODEL No.

AP2D16LV3RS7

PUMP ASSY

PW10V00013F2

AP2D12LV3RS7

PW30V00022F4

BCV35

CONTROL VALVE

PX30V00022F3

BCV35

PW15V00016F1

PW15V00016F2

MSG - 27P - 16E

SLEWING MOTOR

PX15V00018F1

PW15V00018F2

PW15V00018F3

GM04VN

TRAVEL MOTOR

PX15V00019F3

GM04VN

BOOM CYLINDER

PX01V00031F2

ø85 - 50 - 531

ø75 - ø45 - 541

ARM CYLINDER

PX01V00035F2

ø80 - ø45 - 560

PW01V00046F2

ø65 - ø35 - 487

BUCKET CYLINDER

PW01V00046F2

ø65 - ø35-487

SWING CYLINDER

PW01V00050F2

ø80 - ø45 - 488

SWING CYLINDER

PW01V00050F2

ø80 - ø45-488

DOZER CYLINDER

PW01V00048F1

ø80 - ø45 - 173

DOZER CYLINDER

PX01V00033F1

ø90 - ø45-150

SWIVEL JOINT

PW55V00015F1

YV - 7200

SWIVEL JOINT

PW55V00015F1

YV - 7200

PILOT VALVE (ATT)

PA30V00002F2

PV48M1007B

PILOT VALVE (ATT)

PA30V00002F2

PV48M1007B

PILOT VALVE (TRAVEL)

PM30V00019F1

PVD6P4001

PILOT VALVE (TRAVEL)

PM30V00019F1

PVD6P4001

SOLENOID VALVE

PH35V00001F2

2KWE5A - 20 / G12WS - 206A

SOLENOID VALVE

PH35V00001F2

2KWE5A - 20 / G12WS - 206A

SHUTTLE VALVE

PH26V00001F1

SHUTTLE VALVE

PH26V00001F1

PW01V00044F2

ø80 - ø45 - 518

FOR NEW ZEALAND CANOPY PW01V00043F2

ø80 - ø45 - 538

----

PX15V00018F2 MSG - 27P - 16E

FOR NEW ZEALAND CANOPY PX01V00030F2

----

ø85 - ø50 - 556

----

RETURN FILTER (ELEMENT)

PM50V00012F1

Y - 464900

RETURN FILTER (ELEMENT)

PM50V00012F1

Y - 464900

CHECK VALVE

PM50V00013F1

Y - 148300

CHECK VALVE

PM50V00013F1

Y - 148300

SUCTION STRAINER

PM50V00017F4

Y - 583800

SUCTION STRAINER

PM50V00017F4

Y - 583800

INLINE FILTER

PY50V00001F1

Y - 426800

INLINE FILTER

PY50V00001F1

Y - 426800

HYDRAULIC OIL TANK

CHECK VALVE

PW21V00003F1

CHECK VALVE

PW21V00003F1

OIL COOLER

PW53V00002P1

OIL COOLER

PX53V00001P1

----

STOP VALVE

2436R912F2

PF25V00001F1

STOP VALVE

2436R912F2

PF25V00001F1

SELECTOR VALVE

PH30V00007F1

PA30V00005F1

SELECTOR VALVE

PH30V00007F1

PA30V00005F1

RELIEF VALVE

PM22V00005F3

RELIEF VALVE

PM22V00005F3

----

---Y2389

----

CPRV (BCV35)

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

22-1-2

----

---Y - 2389

----

CPRV (BCV35)

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

22-1-3

HYDRAULIC CIRCUITS AND COMPONENT MODELS Applicable Machine Nos. PW08-20001~

SK30SR-2 [USA] No.

NAME

PUMP ASSY

CONTROL VALVE

SLEWING MOTOR

PART No.

Applicable Machine Nos. PW10-22001~

PART No.

NAME

PART No.

PW10V00013F2

MODEL No. AP2D12LV3RS7

PUMP ASSY

PW30V00041F2 BCV35

CONTROL VALVE

PW15V00016F1

PW15V00016F2 MSG - 27P - 16E

SLEWING MOTOR

TRAVEL MOTOR

PW15V00018F2

PW15V00018F3 GM04VN

TRAVEL MOTOR

PX15V00020F2

GM04VN

BOOM CYLINDER

PW01V00044F2

ø80 - ø45 - 518

BOOM CYLINDER

PX01V00031F2

ø85 - 50 - 531

ARM CYLINDER

PW01V00051F2

ø75 - ø45 - 541

ARM CYLINDER

PX01V00035F2

ø80 - ø45 - 560

BUCKET CYLINDER

PW01V00046F2

ø65 - ø35 - 487

BUCKET CYLINDER

PW01V00046F2

ø65 - ø35-487

SWING CYLINDER

PW01V00050F2

ø80 - ø45 - 488

SWING CYLINDER

PW01V00050F2

ø80 - ø45-488

DOZER CYLINDER

PW01V00048F1

ø80 - ø45 - 173

DOZER CYLINDER

PX01V00033F1

ø90 - ø45-150

SWIVEL JOINT

PW55V00015F1

YV - 7200

SWIVEL JOINT

PW55V00015F1

YV - 7200

PILOT VALVE (ATT)

PA30V00002F2

PV48M1007B

PILOT VALVE (ATT)

PA30V00002F2

PV48M1007B

PILOT VALVE (TRAVEL)

PM30V00019F1

PVD6P4001

PILOT VALVE (TRAVEL)

PM30V00019F1

PVD6P4001

SOLENOID VALVE

PH35V00001F2

2KWE5A - 20 / G12WS - 206A

SOLENOID VALVE

PH35V00001F2

2KWE5A - 20 / G12WS - 206A

SHUTTLE VALVE

PH26V00001F1

SHUTTLE VALVE

PH26V00001F1

* 12 *

SELECTOR VALVE (JOHN DEERE MULTI-C/V)

PW30V00026F3 PW30V00041F1

AP2D16LV3RS7

No.

Applicable Machine Nos. PX11-08901~

PW10V00013F1

MODEL No.

Applicable Machine Nos. PX09-08001~

SK35SR-2 [USA]

2436U1458F3

K8AR8

* 12 *

SELECTOR VALVE (JOHN DEERE MULTI-C/V)

PX30V00025F3 PX30V00036F1 PX15V00018F1

PX30V00036F1

BCV35

PX15V00018F2

MSG - 27P - 16E

2436U1458F3

K8AR8

RETURN FILTER (ELEMENT)

PM50V00012F1

Y - 464900

RETURN FILTER (ELEMENT)

PM50V00012F1

Y - 464900

CHECK VALVE

PM50V00013F1

Y - 148300

CHECK VALVE

PM50V00013F1

Y - 148300

SUCTION STRAINER

PM50V00017F4

Y - 583800

SUCTION STRAINER

PM50V00017F4

Y - 583800

INLINE FILTER

PY50V00001F1

Y - 426800

INLINE FILTER

PY50V00001F1

Y - 426800

HYDRAULIC OIL TANK

CHECK VALVE

PW21V00003F1

CHECK VALVE

PW21V00003F1

OIL COOLER

PW53V00002P1

OIL COOLER

PX53V00001P1

SOLENOID VALVE

PE35V00001F1

SOLENOID VALVE

PE35V00001F1

STOP VALVE

2436R912F2

PF25V00001F1

STOP VALVE

2436R912F2

PF25V00001F1

SELECTOR VALVE

PH30V00007F1

PA30V00005F1

SELECTOR VALVE

PH30V00007F1

PA30V00005F1

RELIEF VALVE

PM22V00005F3

CPRV (BCV35)

RELIEF VALVE

PM22V00005F3

SOLENOID VALVE

16105-0000

SOLENOID VALVE

ELBOW (WITH FILTER)

Note

----

PY35V00005F1

---Y2389

07911-00008

PY35V00005F1

PV64H01042P1

• This is for reference only, because the model number might be changed due to improvement. • The Part Nos. with the mark PW08-20001~20994 * 21 :: PW08-20995~ *

22-1-4

* 1 or * 2 are applicable for the following Machine Nos.

Note

----------

PY35V00005F1

---------Y - 2389

07911-00008

CPRV (BCV35) PY35V00005F1

16105-0000

PV64H01042P1

• This is for reference only, because the model number might be changed due to improvement. • The Part Nos. with the mark PX09-08001~08584 * 21 :: PX09-08585~ *

* 1 or * 2 are applicable for the following Machine Nos.

2.2A HYDRAULIC CIRCUIT DIAGRAM [USA] Applicable Machines SK30SR-2 : PW08-20001~20994 SK35SR-2 : PX09-08001~08554

22-1-5

HYDRAULIC CIRCUITS AND COMPONENT MODELS Applicable Machine Nos. PW08-20001~

SK30SR-2 [USA] No.

NAME

PUMP ASSY

CONTROL VALVE

SLEWING MOTOR

PART No.

Applicable Machine Nos. PW10-22001~

PART No.

NAME

PART No.

PW10V00013F2

MODEL No. AP2D12LV3RS7

PUMP ASSY

PW30V00041F2 BCV35

CONTROL VALVE

PW15V00016F1

PW15V00016F2 MSG - 27P - 16E

SLEWING MOTOR

TRAVEL MOTOR

PW15V00018F2

PW15V00018F3 GM04VN

TRAVEL MOTOR

PX15V00020F2

GM04VN

BOOM CYLINDER

PW01V00044F2

ø80 - ø45 - 518

BOOM CYLINDER

PX01V00031F2

ø85 - 50 - 531

ARM CYLINDER

PW01V00051F2

ø75 - ø45 - 541

ARM CYLINDER

PX01V00035F2

ø80 - ø45 - 560

BUCKET CYLINDER

PW01V00046F2

ø65 - ø35 - 487

BUCKET CYLINDER

PW01V00046F2

ø65 - ø35-487

SWING CYLINDER

PW01V00050F2

ø80 - ø45 - 488

SWING CYLINDER

PW01V00050F2

ø80 - ø45-488

DOZER CYLINDER

PW01V00048F1

ø80 - ø45 - 173

DOZER CYLINDER

PX01V00033F1

ø90 - ø45-150

SWIVEL JOINT

PW55V00015F1

YV - 7200

SWIVEL JOINT

PW55V00015F1

YV - 7200

PILOT VALVE (ATT)

PA30V00002F2

PV48M1007B

PILOT VALVE (ATT)

PA30V00002F2

PV48M1007B

PILOT VALVE (TRAVEL)

PM30V00019F1

PVD6P4001

PILOT VALVE (TRAVEL)

PM30V00019F1

PVD6P4001

SOLENOID VALVE

PH35V00001F2

2KWE5A - 20 / G12WS - 206A

SOLENOID VALVE

PH35V00001F2

2KWE5A - 20 / G12WS - 206A

SHUTTLE VALVE

PH26V00001F1

SHUTTLE VALVE

PH26V00001F1

* 12 *

SELECTOR VALVE (JOHN DEERE MULTI-C/V)

PW30V00026F3 PW30V00041F1

AP2D16LV3RS7

No.

Applicable Machine Nos. PX11-08901~

PW10V00013F1

MODEL No.

Applicable Machine Nos. PX09-08001~

SK35SR-2 [USA]

2436U1458F3

K8AR8

* 12 *

SELECTOR VALVE (JOHN DEERE MULTI-C/V)

PX30V00025F3 PX30V00036F1 PX15V00018F1

PX30V00036F1

BCV35

PX15V00018F2

MSG - 27P - 16E

2436U1458F3

K8AR8

RETURN FILTER (ELEMENT)

PM50V00012F1

Y - 464900

RETURN FILTER (ELEMENT)

PM50V00012F1

Y - 464900

CHECK VALVE

PM50V00013F1

Y - 148300

CHECK VALVE

PM50V00013F1

Y - 148300

SUCTION STRAINER

PM50V00017F4

Y - 583800

SUCTION STRAINER

PM50V00017F4

Y - 583800

INLINE FILTER

PY50V00001F1

Y - 426800

INLINE FILTER

PY50V00001F1

Y - 426800

HYDRAULIC OIL TANK

CHECK VALVE

PW21V00003F1

CHECK VALVE

PW21V00003F1

OIL COOLER

PW53V00002P1

OIL COOLER

PX53V00001P1

SOLENOID VALVE

PE35V00001F1

SOLENOID VALVE

PE35V00001F1

STOP VALVE

2436R912F2

PF25V00001F1

STOP VALVE

2436R912F2

PF25V00001F1

SELECTOR VALVE

PH30V00007F1

PA30V00005F1

SELECTOR VALVE

PH30V00007F1

PA30V00005F1

RELIEF VALVE

PM22V00005F3

RELIEF VALVE

PM22V00005F3

SOLENOID VALVE

28 Note

----

---Y2389

07911-00008

CPRV (BCV35)

2 PY35V00005F1 PY35V00005F1 16105-0000 * ELBOW (WITH FILTER) 2 PV64H01042P1 PV64H01042P1 * • This is for reference only, because the model number might be changed due to improvement. • The Part Nos. with the mark 1 or 2 are applicable for the following Machine Nos. * * 1 : PW08-20001~20994 * 2 : PW08-20995~ *

22-1-5A

28 Note

----------

---------Y - 2389

07911-00008

CPRV (BCV35)

2.2B HYDRAULIC CIRCUIT DIAGRAM [USA] Applicable Machines SK30SR-2 : PW08-20995~, PW10-22001~ SK35SR-2 : PX09-08585~, PX11-08901~

22-1-5B

3. HYDRAULIC CIRCUIT OPERATION

3.1 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS Blue ................. Feed, drain circuit, less than 3.5 kgf / cm2 (50 psi) Green .............. Return, make-up circuit, 3.5 ~ 6 kgf / cm2 (50 ~ 85 psi) Purple ............. Secondary pilot pressure, 6 ~ 35 kgf / cm2 (85 ~ 500 psi) Red ................. Primary pilot pressure, 35 ~ 50 kgf / cm2 (500 ~ 710 psi) Orange ............ Main pump drive pressure, 50 ~ 300 kgf / cm2 (710 ~ 4270 psi) Blue tone .........At valve selection Red valve ........ When proportionate valve (reducing) is operating Red solenoid ... In active and exciting Displaying the flow circuit and standby circuit when operating. Regarding the electrical symbols in this manual, refer to the electric circuit diagram.

3.2 NEUTRAL CIRCUIT (1) Pilot Circuit 1) Pilot Primary Pressure Circuit The oil discharged from the A4 port on pump assy (1) enters into the solenoid valve (13) through the line filter (19). By unlocking the safety lock lever (operating conditions), the pressuized oil discharged from the A2 port on solenoid valve (13) is led to the pilot valve (11) for attachment and P port on pilot valve (12) for travelling. While the operating circuit is closed at neutral position, the discharged oil from the pump loses its flowing passage, and returns to the hydraulic oil tank (20) through the relief valve [setting pressure: 35 kg/cm2 (500 psi)] in the solenoid valve (13). 2) Pilot Secondary Pressure Circuit While the pilot valves (11) and (12) 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. (2) Main Circuit 1) Variable Pump Circuit The discharged 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 (20), through each valve of travel straight, travel left, boom and bucket for the P1 oil, and through each valve of travel straight, travel right, arm, swing and service valve for the P2 oil. 2) Third Pump Circuit The oil discharged from A3 port on 3rd pump enters into P3 port on control valve (2). The P3 oil joins together with P2 oil, and the all amount of oil returns into the hydraulic oil tank (20) through each shifting valve of dozer and slew.

22-1-6

BREAKER

9 R1

A2G A4 A3 A1G A1 A2

401

P 404

4 407

406

407

NIBBLER

DOZER

401

404

406

B FOWARD

402 405 Z

FOWARD A

408

BOOM

403

B REVERSE

RED

H REVERSE A

408

403

ARM

405

407

TRAVEL RIGHT

TRAVEL LEFT

402

R P3

R R

RED

302

301

14.7MPa(SK30) 15.7MPa(SK35)

BUCKET

R2 B

303

14.7MPa(SK30) 15.7MPa(SK35)

304

SWING C AGH B D F E

NIBBLER BREAKER

304 R1

305

RAISING LOWERING

305

B LEFT

A RIGHT

22 BUCKET DISCHARGE BOOM RAISING

21 17

ARM DIGGING SLEW RIGHT SLEW LEFT ARM DISCHARGE RASING LOWERING

DIGGING DISCHARGE

BOOM LOWERING

DIGGING DISCHARGE

P2 Pa6 A6 B6 TRAVEL RIGHT

B10 A10 Pa10 Pb8â&#x20AC;&#x2122; Dr1 A9 B8 Pa8 B7 A7 Pa7 P1 BUCKET BOOM TRAVEL LEFT

Pa5

A5 ARM

201

SWING

BUCKET DIGGING RIGHT LEFT B4 B3 SERVICE

P3 Pa2 B2 SLEW

A2 B1 DOZER

206

202 204

25.5MPa

22.6MPa

205 25.5MPa 205 25.5MPa

202 22.6MPa

R.H

LEVER LOCK A2

Pb7

Pb6

13 19

Pb5

L.H

25.5MPa P

Pb2

4 3 2 TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE TRAVEL RIGHT FOWARD TRAVEL LEFT FOWARD

TRAVEL 1-2SPEED CHANGE OVER A1

13-1 P1@ 3.4MPa

Pb8

17.7MPa 25.5MPa

205

205 205

203

25.5MPa

27.5MPa

Pb10

27.5MPa 204

205

SETTING PRESSURE OF RELIEF VALVE No.

@ @ @ @ @ NAME

PRESSURE:MPa {kgf/cm2} (psi)

202 Main relief valve P1,P2

22.6 {230} (3270)

203 Main relief valve P3

17.7 {180} (2560)

204 Over load relief valve

27.5 {280} (3980)

205 Over load relief valve

25.5 {260} (3700)

No. 304

PRESSURE:MPa {kgf/cm2} (psi)

NAME Slew relief valve

13-1 Pilot relief valve

SK30SR-2

14.7 {150} (2130)

SK35SR-2

15.7 {160} (2280) 3.4 {35} (500)

Fig.3 Neutral circuit

22-1-7

3.3 TRAVEL OPERATING CIRCUIT Pilot oil hydraulic system with operating valve

torque. When the motor reaches near to a self-running

3.3.1 2nd Speed Operating Circuit (Independent-forward travel)

condition (over-running) at going down a slope and so on, the oil pressure of supply side gets

(1) Pilot Circuit

down to lower pressure, and the counter balance

1) Shifting signal for 2nd speed travel

valve [brake valve] (408) spool moves to the neu-

When the "Rabbit and Tortoise" mark (at the

tral position with the spring force. As the results,

power cut-off, it automatically takes back for 1st

the passage in return oil side is throttled, and

speed) on the nob of travel right lever is pushed

the motor speed is suppressed by a back-pres-

down, it actuates the 1st and 2nd speed travel

sure, then the motor is controlled to the speed

shifting valve of solenoid valve (13). The pres-

corresponding to the supplied oil volume of the

surized oil signal for 2nd speed is discharged

pump.

from the A1 port of solenoid valve(13), and led to the P port on travel motor (4) through swivel

The counter balance valve spool is so designed

joint (10), and shifts the 2-speed shifting valve

that it is gradually shifted by a throttle effect to

(404).

stop or start the motor absorbing shock at the

2) Changing travel valve spool The pilot secondary pressure is discharged 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 discharged oil from A1 and A2 ports on variable pump enters into the P1 and P2 ports of control valve (2), and led to the B6 and B7 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 The pressurized oil supplied to the travel motor shifts the spool in counter balance valve [brake valve] (408), and opens the oil line that is being closed by the check valve (407), releases parking brake (403), then rotates the travel motor. When the 2nd speed signal is given, the pressurized oil passed through the 2-speed shifting valve (404) shifts shuttle valve (406) to high pressure, and actuates 2-speed shifting piston (401), and then makes the motor high speed with low

22-1-8

start and stop of the machine.

BREAKER

9 R1

A2G A4 A3 A1G A1 A2

401

P 404

4 407

406

407

NIBBLER

DOZER

401

404

406

B FOWARD

402 405 Z

FOWARD A

408

BOOM

403

B REVERSE

RED

H REVERSE A

408

403

ARM

405

407

TRAVEL RIGHT

TRAVEL LEFT

402

R P3

R R

RED

302

301

14.7MPa(SK30) 15.7MPa(SK35)

BUCKET

R2 B

303

14.7MPa(SK30) 15.7MPa(SK35)

304

SWING C AGH B D F E

NIBBLER BREAKER

304 R1

305

RAISING LOWERING

305

B LEFT

A RIGHT

22 BUCKET DISCHARGE BOOM RAISING

21 17

ARM DIGGING SLEW RIGHT SLEW LEFT ARM DISCHARGE RASING LOWERING

DIGGING DISCHARGE

BOOM LOWERING

DIGGING DISCHARGE

P2 Pa6 A6 B6 TRAVEL RIGHT

B10 A10 Pa10 Pb8â&#x20AC;&#x2122; Dr1 A9 B8 Pa8 B7 A7 Pa7 P1 BUCKET BOOM TRAVEL LEFT

Pa5

A5 ARM

201

SWING

BUCKET DIGGING RIGHT LEFT B4 B3 SERVICE

P3 Pa2 B2 SLEW

A2 B1 DOZER

206

202 204

25.5MPa

22.6MPa

205 25.5MPa 205 25.5MPa

202 22.6MPa

R.H

LEVER LOCK A2

Pb7

Pb6

13 19

Pb5

L.H

25.5MPa P

Pb2

4 3 2 TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE TRAVEL RIGHT FOWARD TRAVEL LEFT FOWARD

TRAVEL 1-2SPEED CHANGE OVER A1

13-1 P1@ 3.4MPa

Pb8

17.7MPa 25.5MPa

205

205 205

203

25.5MPa

27.5MPa

Pb10

27.5MPa 204

205

SETTING PRESSURE OF RELIEF VALVE No.

@ @ @ @ @ NAME

PRESSURE:MPa {kgf/cm2} (psi)

202 Main relief valve P1,P2

22.6 {230} (3270)

203 Main relief valve P3

17.7 {180} (2560)

204 Over load relief valve

27.5 {280} (3980)

205 Over load relief valve

25.5 {260} (3700)

No. 304

PRESSURE:MPa {kgf/cm2} (psi)

NAME Slew relief valve

13-1 Pilot relief valve

SK30SR-2

14.7 {150} (2130)

SK35SR-2

15.7 {160} (2280) 3.4 {35} (500)

Fig.4 Travel circuit : Travel (forward) 2nd speed operation

22-1-9

3.4 SLEW OPERATING CIRCUIT Pilot oil hydraulic system with operating lever 3.4.1 Slew (left) Operating Circuit (1) Pilot Circuit 1) Slew Valve Spool Shifting With operation for slew (left), the pilot secondary pressure oil is discharged 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 PG port on the timer valve (303). With the slew operation, the operating pilot secondary pressure is led to SH port on the timer valve (303) through the shuttle valve (14) to shift the spool. It leads the pilot primary pressure 35 kgf/cm2 (500psi) to the parking brake to release it. (Similarly, the arm digging operation releases the slew 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 lag 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 Slewing Motor (3) The oil discharged 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) The relief valve (304) relieves rapidly increased pressure at start and stop of the machine to ease shock. The make-up valve (check valve) (305) has a function to replenish oil from the return oil circuit that is led to the tank [T1 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.

22-1-10

BREAKER

9 R1

A2G A4 A3 A1G A1 A2

401

P 404

4 407

406

407

NIBBLER

DOZER

401

404

406

B FOWARD

402 405 Z

FOWARD A

408

BOOM

403

B REVERSE

RED

H REVERSE A

408

403

ARM

405

407

TRAVEL RIGHT

TRAVEL LEFT

402

R P3

R R

RED

302

301

14.7MPa(SK30) 15.7MPa(SK35)

BUCKET

R2 B

303

14.7MPa(SK30) 15.7MPa(SK35)

304

SWING C AGH B D F E

NIBBLER BREAKER

304 R1

305

RAISING LOWERING

305

B LEFT

A RIGHT

22 BUCKET DISCHARGE BOOM RAISING

21 17

ARM DIGGING SLEW RIGHT SLEW LEFT ARM DISCHARGE RASING LOWERING

DIGGING DISCHARGE

BOOM LOWERING

DIGGING DISCHARGE

P2 Pa6 A6 B6 TRAVEL RIGHT

B10 A10 Pa10 Pb8â&#x20AC;&#x2122; Dr1 A9 B8 Pa8 B7 A7 Pa7 P1 BUCKET BOOM TRAVEL LEFT

Pa5

A5 ARM

201

SWING

BUCKET DIGGING RIGHT LEFT B4 B3 SERVICE

P3 Pa2 B2 SLEW

A2 B1 DOZER

206

202 204

25.5MPa

22.6MPa

205 25.5MPa 205 25.5MPa

202 22.6MPa

R.H

LEVER LOCK A2

Pb7

Pb6

13 19

Pb5

L.H

25.5MPa P

Pb2

4 3 2 TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE TRAVEL RIGHT FOWARD TRAVEL LEFT FOWARD

TRAVEL 1-2SPEED CHANGE OVER A1

13-1 P1@ 3.4MPa

Pb8

17.7MPa 25.5MPa

205

205 205

203

25.5MPa

27.5MPa

Pb10

27.5MPa 204

205

SETTING PRESSURE OF RELIEF VALVE No.

@ @ @ @ @ NAME

PRESSURE:MPa {kgf/cm2} (psi)

202 Main relief valve P1,P2

22.6 {230} (3270)

203 Main relief valve P3

17.7 {180} (2560)

204 Over load relief valve

27.5 {280} (3980)

205 Over load relief valve

25.5 {260} (3700)

No. 304

PRESSURE:MPa {kgf/cm2} (psi)

NAME Slew relief valve

13-1 Pilot relief valve

SK30SR-2

14.7 {150} (2130)

SK35SR-2

15.7 {160} (2280) 3.4 {35} (500)

Fig.5 Slew circuit : Slew (left) operation

22-1-11

3.5 BUCKET OPERATING CIRCUIT Pilot oil hydraulic system with operating lever 3.5.1 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 discharged from the pilot valve (11). The pressurized oil entered into the Pb10 port on control valve (2) shifts the bucket valve spool. (2) Main Circuit 1) Supply Circuit for Cylinder (7) The oil discharged from A1 port on variable pump of pump assy (1) enters into P1 port on control valve (2). The pressurized oil discharged from B10 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 A10 port on control valve (2) and returns into the tank through bucket valve. A stable digging speed is obtainable with the throttling effect on bucket valve. 3.5.2 Bucket Dumping Operating Circuit (1) Pilot Circuit 1) Bucket Spool Shifting When the operating lever is put at bucket dumping position, the pilot secondary pressure oil is discharged from pilot valve (11), and enters into Pa10 port on control valve (2) to shift the bucket valve spool. (2) Main Circuit 1) Supply Circuit for Cylinder (7) Similar to the case for bucket digging, the pressurized oil discharged from A1 port on variable pump enters into P1 port on control valve (2). The oil discharged from A10 port through bucket valve is supplied to the rod side of bucket cylinder (7) to activate the bucket dumping.

22-1-12

BREAKER

9 R1

A2G A4 A3 A1G A1 A2

401

P 404

4 407

406

407

NIBBLER

DOZER

401

404

406

403

B FOWARD

402 405 Z

FOWARD A

408

BOOM

403

B REVERSE

RED

H REVERSE A

408

R H

402 407

TRAVEL RIGHT

TRAVEL LEFT

R P3

R R

RED

302

301

14.7MPa(SK30) 15.7MPa(SK35)

BUCKET

R2 B

303

14.7MPa(SK30) 15.7MPa(SK35)

304

SWING C AGH B D F E

NIBBLER BREAKER

ARM

405

407

304 R1

305

RAISING LOWERING

305

B LEFT

A RIGHT

22 BUCKET DISCHARGE BOOM RAISING

21 17

ARM DIGGING SLEW RIGHT SLEW LEFT ARM DISCHARGE RASING LOWERING

DIGGING DISCHARGE

BOOM LOWERING

DIGGING DISCHARGE

P2 Pa6 A6 B6 TRAVEL RIGHT

B10 A10 Pa10 Pb8â&#x20AC;&#x2122; Dr1 A9 B8 Pa8 B7 A7 Pa7 P1 BUCKET BOOM TRAVEL LEFT

Pa5

A5 ARM

201

SWING

BUCKET DIGGING RIGHT LEFT B4 B3 SERVICE

P3 Pa2 B2 SLEW

A2 B1 DOZER

206

202 204

25.5MPa

22.6MPa

205 25.5MPa 205 25.5MPa

202 22.6MPa

R.H

LEVER LOCK A2

Pb7

Pb6

13 19

Pb5

L.H

25.5MPa P

Pb2

4 3 2 TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE TRAVEL RIGHT FOWARD TRAVEL LEFT FOWARD

TRAVEL 1-2SPEED CHANGE OVER A1

13-1 P1@ 3.4MPa

Pb8

17.7MPa 25.5MPa

205

205 205

203

25.5MPa

27.5MPa

Pb10

27.5MPa 204

205

SETTING PRESSURE OF RELIEF VALVE No.

@ @ @ @ @ NAME

PRESSURE:MPa {kgf/cm2} (psi)

202 Main relief valve P1,P2

22.6 {230} (3270)

203 Main relief valve P3

17.7 {180} (2560)

204 Over load relief valve

27.5 {280} (3980)

205 Over load relief valve

25.5 {260} (3700)

No. 304

PRESSURE:MPa {kgf/cm2} (psi)

NAME Slew relief valve

13-1 Pilot relief valve

SK30SR-2

14.7 {150} (2130)

SK35SR-2

15.7 {160} (2280) 3.4 {35} (500)

Fig.6 Bucket circuit : Bucket digging operation

22-1-13

3.6 BOOM OPERATING CIRCUIT Pilot oil hydraulic system with operating lever 3.6.1 Boom Raising Operating Circuit (1) Pilot Circuit 1) Boom Spool Shifting When the operating lever is put at boom raising position, the pilot secondary pressure oil is discharged from pilot valve (11). The pressurized oil entered into Pa8 port on control valve (2) shifts the boom valve spool. (2) Main Circuit 1) Supply Circuit for Cylinder (5) The oil discharged from A1 port on variable pump of pump assy (1) enters into P1 port on control valve (2). The oil discharged from A9 port through boom valve and lock valve is supplied to the head side of boom cylinder (5) to raise the boom. 3.6.2 Boom Lowering Operating Circuit (1) Pilot Circuit 1) Boom Spool Shifting When the operating lever is put at boom lowering position, the pilot secondary pressure oil is discharged 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) Main Circuit 1) Supply Circuit for Cylinder (5) and Return Oil Circuit The pressurized oil discharged 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 lower the boom. The oil returned from the head side of cylinder (5) enters into A9 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. Boom lock valve (206) This is of a check valve mechanism to prevent the boom from lowering due to its own weight

22-1-14

BREAKER

9 R1

A2G A4 A3 A1G A1 A2

401

P 404

4 407

406

407

NIBBLER

DOZER

401

404

406

B FOWARD

402 405 Z

FOWARD A

408

BOOM

403

B REVERSE

RED

H REVERSE A

408

403

ARM

405

407

TRAVEL RIGHT

TRAVEL LEFT

402

R P3

R R

RED

302

301

14.7MPa(SK30) 15.7MPa(SK35)

BUCKET

R2 B

303

14.7MPa(SK30) 15.7MPa(SK35)

304

SWING C AGH B D F E

NIBBLER BREAKER

304 R1

305

RAISING LOWERING

305

B LEFT

A RIGHT

22 BUCKET DISCHARGE BOOM RAISING

21 17

ARM DIGGING SLEW RIGHT SLEW LEFT ARM DISCHARGE RASING LOWERING

DIGGING DISCHARGE

BOOM LOWERING

DIGGING DISCHARGE

P2 Pa6 A6 B6 TRAVEL RIGHT

B10 A10 Pa10 Pb8â&#x20AC;&#x2122; Dr1 A9 B8 Pa8 B7 A7 Pa7 P1 BUCKET BOOM TRAVEL LEFT

Pa5

A5 ARM

201

SWING

BUCKET DIGGING RIGHT LEFT B4 B3 SERVICE

P3 Pa2 B2 SLEW

A2 B1 DOZER

206

202 204

25.5MPa

22.6MPa

205 25.5MPa 205 25.5MPa

202 22.6MPa

R.H

LEVER LOCK A2

Pb7

Pb6

13 19

Pb5

L.H

25.5MPa P

Pb2

4 3 2 TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE TRAVEL RIGHT FOWARD TRAVEL LEFT FOWARD

TRAVEL 1-2SPEED CHANGE OVER A1

13-1 P1@ 3.4MPa

Pb8

17.7MPa 25.5MPa

205

205 205

203

25.5MPa

27.5MPa

Pb10

27.5MPa 204

205

SETTING PRESSURE OF RELIEF VALVE No.

@ @ @ @ @ NAME

PRESSURE:MPa {kgf/cm2} (psi)

202 Main relief valve P1,P2

22.6 {230} (3270)

203 Main relief valve P3

17.7 {180} (2560)

204 Over load relief valve

27.5 {280} (3980)

205 Over load relief valve

25.5 {260} (3700)

No. 304

PRESSURE:MPa {kgf/cm2} (psi)

NAME Slew relief valve

13-1 Pilot relief valve

SK30SR-2

14.7 {150} (2130)

SK35SR-2

15.7 {160} (2280) 3.4 {35} (500)

Fig.7 Boom circuit : Boom raising operation

22-1-15

3.7 ARM OPERATING CIRCUIT Pilot oil hydraulic system with function to recirculate return oil while digging with light load. 3.7.1 Arm Digging Operating Circuit (1) Pilot Circuit 1) Shift for Arm Spool At the arm digging operation, the pilot secondary pressure discharged from the pilot valve (11) is led to the Pa5 port on control valve (2) to shift the arm valve spool. Furthermore, the pilot secondary pressure acts to the SH port on timer valve (303) through the shuttle valve (14) to release the parking brake. (2) Main Circuit 1) Supply Circuit for Cylinder (6) The oil discharged from the A2 port on variable pump enters into the P2 port on control valve (2). The pressurized oil came out from the A5 port through the arm valve is supplied to the the head side of arm cylinder (6) to actuate the digging work. 2) Return Line from Cylinder (6) The return oil from the the rod side of arm cylinder enters into the B5 port on control valve(2), and is led to the return line from the T2 port through arm valve, then return to the tank. At the low load operation, the oil returned from the cylinder is raised its pressure by a throttle effect in the arm valve, and a part of pressurized return oil pushes up the check valve which connects to the supply circuit. The working speed is increased by such recirculation system for the return oil. 3.7.2 Operating Circuit for Arm Out (DISCHARGE) (1) Pilot Circuit At the operation for arm out, the pilot secondary pressure is discharged from the pilot valve (11), and led to the Pb5 port on control valve (2) to shift the arm valve spool. (2) Main Circuit Similar to the case for digging, the oil entered into the control vale (2) is discharged from the B5 port, and supplied to the rod side of arm cyl-

22-1-16

BREAKER

9 R1

A2G A4 A3 A1G A1 A2

401

P 404

4 407

406

407

NIBBLER

DOZER

401

404

406

B FOWARD

402 405 Z

FOWARD A

408

BOOM

403

B REVERSE

RED

H REVERSE A

408

403

ARM

405

407

TRAVEL RIGHT

TRAVEL LEFT

402

R P3

R R

RED

302

301

14.7MPa(SK30) 15.7MPa(SK35)

BUCKET

R2 B

303

14.7MPa(SK30) 15.7MPa(SK35)

304

SWING C AGH B D F E

NIBBLER BREAKER

304 R1

305

RAISING LOWERING

305

B LEFT

A RIGHT

22 BUCKET DISCHARGE BOOM RAISING

21 17

ARM DIGGING SLEW RIGHT SLEW LEFT ARM DISCHARGE RASING LOWERING

DIGGING DISCHARGE

BOOM LOWERING

DIGGING DISCHARGE

P2 Pa6 A6 B6 TRAVEL RIGHT

B10 A10 Pa10 Pb8â&#x20AC;&#x2122; Dr1 A9 B8 Pa8 B7 A7 Pa7 P1 BUCKET BOOM TRAVEL LEFT

Pa5

A5 ARM

201

SWING

BUCKET DIGGING RIGHT LEFT B4 B3 SERVICE

P3 Pa2 B2 SLEW

A2 B1 DOZER

206

202 204

25.5MPa

22.6MPa

205 25.5MPa 205 25.5MPa

202 22.6MPa

R.H

LEVER LOCK A2

Pb7

Pb6

13 19

Pb5

L.H

25.5MPa P

Pb2

4 3 2 TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE TRAVEL RIGHT FOWARD TRAVEL LEFT FOWARD

TRAVEL 1-2SPEED CHANGE OVER A1

13-1 P1@ 3.4MPa

Pb8

17.7MPa 25.5MPa

205

205 205

203

25.5MPa

27.5MPa

Pb10

27.5MPa 204

205

SETTING PRESSURE OF RELIEF VALVE No.

@ @ @ @ @ NAME

PRESSURE:MPa {kgf/cm2} (psi)

202 Main relief valve P1,P2

22.6 {230} (3270)

203 Main relief valve P3

17.7 {180} (2560)

204 Over load relief valve

27.5 {280} (3980)

205 Over load relief valve

25.5 {260} (3700)

No. 304

PRESSURE:MPa {kgf/cm2} (psi)

NAME Slew relief valve

13-1 Pilot relief valve

SK30SR-2

14.7 {150} (2130)

SK35SR-2

15.7 {160} (2280) 3.4 {35} (500)

Fig.8 Arm circuit : Arm digging operation

22-1-17

3.8 SWING OPERATING CIRCUIT Cable driving system with operating pedal 3.8.1 Swing (left) Operating Circuit (1) Swing Operation By means of stepping down the swing (left) operating 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, as the same case as the dozer, it is activated regardless to the safety lock lever. (2) Main Circuit 1) Supply Circuit for Cylinder (10) The discharged oil from A2 port on variable pump enters into P2 port on control valve (2), and comes out from B4 port through cylinder valve, and is supplied to the head side of cylinder (8) to activate the swing (left). 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.

22-1-18

BREAKER

9 R1

A2G A4 A3 A1G A1 A2

401

P 404

4 407

406

407

NIBBLER

DOZER

401

404

406

B FOWARD

402 405 Z

FOWARD A

408

BOOM

403

B REVERSE

RED

H REVERSE A

408

403

ARM

405

407

TRAVEL RIGHT

TRAVEL LEFT

402

R P3

R R

RED

302

301

14.7MPa(SK30) 15.7MPa(SK35)

BUCKET

R2 B

303

14.7MPa(SK30) 15.7MPa(SK35)

304

SWING C AGH B D F E

NIBBLER BREAKER

304 R1

305

RAISING LOWERING

305

B LEFT

A RIGHT

22 BUCKET DISCHARGE BOOM RAISING

21 17

ARM DIGGING SLEW RIGHT SLEW LEFT ARM DISCHARGE RASING LOWERING

DIGGING DISCHARGE

BOOM LOWERING

DIGGING DISCHARGE

P2 Pa6 A6 B6 TRAVEL RIGHT

B10 A10 Pa10 Pb8â&#x20AC;&#x2122; Dr1 A9 B8 Pa8 B7 A7 Pa7 P1 BUCKET BOOM TRAVEL LEFT

Pa5

A5 ARM

201

SWING

BUCKET DIGGING RIGHT LEFT B4 B3 SERVICE

P3 Pa2 B2 SLEW

A2 B1 DOZER

206

202 204

25.5MPa

22.6MPa

205 25.5MPa 205 25.5MPa

202 22.6MPa

R.H

LEVER LOCK A2

Pb7

Pb6

13 19

Pb5

L.H

25.5MPa P

Pb2

4 3 2 TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE TRAVEL RIGHT FOWARD TRAVEL LEFT FOWARD

TRAVEL 1-2SPEED CHANGE OVER A1

13-1 P1@ 3.4MPa

Pb8

17.7MPa 25.5MPa

205

205 205

203

25.5MPa

27.5MPa

Pb10

27.5MPa 204

205

SETTING PRESSURE OF RELIEF VALVE No.

@ @ @ @ @ NAME

PRESSURE:MPa {kgf/cm2} (psi)

202 Main relief valve P1,P2

22.6 {230} (3270)

203 Main relief valve P3

17.7 {180} (2560)

204 Over load relief valve

27.5 {280} (3980)

205 Over load relief valve

25.5 {260} (3700)

No. 304

PRESSURE:MPa {kgf/cm2} (psi)

NAME Slew relief valve

13-1 Pilot relief valve

SK30SR-2

14.7 {150} (2130)

SK35SR-2

15.7 {160} (2280) 3.4 {35} (500)

Fig.9 Swing circuit : Swing (left) operation

22-1-19

3.9 DOZER OPERATING CIRCUIT Cable driving system with operating lever 3.9.1 Dozer Lowering Operating Circuit (1) Dozer Operation When the valve operating lever is pushed forward, the dozer spool in control valve (2) is shifted with the cable. Since the pilot oil pressure is not utilized for it, as the same case as the swing, this is activated regardless to the safety lock lever. (2) Main Circuit 1) Supply Circuit for Cylinder (9) The oil discharged from A3 port on third pump in pump assy (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 lowering motion. After operating the dozer operating lever while engine is stopped keeping the dozer at raised condition, when the dozer operating lever is operated to lower the dozer, the dozer is suddenly dropped. The caution should be cared for it.

22-1-20

BREAKER

9 R1

A2G A4 A3 A1G A1 A2

401

P 404

4 407

406

407

NIBBLER

DOZER

401

404

406

B FOWARD

402 405 Z

FOWARD A

408

BOOM

403

B REVERSE

RED

H REVERSE A

408

403

ARM

405

407

TRAVEL RIGHT

TRAVEL LEFT

402

R P3

R R

RED

302

301

14.7MPa(SK30) 15.7MPa(SK35)

BUCKET

R2 B

303

14.7MPa(SK30) 15.7MPa(SK35)

304

SWING C AGH B D F E

NIBBLER BREAKER

304 R1

305

RAISING LOWERING

305

B LEFT

A RIGHT

22 BUCKET DISCHARGE BOOM RAISING

21 17

ARM DIGGING SLEW RIGHT SLEW LEFT ARM DISCHARGE RASING LOWERING

DIGGING DISCHARGE

BOOM LOWERING

DIGGING DISCHARGE

P2 Pa6 A6 B6 TRAVEL RIGHT

B10 A10 Pa10 Pb8â&#x20AC;&#x2122; Dr1 A9 B8 Pa8 B7 A7 Pa7 P1 BUCKET BOOM TRAVEL LEFT

Pa5

A5 ARM

201

SWING

BUCKET DIGGING RIGHT LEFT B4 B3 SERVICE

P3 Pa2 B2 SLEW

A2 B1 DOZER

206

202 204

25.5MPa

22.6MPa

205 25.5MPa 205 25.5MPa

202 22.6MPa

R.H

LEVER LOCK A2

Pb7

Pb6

13 19

Pb5

L.H

25.5MPa P

Pb2

4 3 2 TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE TRAVEL RIGHT FOWARD TRAVEL LEFT FOWARD

TRAVEL 1-2SPEED CHANGE OVER A1

13-1 P1@ 3.4MPa

Pb8

17.7MPa 25.5MPa

205

205 205

203

25.5MPa

27.5MPa

Pb10

27.5MPa 204

205

SETTING PRESSURE OF RELIEF VALVE No.

@ @ @ @ @ NAME

PRESSURE:MPa {kgf/cm2} (psi)

202 Main relief valve P1,P2

22.6 {230} (3270)

203 Main relief valve P3

17.7 {180} (2560)

204 Over load relief valve

27.5 {280} (3980)

205 Over load relief valve

25.5 {260} (3700)

No. 304

PRESSURE:MPa {kgf/cm2} (psi)

NAME Slew relief valve

13-1 Pilot relief valve

SK30SR-2

14.7 {150} (2130)

SK35SR-2

15.7 {160} (2280) 3.4 {35} (500)

Fig.10 Dozer circuit : Dozer blade lowering operation

22-1-21

3.10 TRAVEL / DOZER COMBINED OPERATING CIRCUIT At the combined operation of travel and dozer at the same time, the straight traveling is secured with this function. 3.10.1 Travel (1st speed forwarding)/Dozer Lowering Operating Circuit 1) Pilot Circuit The traveling is of the pilot oil hydraulic system with operating lever, and the dozer is of the cable driving system with operating lever.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 discharged 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 discharged 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). 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 traveling. Thus the straight traveling is maintained. As the above mentioned, the traveling speed is not changed from the single operation for traveling maintaining the straight traveling.

22-1-22

BREAKER

9 R1

A2G A4 A3 A1G A1 A2

401

P 404

4 407

406

407

NIBBLER

DOZER

401

404

406

B FOWARD

402 405 Z

FOWARD A

408

BOOM

403

B REVERSE

RED

H REVERSE A

408

403

ARM

405

407

TRAVEL RIGHT

TRAVEL LEFT

402

R P3

R R

RED

302

301

14.7MPa(SK30) 15.7MPa(SK35)

BUCKET

R2 B

303

14.7MPa(SK30) 15.7MPa(SK35)

304

SWING C AGH B D F E

NIBBLER BREAKER

304 R1

305

RAISING LOWERING

305

B LEFT

A RIGHT

22 BUCKET DISCHARGE BOOM RAISING

21 17

ARM DIGGING SLEW RIGHT SLEW LEFT ARM DISCHARGE RASING LOWERING

DIGGING DISCHARGE

BOOM LOWERING

DIGGING DISCHARGE

P2 Pa6 A6 B6 TRAVEL RIGHT

B10 A10 Pa10 Pb8â&#x20AC;&#x2122; Dr1 A9 B8 Pa8 B7 A7 Pa7 P1 BUCKET BOOM TRAVEL LEFT

Pa5

A5 ARM

201

SWING

BUCKET DIGGING RIGHT LEFT B4 B3 SERVICE

P3 Pa2 B2 SLEW

A2 B1 DOZER

206

202 204

25.5MPa

22.6MPa

205 25.5MPa 205 25.5MPa

202 22.6MPa

R.H

LEVER LOCK A2

Pb7

Pb6

13 19

Pb5

L.H

25.5MPa P

Pb2

4 3 2 TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE TRAVEL RIGHT FOWARD TRAVEL LEFT FOWARD

TRAVEL 1-2SPEED CHANGE OVER A1

13-1 P1@ 3.4MPa

Pb8

17.7MPa 25.5MPa

205

205 205

203

25.5MPa

27.5MPa

Pb10

27.5MPa 204

205

SETTING PRESSURE OF RELIEF VALVE No.

@ @ @ @ @ NAME

PRESSURE:MPa {kgf/cm2} (psi)

202 Main relief valve P1,P2

22.6 {230} (3270)

203 Main relief valve P3

17.7 {180} (2560)

204 Over load relief valve

27.5 {280} (3980)

205 Over load relief valve

25.5 {260} (3700)

No. 304

PRESSURE:MPa {kgf/cm2} (psi)

NAME Slew relief valve

13-1 Pilot relief valve

SK30SR-2

14.7 {150} (2130)

SK35SR-2

15.7 {160} (2280) 3.4 {35} (500)

Fig.11 Combined circuit : Travel (forward) 1st / dozer lowering operation

22-1-23

3.11 TRAVEL / BOOM COMBINED OPERATING CIRCUIT At the combined operation of travel and boom at

At the combined operation of travel/boom at the

the same time, the straight traveling is secured

same time, the pressurized oils of P1 and P2

with this function.

ports join together in the travel straight valve, and their pressures are equalized at the same level.

3.11.1 Travel (1st speed forward) / Boom

Then the oil is preferentially supplied for the travel

Raising Operating Circuit

motors through the throttle notch on the travel straight valve spool.

1) Pilot Circuit The traveling/boom raising 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 raising oper-

(

The distribution of oil for the boom (attachment) and travel motor is adjusted by the opening degree of the throttle.

ating lever, the pilot secondary pressure shifts the travel valve spool and/or boom spool in the

Although the above function caused for slowing

control valve (2).

down the travel speed, the combined operations

This operation blocks the travel (left) valve and

for traveling and boom raising are available at

boom valve in the pilot primary pressure circuit.

the same time, and the straight traveling is also

Therefore, the pressure of supplied oil which lost

maintained.

its way to go, is raised, and overcomes the spring force in travel straight valve (201) to shift the valve spool. 2) Main Circuit The oil discharged from A1 and A2 ports on the variable pump enters into P1 and P2 ports on the control valve (2). The pressurized oils of P1 and P2 ports join together in the travel straight valve, and divided into two flows directing to attachment circuit and travel circuit of left and right. The oil divided for the attachment circuit is led to the boom cylinder (5) through the boom valve. The other oil divided for the travel circuit is led to the swivel joint (10) and travel motor (4) through the travel spool.

22-1-24

)

BREAKER

9 R1

A2G A4 A3 A1G A1 A2

401

P 404

4 407

406

407

NIBBLER

DOZER

401

404

406

B FOWARD

402 405 Z

FOWARD A

408

BOOM

403

B REVERSE

RED

H REVERSE A

408

403

ARM

405

407

TRAVEL RIGHT

TRAVEL LEFT

402

R P3

R R

RED

302

301

14.7MPa(SK30) 15.7MPa(SK35)

BUCKET

R2 B

303

14.7MPa(SK30) 15.7MPa(SK35)

304

SWING C AGH B D F E

NIBBLER BREAKER

304 R1

305

RAISING LOWERING

305

B LEFT

A RIGHT

22 BUCKET DISCHARGE BOOM RAISING

21 17

ARM DIGGING SLEW RIGHT SLEW LEFT ARM DISCHARGE RASING LOWERING

DIGGING DISCHARGE

BOOM LOWERING

DIGGING DISCHARGE

P2 Pa6 A6 B6 TRAVEL RIGHT

B10 A10 Pa10 Pb8â&#x20AC;&#x2122; Dr1 A9 B8 Pa8 B7 A7 Pa7 P1 BUCKET BOOM TRAVEL LEFT

Pa5

A5 ARM

201

SWING

BUCKET DIGGING RIGHT LEFT B4 B3 SERVICE

P3 Pa2 B2 SLEW

A2 B1 DOZER

206

202 204

25.5MPa

22.6MPa

205 25.5MPa 205 25.5MPa

202 22.6MPa

R.H

LEVER LOCK A2

Pb7

Pb6

13 19

Pb5

L.H

25.5MPa P

Pb2

4 3 2 TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE TRAVEL RIGHT FOWARD TRAVEL LEFT FOWARD

TRAVEL 1-2SPEED CHANGE OVER A1

13-1 P1@ 3.4MPa

Pb8

17.7MPa 25.5MPa

205

205 205

203

25.5MPa

27.5MPa

Pb10

27.5MPa 204

205

SETTING PRESSURE OF RELIEF VALVE No.

@ @ @ @ @ NAME

PRESSURE:MPa {kgf/cm2} (psi)

202 Main relief valve P1,P2

22.6 {230} (3270)

203 Main relief valve P3

17.7 {180} (2560)

204 Over load relief valve

27.5 {280} (3980)

205 Over load relief valve

25.5 {260} (3700)

No. 304

PRESSURE:MPa {kgf/cm2} (psi)

NAME Slew relief valve

13-1 Pilot relief valve

SK30SR-2

14.7 {150} (2130)

SK35SR-2

15.7 {160} (2280) 3.4 {35} (500)

Fig.12 Combined circuit : Travel (forward) 1st / boom raising operation

22-1-25

3.12 SLEW OPERATING CIRCUIT [USA] Pilot oil hydraulic system with operating lever (Shifting slew/swing with selector valve ) 3.12.1 Slew (left) Operating Circuit (1) Pilot Circuit

(2) Main Circuit

1) Slew Valve Spool Shifting

1) Supply Circuit for Slewing Motor (3)

(The selector valve (23) is usually shifted to the

The oil discharged from the A3 port on hydraulic

slew side.)

oil pump (1) is supplied to the B port on slewing motor (3) through the P3 port on control valve

With operation for slew (left), the pilot secondary

(2) and slew valve to drive the slewing motor.

pressure oil is discharged from the pilot valve (11) and led to Pb2 port on control valve (2)

2) Slewing Motor (3)

through the selector valve (15) and solenoid

The relief valve (304) relieves rapidly increased

valve (23) to shift the slew valve spool.

pressure at start and stop of the machine to ease shock. The make-up valve (check valve) (305) has a

2) Releasing Parking Brake The pilot primary pressure is always led to PG

function to replenish oil from the return oil circuit

port on the timer valve (303). With the slew op-

that is led to the tank [T1 port on control valve

eration, the operating pilot secondary pressure

(2)] to the slewing motor, to prevent the slewing

is led to SH port on the timer valve (303) through

motor form the cavitations due to negative pres-

the shuttle valve (14) to shift the spool. It leads

sure generated in it because of inertia on the

the pilot primary pressure 35 kgf/cm (500 psi)

slewing mass.

to the parking brake to release it. (Similarly, the arm digging operation releases the slew brake.)

3.12.2 Selector Valve (15) (J/D Multi-control Valve)

3) Activating Parking Brake

By means of shifting this valve, the operations

When the slew operating lever is returned to neu-

for boom and arm are interchangeable. Namely,

tral position to stop slewing, the pilot secondary

the boom operating lever is changed to arm op-

pressure disappears causing to shift the timer

erating lever, and vice versa.

valve (303), then the pressurized oil is shut down. The oil in the brake cylinder is discharged due to

22-1-26

3.12.3 Solenoid Valve (23)

spring force, and drained through the throttle in

This solenoid valve is to interchange the operat-

the timer valve (303). Thus the braking is acti-

ing lever with slew or swing. Usually, the operat-

vated with some time lag for 2.5 to 5.0 seconds

ing lever is used for slewing. By means of shift-

to smoothly absorb the slewing inertia at its stop

ing the solenoid valve, it is interchanged to swing

of motion.

operation.

9 D2 A2G A4 A3 A1G A1 A2

401

P 404

4 408

403

407

406

402 405

REVERSE A

FOWARD A

B FOWARD

B REVERSE

403

R H

BREAKER

R R

303

304 R1

305

14.7MPa(SK30) 15.7MPa(SK35)

304 R2

BUCKET

301

14.7MPa(SK30) 15.7MPa(SK35)

NIBBLER

ARM

302

405

TRAVEL LEFT

TRAVEL RIGHT

RED

BOOM

R Z

NIBBLER

402 407

408

407

DOZER

401

404

406

RED

BREAKER

B LEFT

A RIGHT

A D

SWING C AGH B D F E

SWING LEFT SLEW LEFT SWING RIGHT SLEW RIGHT

H RAISING LOWERING

T A2B2 A1B1

22 BUCKET DISCHARGE P2 BOOM RAISING PW-31 P

21 17

DIGGING DISCHARGE

PW-30 P

ARM DIGGING ARM DISCHARGE BOOM LOWERING BUCKET DIGGING

RASING LOWERING

P2 Pa6 A6 B6 TRAVEL RIGHT

B10 A10 Pa10 Pb8â&#x20AC;&#x2122; Dr1 A9 B8 Pa8 B7 A7 Pa7 P1 BUCKET BOOM TRAVEL LEFT

Pa5

A5 ARM

201

B5 Pa4

SWING

DB HF D RIGHT LEFT B4 B3 SERVICE

ACE G P3 Pa2 B2 SLEW

A2 B1 DOZER

A1 42

206 27.5MPa 204

205

202 204

25.5MPa

22.6MPa

205 25.5MPa 205 25.5MPa

202 22.6MPa

25.5MPa

203 205

205

27.5MPa 205

17.7MPa

R.H

LEVER LOCK A2

Pb8

Pb7

Pb6

Pb5

13 19

Pb4

T L.H

Pb2

4 3 2 TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE TRAVEL RIGHT FOWARD TRAVEL LEFT FOWARD

TRAVEL 1-2SPEED CHANGE OVER A1

13-1 P1@ 3.4MPa

25.5MPa

25.5MPa Pb10

SETTING PRESSURE OF RELIEF VALVE No.

@ @ @ @ @ NAME

PRESSURE:MPa {kgf/cm2} (psi)

202 Main relief valve P1,P2

22.6 {230} (3270)

203 Main relief valve P3

17.7 {180} (2560)

204 Over load relief valve

27.5 {280} (3980)

205 Over load relief valve

25.5 {260} (3700)

No. 304

PRESSURE:MPa {kgf/cm2} (psi)

NAME Slew relief valve

13-1 Pilot relief valve

SK30SR-2

14.7 {150} (2130)

SK35SR-2

15.7 {160} (2280) 3.4 {35} (500)

Fig.13 Slew circuit : Slew (left) operation [USA]

22-1-27

3.13 SWING OPERATING CIRCUIT [USA] Pilot oil hydraulic system with operating lever (Shifting slew/swing with selector valve ) 3.13.1 Swing (left) Operating Circuit (1) Swing Operation The solenoid valve (23) is activated to shift the valve spool to swing side. With the operation for swing (left), pilot secondary pressure is discharged from the pilot valve (11). The pressurized oil is led to Pb4 port on control valve (2) through the selector valve (15) and solenoid valve to shift the swing valve spool. (2) Main Circuit Supply Circuit for Cylinder (8) The oil discharged from the A2 port on variable pump enters into P2 port on control valve (2). It is discharged from B4 port through swing valve, and supplied to head side of cylinder (8) to operate swing (left) motion. 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.

22-1-28

9 D2 A2G A4 A3 A1G A1 A2

401

P 404

4 408

403

407

406

402 405

REVERSE A

FOWARD A

B FOWARD

B REVERSE

403

R H

BREAKER

R R

303

304 R1

305

14.7MPa(SK30) 15.7MPa(SK35)

304 R2

BUCKET

301

14.7MPa(SK30) 15.7MPa(SK35)

NIBBLER

ARM

302

405

TRAVEL LEFT

TRAVEL RIGHT

RED

BOOM

R Z

NIBBLER

402 407

408

407

DOZER

401

404

406

RED

BREAKER

B LEFT

A RIGHT

A D

SWING C AGH B D F E

SWING LEFT SLEW LEFT SWING RIGHT SLEW RIGHT

H RAISING LOWERING

T A2B2 A1B1

22 BUCKET DISCHARGE P2 BOOM RAISING PW-31 P

21 17

DIGGING DISCHARGE

PW-30 P

ARM DIGGING ARM DISCHARGE BOOM LOWERING BUCKET DIGGING

RASING LOWERING

P2 Pa6 A6 B6 TRAVEL RIGHT

B10 A10 Pa10 Pb8â&#x20AC;&#x2122; Dr1 A9 B8 Pa8 B7 A7 Pa7 P1 BUCKET BOOM TRAVEL LEFT

Pa5

A5 ARM

201

B5 Pa4

SWING

DB HF D RIGHT LEFT B4 B3 SERVICE

ACE G P3 Pa2 B2 SLEW

A2 B1 DOZER

A1 42

206 27.5MPa 204

205

202 204

25.5MPa

22.6MPa

205 25.5MPa 205 25.5MPa

202 22.6MPa

25.5MPa

203 205

205

27.5MPa 205

17.7MPa

R.H

LEVER LOCK A2

Pb8

Pb7

Pb6

Pb5

13 19

Pb4

T L.H

Pb2

4 3 2 TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE TRAVEL RIGHT FOWARD TRAVEL LEFT FOWARD

TRAVEL 1-2SPEED CHANGE OVER A1

13-1 P1@ 3.4MPa

25.5MPa

25.5MPa Pb10

SETTING PRESSURE OF RELIEF VALVE No.

@ @ @ @ @ NAME

PRESSURE:MPa {kgf/cm2} (psi)

202 Main relief valve P1,P2

22.6 {230} (3270)

203 Main relief valve P3

17.7 {180} (2560)

204 Over load relief valve

27.5 {280} (3980)

205 Over load relief valve

25.5 {260} (3700)

No. 304

PRESSURE:MPa {kgf/cm2} (psi)

NAME Slew relief valve

13-1 Pilot relief valve

SK30SR-2

14.7 {150} (2130)

SK35SR-2

15.7 {160} (2280) 3.4 {35} (500)

Fig.14 Swing circuit : Swing (left) operation [USA]

22-1-29

4. SCHEMATIC PIPING FOR HYDRAULIC SYSYTEM FOR EU HYDRAULIC OIL TANK

SWING CYLINDER

RETURN FILTER (WITH RELIEF VALVE)

ARM CYLINDER

SUCTION STRAINER DOZER CYLINDER

TRAVEL MOTOR (RIGHT)

BOOM CYLINDER CHECK VALVE

SLEWING MOTOR

BACKWARD

FORWARD FORWARD

SWIVEL JOINT

BACKWARD

SLEW LEFT SLEW RIGHT

BUCKET CYLINDER

DOZER SLEW

BUCKET DISCHARGE

ATT PILOT VALVE (R.H.) FILTER

BOOM LOWER

SERVICE BUCKET DIG. BOOM RAISE

SWING

TRAVEL PILOT VALVE

OIL COOLER

ARM

TRAVEL RIGHT

SHUTTLE VALVE

TRAVEL LEFT

SLEW RIGHT

ATT PILOT VALVE (L.H.)

BOOM

TRAVEL MOTOR (LEFT)

ARM DISCHARGE

BUCKET

CONTROL VALVE

BREAKER

LOWER TIER

FILTER

ENGINE

BREAKER SLEW LEFT ARM DIG.

HYDRAULIC PUMP

NIBBLER

FILTER

SOLENOID VALVE FILTER

UPPER TIER

BLOCK

SELECTOR VALVE STOP VALVE

PILOT CIRCUIT

RELIEF VALVE

MAIN PUMP DRIVE PRESSURE CIRCUIT TRAVEL 2-SPEED

22-1-30

LEVER LOCK

SUPPLY / RETURN (DRAIN) CIRCUIT

SCHEMATIC PIPING FOR HYDRAULIC SYSYTEM FOR USA HYDRAULIC OIL TANK

SWING CYLINDER

RETURN FILTER (WITH RELIEF VALVE)

ARM CYLINDER

SUCTION STRAINER DOZER CYLINDER

TRAVEL MOTOR (RIGHT)

BOOM CYLINDER SLEWING MOTOR

CHECK VALVE

BACKWARD

FORWARD FORWARD

SWIVEL JOINT

BACKWARD

SLEW LEFT SLEW RIGHT

BUCKET CYLINDER

DOZER SLEW

BUCKET DISCHARGE

ATT PILOT VALVE (R.H.) FILTER

BOOM LOWER

SERVICE BUCKET DIG. BOOM RAISE

SWING

TRAVEL PILOT VALVE

OIL COOLER

ARM TRAVEL RIGHT

ENGINE

TRAVEL LEFT

FILTER

SLEW / SWING RIGHT

BOOM

SHUTTLE VALVE

ATT PILOT VALVE (L.H.) TRAVEL MOTOR (LEFT)

ARM DISCHARGE

BREAKER BREAKER SLEW / SWING LEFT

BUCKET

ARM DIG.

CONTROL VALVE G E

F H

P SW30 P SW31

C A

B D P1

SOLENOID VALVE

HYDRAULIC PUMP

NIBBLER

FILTER SELECTOR VALVE SELECTOR VALVE (J/D MULTI C/V)

STOP VALVE

FILTER

B1 A1

B2 A2

SOLENOID VALVE PILOT CIRCUIT

RELIEF VALVE

MAIN PUMP DRIVE PRESSURE CIRCUIT SUPPLY / RETURN (DRAIN) CIRCUIT TRAVEL 2-SPEED

LEVER LOCK

22-1-31

NOTES

22-1-32

NOTES

Book Code No.

PW23 02E ➁

NEW HOLLAND EH35 Model Cross-reference: SK35SR-2 is NEW HOLLAND Model EH35

ELECTRICAL SYSTEM TABLE OF CONTENTS 1. HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION ........................................... 1-1 2. ELECTRIC CIRCUIT DIAGRAM ............................................................ 1-3 3. ELECTRICAL EQUIPMENT & HARNESS ............................................. 1-5 Applicable Machines SK30SR-2 : PW08-20001~ SK35SR-2 : PX09-08001~ 3.1 Electrical Equipment List .................................................................. 1-5 3.2 Harness & Cable List ...................................................................... . 1-6 3.3 Electrical Equipment & Harness Connection ................................... 1-7 3.4 Components & Harness Arrangement ............................................. 1-8 3.5 Detail of Harness & Cable ............................................................... 1-14 4. ELECTRICAL EQUIPMENT & HARNESS .............................................1-14 Applicable Machines SK30SR-2 : PW10-22001~ SK35SR-2 : PX11-08901~ 4.1 Electrical Equipment List ..................................................................1-27 4.2 Harness & Cable List ...................................................................... 1-28 4.3 Components & Harness Arrangement ............................................. 1-29 4.4 Detail of Harness & Cable ............................................................... 1-42

23 -0-1 ➁

PW23

Revision First edition First revision Second revision

Date of Issue January, 2001 November, 2001 December, 2002

Remarks S5PW2302E A S5PW2302E ➀ A S5PW2302E ➁ A

Any use of editorial or pictorial content is strictly prohibited without express written permission from New Holland Construction, LLC. Carol Stream, IL 60188 U.S.A. Copyright © 2003 New Holland Construction, LLC. All Rights Reserved.

23-0-2 ➁

1. HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION (2) The connector is to be connected with engaging (1) In the diagram, the number, size and color of

the male (M)

female (F) connectors of the

same number. The size of the wire is to be 0.75 sq (square mm

Example : CN-101M and CN-101F

= mm2

Where : M means for Male, and F for Female.

Example :

R (3) Wire Color : Red

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

Wire Size : 2 sq (mm2) Wire No. : 6

(4) The AVSS wires are to be used for the size between 0.75 sq and 2 sq. AVS wires between 3 sq and 5 sq and others are AV wires, unless

WIRING COLOR TABLE

otherwise specified.

Symboll B

Color BLACK

Symboll O

Color ORANGE

GREEN

BROWN

BLUE

LIGHT GREEN

RED

GRAY

WHITE

SKY BLUE

YELLOW

PINK

(5) The wire size is 0.75 sq, unless otherwise specified. (6) The treatment for the harness end is to be as follows : 1)

VIOLET

After roughly applyingPH35V00001F1 harness taping, wires are installed in a corrugated tube.

Harness taping by two plies.

No harness treatment for connection.

1.2 HARNESS CONNECTION (1) Indication for Connector LOCK

CONNECTOR No.

WIRE No.

(7) The length for the above (6)-3) is to be 30 ± 10 mm. (1.2 ± 0.4 in), and the length includes in

CONNECTOR NAME WIRE COLOR

1) The figure for the connector pin arrangement is

2) The numbers in the No., and

show t

wire

letters show t

wire

color. 3) On the side face of connector, the connector name and serial numberr of the connector No. are indicated. 4) At the place indicated as "DOUBLE SPLICE", Two wires are connected to one place.

23-1-1

the total length of wire shown in the diagram.

This page is blank because of editing convenience.

23-1-2

6 WG

E-1 FUSE BOX

14 2WR

8 3R

8 5R

47 3L

13BW 1.25

S H O T E O A F A N R F T T

14 2WR

9 8R

8 8R B C

47 3L

M-1: STARTER MOTOR

E-4: FUSIBLE LINK (D-12)

B S

20B

R-1: BATTERY RELAY

POSITION

11 WY

R-8: CHARGE INDICATOR RELAY

6 WG

BAT P

11 WY 81 GW 6 WG

‚P

IG IC REG

R-2: SAFETY RELAY

7 2RB

ACC

ENGINE

E-13: BATTERY 20B

8 2R 71 3Y 7 2RB 72 L TERMINAL

Applicable Machines: SK30SR-2 PW08-20001~ SK35SR-2 PX09-08001~

INST-PANEL AND RELAY ASSY

9 8R

10A

30A

10A

30A

WY 1 RADIO, HEATER, WIPER 1.25 YB 2 RELAY, SOL. YG 3 WORK LIGHT 1.25 2RG 4 HORN, ROOM LAMP 2W 5 TIMER, RELAY WG 6 CLUSTER GAUGE

2. ELECTRIC CIRCUIT DIAGRAM 2A. ELECTRIC CIRCUIT DIAGRAM (1/3)

47 3L

E 2B 5 W 70 2GR

E-8: AIR HEATER

72 L

E-2: GENERATOR

13 BW 1.25

SW-1: KEY SW. 5 5 15 16

5 2W

5 W

(D-2)

W 2W YG RW

R-7: ENG. STOP RELAY

TO (2/2)

‚a

4 RG

POSITION

‚a

1 WY

(D-1) E-3: HORN

4 1

20A 4 1.25RG

‚a

TERMINAL

E-15: FUSE

L-1: ROOM LAMP (FOR CAB)

E-10: RADIO (FOR CAB)

O L H F F O I

POSITION TERMINAL

M BLOWER MOTOR R-10: CONDENSER SPEED SHIFT RELAY SW-16: CONDENSER SPEED SHIFT SW.

SV-5: POWER SHIFT SOL. 90 RW

19 LB

W W A O O A S F S H H E F N E R R

89 1.25RL 1 LR

18 LY

‚a

R-13: COOLER RELAY

‚a

SW-4: WIPER WASHER SW. (FOR CAB)

COOLER (FOR CAB)

17 PB SW-7: HORN SW.

SW-10: HEATER SW.

SV-3: ENG. STOP SOL.

(D-3)

R-6: TIMER UNIT

4 RG

1 WY

HOLD PULL

E-16: COOLING UNIT

1 WY M-2: WIPER MOTOR (FOR CAB) 20 G

22 Br

21 WB

1 WY

E-15: FUSE M

20A 4 1.25RG

M SW-15: HI. LOW PRESS. SW.

E-18: COMPRESSOR

91 1.25 O

‚a L

E-17: CONDENSER MOTOR

R-11: CONDENSER RELAY

‚a E-12: HEATER

STANDARDS OF WIRE COLOR ELECTRIC POWER SOURCE CIRCUIT

TO (2/2)

‚a M M-3: WASHER MOTOR (FOR CAB)

POWER AND CONTROL CIRCUIT EARTH CIRCUIT

23-1-3

2A. ELECTRIC CIRCUIT DIAGRAM (2/3) Applicable Machines: SK30SR-2 PW08-20001~ SK35SR-2 PX09-08001~

INST-PANEL AND RELAY ASSY

E-6: CLUSTER GAUGE

R-9: OPT WORK LIGHT RELAY

FROM (1/2) SW-2: WORKING LIGHT SW. 86 LgR

3 YG 2 YB

ENGINE FROM (1/2)

‚a L-2: BOOM WORKING LIGHT LEFT

SW-8: LEVER LOCK SW. (RIGHT)

SW-9: LEVER LOCK SW. (LEFT) 4 10 PL R24, R25: (USA STD) NIBBLER OPEN ¥ CLOSE RELAY 39 GW

60 GY 64 LW

A P1

3 YG

63 BY

M-4: DECEL MOTOR

OPT.

50 GW 52 YR

60 GY

91 L 6

6 WG 1

HOLD

2 61 LB 4 45 BW

HOLD

3 43 Lg 5 46 WB

‚a 6

‚a

2 SW-11: DECEL SW. 2 YB

SV-2: TWO-SPEED SELECT SOL ‚a

SW-3: TWO-SPEED SELECT SW.

OCEANIA STD•iEU OPT•j

E-6: CLUSTER GAUGE TWO-SPEED

LB 7 57 GB 58 6

EMPTY ENG. WATER TEMP.

CHARGE 0000

2 86 LgR

2 3

HOUR METER

(D-5)

SW-26 : TRAVEL LEFT (FORWARD) PRESS. SW. ‚a

48 LgB 6

81 GW ‚P R-8: CHARGE INDICATOR RELAY

SW-27 : TRAVEL LEFT (BACKWARD) PRESS. SW.

E-2: GENERATOR

THERMO METER 20 52 YR ILLUMINATION ‚a 15

E-20: TRAVEL ALARM

SW-25 : TRAVEL RIGHT (BACKWARD) PRESS. SW.

50 GW

P 17 49 YB 56 14

FUEL METER

SW-23: SW-24: TRAVEL ALARM SELECT SW. TRAVEL RIGHT (FORWARD) PRESS. SW. 54 PL 55 YL WY ‚a

YG 4 51

ENG. OIL PRESS.

SW-5: ENG. WATER TEMP. SW. SW-6: ENG. OIL PRESS. SW. SE-2: COOLANT THERMO SENSOR SW-12: AIR FILTER RESTRICTION SW. USA STD

51 YG

R-3: DECEL RELAY E-14: SEQUENCE BOX

‚a

SV-1: OPERATING LEVER LOCK SOL.

63 BY 64 LW

(USA OPT)

‚a

SW-2: WORKING LIGHT SW.

SE-1: FUEL SENSOR 1

AIR FILTER RESTRICTION 9

54 PL

SW-24: TRAVEL RIGHT (FORWARD) PRESS. SW. 55 YL ‚a

E-20: TRAVEL ALARM

SW-25: TRAVEL RIGHT (BACKWARD) PRESS. SW. SW-26: TRAVEL LEFT (FORWARD) PRESS. SW. SW-27: TRAVEL LEFT (BACKWARD) PRESS. SW. (OPT)

EU STD

3 1.25YG 3 86 LgR SW-2: WORKING LIGHT SW.

23-1-4

R-9: OPT. WORK LIGHT RELAY 87 1.25BrR ‚a

(OPT) ‚a ‚a

(D-7)

L-3: CAB WORKING LIGHT L-4: CAB WORKING LIGHT

1 ‚a

M-6: FUEL PUMP (AUTO AIR BLEED)

SOCKET E-7: POWER SOCKET

‚a

2A. ELECTRIC CIRCUIT DIAGRAM (3/3) Applicable Machines: SK30SR-2 PW08-20001~ SK35SR-2 PX09-08001~

USA STD

[

SK30SR-2 : PW08-20995~ SK35SR-2 : PX09-08585~

Applicable Machines

SW-9: LEVER LOCK SW. (LEFT)

]

R-24: 112 WR NIBBLER OPEN RELAY 108 LW

SW-33: NIBBLER OPEN SW. ‚a

110

‚a

SV-9: NIBBLER OPEN SOL.

113 OW 109 LO SW-34: NIBBLER CLOSE SW. ‚a

111

R-25: NIBBLER CLOSE RELAY

‚a

SV-10: NIBBLER CLOSE SOL.

USA STD

SW-28: SLEW / SWING R-22: SW. SELECT RELAY SELECT SW. 3 YG SW-31: SLEW / SWING LEVER PRESS. SW. RIGHT SW-30: SLEW / SWING LEVER PRESS. SW. LEFT

105 LG

106 W ‚a

R-14: SLEW / SWING SELECT RELAY ‚a

101 GW

107 WR

SV-12: SLEW / SWING SELECT SOL. ‚a

D-13:

‚a 100 Lg R-23: SLEW / SWING PRESERVATION RELAY

23-1-4A

2B. ELECTRIC CIRCUIT DIAGRAM (1/3) Applicable Machines: SK30SR-2 PW08-20001~ SK35SR-2 PX09-08001~

20B 6

E-1 FUSE BOX

R-1: BATTERY RELAY 14 2WR

8 3R

8 5R

47 3LY

13BW 1.25

S H O T E O A F A N R F T T

47 3LY

R-8: CHARGE INDICATOR RELAY

6 WG

BAT P

11 WY 81 O 6 WG

‚P

IG IC REG

R-2: SAFETY RELAY

47 3LY

13 BW 1.25

E 2B 5 W 70 2BR

(D-14)

SW-1: KEY SW. 5 5 15 16

5 2W

5 W

(D-2)

W 2W YG RW

TO (2/2)

‚a

POSITION

‚a

1 WY

(D-1) E-3: HORN

E-15: FUSE

L-1: ROOM LAMP (FOR CAB) 4 1

20A 4 1.25RG

‚a

TERMINAL

COOLER (FOR CAB)

17 PB SW-7: HORN SW.

E-10: RADIO (FOR CAB)

O L H F F O I

POSITION TERMINAL

M BLOWER MOTOR R-10: CONDENSER SPEED SHIFT RELAY SW-16: CONDENSER SPEED SHIFT SW.

SV-5: POWER SHIFT SOL. 90 RW

19 LB

W W A O O A S F S H H E F N E R R

89 1.25RL 1 WY

18 LY

‚a

R-13: COOLER RELAY

‚a

SW-4: WIPER WASHER SW. (FOR CAB)

SV-3: ENG. STOP SOL.

(D-3)

R-6: TIMER UNIT

4 RG

SW-10: HEATER SW.

HOLD PULL

R-7: ENG. STOP RELAY

4 RG

1 WY

E-2: GENERATOR (40A)

E-8: AIR HEATER

72 L

M-2: WIPER MOTOR (FOR CAB) 20 G

22 Br

21 WB

1 WY

E-15: FUSE M

20A 4 1.25RG

M SW-15: HI. LOW PRESS. SW.

E-18: COMPRESSOR

92 1.25 O

‚a L

E-17: CONDENSER MOTOR

R-11: CONDENSER RELAY

E-16: COOLING UNIT

1 WY

‚a E-12: HEATER

STANDARDS OF WIRE COLOR ELECTRIC POWER SOURCE CIRCUIT

TO (2/2)

23-1-4B

9 5R

11 WY

7 2RB

ACC

14 2WR

8 5R B C

M-1: STARTER MOTOR

E-4: FUSIBLE LINK (D-12)

POSITION

B S

20B

6 WG

8 2R 71 3Y 7 2RB 72 L TERMINAL

ENGINE E-13: BATTERY

9 5R

10A

30A

10A

30A

RADIO, HEATER WY 1 WIPER 1.25 YB 2 RELAY, SOL. 2YG 3 WORK LIGHT 1.25 2RG HORN 4 ROOM LAMP 2W 5 TIMER, RELAY WG 6 CLUSTER GAUGE

INST-PANEL AND RELAY ASSY

‚a M M-3: WASHER MOTOR (FOR CAB)

POWER AND CONTROL CIRCUIT EARTH CIRCUIT

2B. ELECTRIC CIRCUIT DIAGRAM (2/3) Applicable Machines: SK30SR-2 PW08-20001~ SK35SR-2 PX09-08001~

INST-PANEL AND RELAY ASSY

E-6: CLUSTER GAUGE

R-9: OPT WORK LIGHT RELAY

FROM (1/2)

‚n ‚m

‚n ‚e ‚e

POSITION TERMINAL

SW-2: WORKING LIGHT SW.

E L

86 LgR

FROM (1/2)

‚a L-2: BOOM WORKING LIGHT LEFT (55W)

SW-9: LEVER LOCK SW. 4

3 YG 2 YB

ENGINE

R24, R25: (USA STD) NIBBLER OPEN ¥ CLOSE RELAY 39 GW

60 GY 64 LW

A P1

3 YG

63 BY

M-4: DECEL MOTOR

OPT.

50 GW 52 YR

60 GY

91 L 6

6 WG 1

HOLD

2 61 LB 4 45 BW

HOLD

3 43 Lg 5 46 WB

‚a 6

‚a

2 SW-11: DECEL SW. 2 YB

SV-2: TWO-SPEED SELECT SOL ‚a

SW-3: TWO-SPEED SELECT SW.

OCEANIA STD•iEU OPT•j

E-6: CLUSTER GAUGE 5

TWO-SPEED

LB 7 57 GB 58 6

EMPTY ENG. WATER TEMP.

CHARGE 0000 13 2 86 LgR

SW-23: SW-24: TRAVEL ALARM SELECT SW. TRAVEL RIGHT (FORWARD) PRESS. SW. 54 PL 55 YL WY ‚a

(D-4)

2 3

HOUR METER

SW-26 : TRAVEL LEFT (FORWARD) PRESS. SW.

50 GW ‚a

48 LgB

P 17 49 YB 56 14

FUEL METER

E-20: TRAVEL ALARM

SW-25 : TRAVEL RIGHT (BACKWARD) PRESS. SW.

YG 4 51

ENG. OIL PRESS.

SW-5: ENG. WATER TEMP. SW. SW-6: ENG. OIL PRESS. SW. SE-2: COOLANT THERMO SENSOR SW-12: AIR FILTER RESTRICTION SW. USA STD

51 YG

R-3: DECEL RELAY E-14: SEQUENCE BOX

‚a

SV-1: OPERATING LEVER LOCK SOL.

63 BY 64 LW

81 O

‚P

R-8: CHARGE INDICATOR RELAY

SW-27 : TRAVEL LEFT (BACKWARD) PRESS. SW.

E-2: GENERATOR

THERMO METER 20 52 YR ILLUMINATION ‚a 15

(USA OPT)

‚a

SW-2: WORKING LIGHT SW.

SE-1: FUEL SENSOR 1

AIR FILTER RESTRICTION 9 91 L

54 PL

SW-24: TRAVEL RIGHT (FORWARD) PRESS. SW. 55 YL ‚a

E-20: TRAVEL ALARM

SW-25: TRAVEL RIGHT (BACKWARD) PRESS. SW. SW-26: TRAVEL LEFT (FORWARD) PRESS. SW. SW-27: TRAVEL LEFT (BACKWARD) PRESS. SW. (OPT)

EU STD

3 1.25YG 3 86 LgR SW-2: WORKING LIGHT SW.

R-9: OPT. WORK LIGHT RELAY 87 1.25BrR ‚a

(OPT) ‚a ‚a

L-3: CAB WORKING LIGHT L-4: CAB WORKING LIGHT

1 ‚a

M-6: FUEL PUMP (AUTO AIR BLEED)

SOCKET E-7: POWER SOCKET

‚a

23-1-4C

2B. ELECTRIC CIRCUIT DIAGRAM (3/3) Applicable Machines: SK30SR-2 PW08-20001~ SK35SR-2 PX09-08001~

USA STD SW-9: LEVER LOCK SW. (LEFT)

R-24: 112 WR NIBBLER OPEN RELAY 108 LW

SW-33: NIBBLER OPEN SW. ‚a

110

‚a

SV-9: NIBBLER OPEN SOL.

113 OW 109 LO SW-34: NIBBLER CLOSE SW. ‚a

111

R-25: NIBBLER CLOSE RELAY

‚a

SV-10: NIBBLER CLOSE SOL.

USA STD

SW-28: SLEW / SWING R-22: SW. SELECT RELAY SELECT SW. 3 YG SW-31: SLEW / SWING LEVER PRESS. SW. RIGHT SW-30: SLEW / SWING LEVER PRESS. SW. LEFT

23-1-4D

105 LG

106 W ‚a

R-14: SLEW / SWING SELECT RELAY ‚a

101 GW

107 WR ‚a 100 Lg R-23: SLEW / SWING PRESERVATION RELAY

D-13:

SV-12: SLEW / SWING SELECT SOL. ‚a

3. ELECTRICAL EQUIPMENT & HARNESS

[ Applicable Machines

3.1 ELECTRICAL EQUIPMENT LIST

E-1 E-2

Electical Fittings

E-3 E-4 E-6 E-7 E-8 E-10 E-12 E-13 E-14 E-15 E-20

Light

L-1 L-2 L-3 L-4 M-1

Motor

M-2 M-3 M-4 M-6

Relay

R-1 R-2 R-3 R-6 R-7 R-8 R-9 R14 R-22 R-23 [R-24] [R-25]

Group Code

2475U38

YN02D01001P1 2475U38

[USA] YN02D01001P1 2475R132 EU•USA PM73E00004F6 FUSE BOX OCE PM73E00004F3 GENERATOR E/G accessory (ALTERNATOR) (119836-77201) HORN PH53S00001P1 FUSIBLE LINK PH73S0001P1 EU•OCE PM59S00002F2 GAUGE CLUSTER USA PV59S00001F2 POWER SOCKET [EU] YN81S00001P1 AIR HEATER E/G accessory (129120-77501) RADIO (OPT) Cab accessory (PY54S00001P1) HEATER (OPT) PM21M00005F1 BATTERY PU72S00001P1 SEQUENCE BOX PA24S00002P3 FUSE BOX (OPT) PH73E00004F1 (FOR COOLER) TRAVEL ALARM PM50S00001S001 [OCEANIA] ROOM LAMP Cab accessory (2456U114) BOOM WORKING LIGHT (LH) 2456R243F2 CAB WORKING LIGHT (OPT) PY80S00002F1 CAB WORKING LIGHT (OPT) STARTER MOTOR E/G accessory (129698-77010) WIPER MOTOR Cab accessory (YJ76S00001P1) WASHER MOTOR PE54C00002S002 DECELERATION MOTOR [PM20S00001F1] [EU•USA] (OCE:OPT) PM20S00004F1 FUEL PUMP (OPT) PM22P0001P1 (AUTO AIR BLEED) BATTERY RELAY PH24S00001P1 SAFETY RELAY PH24S00002P1 DECELERATION PM24S00001P1 RELAY (OPT) TIMER UNIT PH25S00002P1 E/G STOP RELAY PH24S00001P1 CHARRGE INDICATOR PA24E01001P1 RELAY OPT. WORK LIGHT RELAY PM24S00001P1 SLEW / SWING PA24E01001P1 SELECT RELAY [USA] S.W. SELECT RELAY [USA] PM24S00001P1 SLEW/SWING PRESERVATION RELAY [USA] NIBBLER OPEN RELAY [USA] NIBBLER CLOSE RELAY [USA] PA24E01001P1

Sensor

DIODE DIODE DIODE DIODE DIODE DIODE DIODE DIODE

Part No.

SE-1 SE-2

]

Part Name FUEL SENSOR ENGINE THERMO SENSOR

Part No. PW52S00002P2 PA24S00003P1

PH35V00001F2 LEVER LOOK SOL. 2-SPEED SELECT SOL. E/G STOP SOL. E/G accessory (119233-77931) SV-5 POWER SHIFT SOL. YJ35V00004F1 (Cooler Spec) [SV-9] NIBBLER OPEN SOL. [USA] PY35V00005F1 [SV-10] NIBBLER CLOSE SOL. [USA] SV-12 SLEW / SWING PE35V00001F1 SELECT SOL. [USA] SV-1 SV-2 SV-3

Solenoid

D-1 D-2 D-3 D-5 D-7 D-12 D-13 D-14

Part Name

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

Switch

Diode

Group Code

SK30SR-2 : PW08-20001~ SK35SR-2 : PX09-08001~

SW-23 SW-24 SW-25 SW-26 SW-27 SW-28 SW-30 SW-31 [SW-33] [SW-34]

KEY SWITCH WORKING LIGHT SW. 2-SPEED SELECT SW. WIPER WASHER SW. E/G COOLANT TEMP. SW. E/G OIL PRESSURE SW.

PM50E00001F1 PV24E01001P1 YN03M01286S002 PY50S00004P1 PM50S00006P1 E/G accessory (114250-39450) EU•OCE YN50E01001P1 . HORN SW . USA LF03M01005F1 LEVER LOCK SW. (RH) EU•OCE PA50S00001P1 LEVER LOCK SW. (LH) HEATER SW. (OPT) PY50S00003P1 DECELERATION SW. PM50S00005P1 AIR FILTER CLOGGING YR11P00008S005 SW. [USA] TRAVEL ALARM SELECT SW. 2479U1190F16 [OCEANIA] TRAVEL RIGHT (FORWARD) GB50S00049F1 PRESSURE SW. [OCEANIA] TRAVEL RIGHT (BACKWARD) PRESSURE SW. [OCEANIA] TRAVEL LEFT (FORWARD) PRESSURE SW. [OCEANIA] TRAVEL LEFT (BACKWARD) PRESSURE SW. [OCEANIA] SLEW / SWING LF03M01005F3 SELECT SW. [USA] SLEW / SWING LEVER GB50S00049F1 PRESS. SW. (LH)[USA] SLEW / SWING LEVER PRESS. SW. (RH)[USA] NIBBLER OPEN SW. [USA] LF03M01005F3 NIBBLER CLOSE SW. [USA]

(Note) • The Code Nos. in [ ] are applicable for the following Machine Nos. SK30SR-2 : PW08-20995~ SK35SR-2 : PX09-08585~ • The Part Nos. before the improvement / change are put in [ ].

23-1-5

3.2 HARNESS & CABLE LIST

Code

Name

Remark

Part No. [PW13E01028P3]

H-1

EU & OCEANIA

PW13E01028P4

Main Harness

[PW13E01028P3, P4] PW13E01036P1 [PW11E01009P2]

*1 *2

USA For Hand Control EU

PW11E01009P3 H-2

[PW11E01012P2, P3, P4]

Instrument Panel Harness

PW11E01019P1 PW11E01005P4

*1 *2

USA For Hand Control OCEANIA

PW16E01004P3

EU & OCEANIA

PW16E01005P1

USA

H-3

Engine Harness

H-4

Battery Cable +

PW13E01030P1

H-5

Battery Earth Cable -

PW13E01024D1

H-6

Engine Earth Cable

PM13E01056D4

H-7

Boom Harness

H-8

Key Switch Harness

PM50E01003P1

H-9

Auto Air Bleed Harness

PW13E01029P1

(OPT)

H-10

Connection Harness with Cab

PW11E01010P1

(EU & USA :OPT)

PW11E01006P2

OCEANIA

H-11

Cab Harness

PM02C01046P1

(OPT)

H-12

Slew / Swing Solenoid Harness PW11E01011P2

H-13

Travel Alarm Harness

PW13E01032P1

OCEANIA (EU & USA : OPT)

H-14

Travel Alarm Switch Harness

PM13E01063P2

OCEANIA (EU : OPT)

PM15E01002D8

SK30SR-2

PM15E01002D4

SK35SR-2

USA

(Note) • The Part Nos. before the improvement / change are put in [ ]. • The Part Nos. with the mark 1 or 2 are applicable for the following Machine Nos. 1 SK30SR-2 : PW08-20001~20994 SK35SR-2 : PX09-08001~08584 2 SK30SR-2 : PW08-20995~ SK35SR-2 : PX09-08585~

23-1-6

3.3 ELECTRICAL EQUIPMENT & HARNESS CONNECTION DRAWING

23-1-7

3.4 COMPONENTS & HARNESS ARRANGEMENT 3.4.1 Upper Frame Portion (1/4)

23-1-8

3.4.1 Upper Frame Portion (2/4)

23-1-9

3.4.1 Upper Frame Portion (3/4)

23-1-10

3.4.1 Upper Frame Portion (4/4) â&#x20AC;¢ for USA (Hand Control : Nibbler & Slew / Swing) Applicable Machines SK30SR-2 : PW08-20995~ SK35SR-2 : PX09-08585~

23-1-10-(1)

NOTES

23-1-10-(2)

NOTES

3.4.2 Engine Portion

23-1-11

3.4.3 Instrument Panel Portion

23-1-12

3.4.4 Fuel Tank Portion

3.4.5 Attachment Portion

SE-1 ; FUEL SENSOR FUEL TANK

23-1-13

3.4.6 Cab Portion (OPT)

3.4.7 Travel Alarm Portion (1/2) [OCEANIA] (EU & USA : OPT)

(Note) PRESSURE SWITCH • APPLY SEAL TAPE THE SCREW • TIGHTENING TORQUE 2.2 kgf • m (16 lbf • ft)

23-1-13-(1)

3.4.7 Travel Alarm Portion (2/2) [OCEANIA] (EU â&#x20AC;¢ USA OPT)

23-1-13-(2)

3.5 DETAIL HARNESS & CABLE

BEFORE CHANGES FOR IMPROVEMENT MAIN HARNESS CONNECTION TABLE

3.5.1A Main Harness : (No. H-1)

MAIN HARNESS CONNECTION TABLE

CONNECTORS SELECTION TABLE

(Note) • This diagram shows the harness connections after the changes for improvement. (The changed portions are shown in a separate box as “Before changes for improvement.”) Aplicable machine numbers to the changes for improvement : SK30SR-2 : PW08-20607~ SK35SR-2 : PX09-08358~

23-1-14

3.5.1B Main Harness : (No. H-1) â&#x20AC;¢ for USA (Hand Control Type) Applicable Machines SK30SR-2 : PW08-20995~ SK35SR-2 : PX09-08585~

23-1-14-(1)

NOTES

23-1-14-(2)

NOTES

3.5.2 (A) Instrument Panel Harness (No. H-2) ----- (1/2) for EU

23-1-15

3.5.2 (A) Instrument Panel Harness (No. H-2) ----- (2/2) for EU

23-1-16

3.5.2 (A) Instrument Panel Harness (No. H-2) for EU

CONNECTORS SELECTION TABLE

INSTRUMENT PANEL HARNESS CONNECTION TABLE

(Note) • This table shows the conditions after the changes for improvement. • The tables before the changes for improvement are shown in the below as Å¶1, Å¶2 and Å¶3.

23-1-17

3.5.2 (B) Instrument Panel Harness (No. H-2) ----- (1/2) • for USA Applicable Machines SK30SR-2 : PW08-20001~20994 SK35SR-2 : PX09-08001~08584

23-1-18

3.5.2 (B) Instrument Panel Harness (No. H-2) ----- (2/2) • for USA Applicable Machines SK30SR-2 : PW08-20001~20994 SK35SR-2 : PX09-08001~08584

23-1-19

3.5.2 (B) Instrument Panel Harness (No. H-2) • for USA Applicable Machines SK30SR-2 : PW08-20001~20994 SK35SR-2 : PX09-08001~08584

CONNECTORS SELECTION TABLE

INSTRUMENT PANEL HARNESS CONNECTION TABLE

(Note) • This table shows the conditions after the changes for improvement. • The tables before the changes for improvement are shown in the below as Å¶1, Å¶2 and Å¶3.

23-1-19-(1)

3.5.2 (C) Instrument Panel Harness (No. H-2) ----- (1/2) â&#x20AC;¢ for USA (Hand Control Type) Applicable Machines SK30SR-2 : PW08-20995~ SK35SR-2 : PX09-08585~

23-1-19-(2)

3.5.2 (C) Instrument Panel Harness (No. H-2) ----- (2/2) â&#x20AC;¢ for USA (Hand Control Type) Applicable Machines SK30SR-2 : PW08-20995~ SK35SR-2 : PX09-08585~

23-1-19-(3)

3.5.2 (C) Instrument Panel Harness (No. H-2) â&#x20AC;¢ for USA (Hand Control Type) Applicable Machines SK30SR-2 : PW08-20995~ SK35SR-2 : PX09-08585~ INSTRUMENT PANEL HARNESS CONNECTION TABLE

CONNECTORS SELECTION TABLE

23-1-19-(4)

3.5.2 (D) Instrument Panel Harness (No. H-2) ----- (1/2) for OCEANIA

23-1-20-(1)

3.5.2 (D) Instrument Panel Harness (No. H-2) ----- (2/2) for OCEANIA

23-1-20-(2)

3.5.2 (D) Instrument Panel Harness (No. H-2) for OCEANIA

23-1-20-(3)

INSTRUMENT PANEL HARNESS CONNECTION TABLE

CONNECTORS SELECTION TABLE

3.5.3 (A) Engine Harness (No. H-3) [EU & OCEANIA]

HARNESS CONNECTION TABLE

CONNECTORS SELECTION TABLE

23-1-21

3.5.3 (A) Engine Harness (No. H-3) [USA]

HARNESS CONNECTION TABLE

23-1-22

CONNECTORS SELECTION TABLE

3.5.4 Battery Cable + (No. H-4)

3.5.7 Boom Harness (No. H-7)

3.5.5 Battery Earth Cable - (No. H-5)

3.5.8 Key Switch Harness (No. H-8)

3.5.6 Engine Earth Cable (No. H-6)

23-1-23

3.5.9 Auto Air Bleed Harness (No. H-9) (OPT.)

3.5.10 (B) Connection Harness with Cab (No. H-10) (OPT.) for OCEANIA

3.5.10 (A) Connection Harness with Cab (No. H-10) (OPT.) for EU & USA

HARNESS CONNECTION TABLE

CONNECTORS SELECTION TABLE HARNESS CONNECTION TABLE

CONNECTORS SELECTION TABLE

23-1-24

3.5.11 Cab Harness (No. H-11) (OPT.) Body GND LA108

Working light CB104

CA104

Washer motor CN2-F

3.5.12 Slew/Swing Solenoid Harness (No. H-12) [USA]

* *

Wiper motor CN3-F

Cooler CN8-F

Room light CB104

Main harness CN1-M

After insulation taping is applied, fix the marked harness to main harness with clip.

CONNECTORS SELECTION TABLE

23-1-25

3.5.13 Travel Alarm Harness (No. H-13) [OCEANIA]

3.5.14 Travel Alarm Switch Harness (No. H-14) [OCEANIA]

CONNECTORS SELECTION TABLE

HARNESS CONNECTION TABLE

23-1-26

4. ELECTRICAL EQUIPMENT & HARNESS

[ Applicable Machines

4.1 ELECTRICAL EQUIPMENT LIST

E-1 E-2

PM73E00004F6 E/G accessory (119836-77201) PH53S00001P1 PH73S0001P1 EU•OCE PM59S00002F2 GAUGE CLUSTER USA PV59S00001F2 POWER SOCKET [EU] PF81S01001P1 AIR HEATER E/G accessory (129120-77501) RADIO (OPT) Cab accessory (PY54S00001P1) HEATER (OPT) PM21M00005F1 BATTERY PU72S00001P1 SEQUENCE BOX PA24S00002P3 FUSE BOX (OPT) PH73E00004F1 (FOR COOLER) TRAVEL ALARM PM50S00001S001 [OCEANIA] ROOM LAMP Cab accessory (PM80S00006P1) BOOM WORKING LIGHT (LH) PM80S00005F1 CAB WORKING LIGHT (OPT) PY80S00002F1 CAB WORKING LIGHT (OPT) STARTER MOTOR E/G accessory (129698-77010) WIPER MOTOR Cab accessory (PM76S00001F1) PE54C00002S002 WASHER MOTOR DECELERATION MOTOR PW20S00005F1 [EU•USA] (OCE:OPT) FUEL PUMP (OPT) PM22P0001P1 (AUTO AIR BLEED) BATTERY RELAY PH24S00001P1 SAFETY RELAY PH24S00002P1 DECELERATION PM24S00001P1 RELAY (OPT) TIMER UNIT PH25S00002P1 E/G STOP RELAY PH24S00001P1 CHARRGE INDICATOR PA24E01001P1 RELAY OPT. WORK LIGHT RELAY PM24S00001P1 SLEW / SWING PA24E01001P1 SELECT RELAY [USA] S.W. SELECT RELAY [USA] PM24S00001P1 SLEW/SWING PRESERPA24E01001P1 VATION RELAY [USA] NIBBLER OPEN RELAY [USA] PM24S00001P1 NIBBLER CLOSE RELAY [USA] PA24E01001P1

Electical Fittings

E-6 E-7 E-8 E-10 E-12 E-13 E-14 E-15

Light

L-1 L-2 L-3 L-4 M-1 M-2 M-3 M-4 M-6 R-1 R-2 R-3 R-6 R-7 R-8 R-9 R14 R-22 R-23 R-24 R-25

2475U38

YN02D01001P1

]

Part Name

Part No.

SE-1 SE-2

FUEL SENSOR ENGINE THERMO SENSOR

PW52S00002P2 PA24S00003P1

SV-1 SV-2 SV-3

LEVER LOOK SOL. PH35V00001F2 2-SPEED SELECT SOL. E/G STOP SOL. E/G accessory (119233-77931) POWER SHIFT SOL. YJ35V00004F1 (Cooler Spec) NIBBLER OPEN SOL. [USA] PY35V00005F1 NIBBLER CLOSE SOL. [USA] SLEW / SWING PE35V00001F1 SELECT SOL. [USA]

[USA] YN02D01001P1

Solenoid

FUSE BOX GENERATOR (ALTERNATOR) HORN FUSIBLE LINK

Group Code Sensor

DIODE DIODE DIODE DIODE DIODE DIODE DIODE

E-20

Motor

Part No.

D-1 D-2 D-3 D-4 D-12 D-13 D-14

E-3 E-4

Relay

Part Name

SV-5 SV-9 SV-10 SV-12

SW-1 SW-2 SW-3 SW-4 SW-5 SW-6 SW-7 SW-9 SW-10 SW-11 SW-12

Switch

Diode

Group Code

SK30SR-2 : PW10-22001~ SK35SR-2 : PX11-08901~

23-1-27

SW-23 SW-24 SW-25 SW-26 SW-27 SW-28 SW-30 SW-31 SW-33 SW-34

KEY SWITCH WORKING LIGHT SW. 2-SPEED SELECT SW. WIPER WASHER SW. E/G COOLANT TEMP. SW. E/G OIL PRESSURE SW.

PH50S00007S001 PV24E01001P1 YN03M01286S002 PY50S00004P1 PM50S00006P1 E/G accessory (114250-39450) EU•OCE YN50E01001P1 . HORN SW . USA LF03M01005F1 LEVER LOCK SW. (LH) PA50S00001P1 HEATER SW. (OPT) PY50S00003P1 DECELERATION SW. PM50S00005P1 EU•OCE 2446U336S8 AIR FILTER CLOGGING SW. USA YR11P00008S005 TRAVEL ALARM SELECT SW. G2479U1190F16 [OCEANIA] TRAVEL RIGHT (FORWARD) GB50S00049F1 PRESSURE SW. [OCEANIA] TRAVEL RIGHT (BACKWARD) PRESSURE SW. [OCEANIA] TRAVEL LEFT (FORWARD) PRESSURE SW. [OCEANIA] TRAVEL LEFT (BACKWARD) PRESSURE SW. [OCEANIA] SLEW / SWING LF03M01005F3 SELECT SW. [USA] SLEW / SWING LEVER GB50S00049F1 PRESS. SW. (LH)[USA] SLEW / SWING LEVER PRESS. SW. (RH)[USA] NIBBLER OPEN SW. [USA] LF03M01005F3 NIBBLER CLOSE SW. [USA]

4.2 HARNESS & CABLE LIST

Code

H-1

Name

Instrument Panel & Main Harness

Remark

Part No. PW14E01007P1

PW14E01009P1

USA

PW14E01008P1

OCEANIA

PW16E01011P1

EU & OCEANIA

PW16E01012P1

USA

H-3

Engine Harness

H-4

Battery Cable +

PW13E01037P1

H-5

Battery Earth Cable -

PW13E01024D1

H-6

Engine Earth Cable

PM13E01056D4

H-7

Boom Harness

PM15E01007D3

Auto Air Bleed Harness

PW13E01029P1

(OPT)

PM13E01074D1

(OPT)

H-9A H-9B

Connection Harness with Auto Air Bleed

H-10

Connection Harness with Cab

PH14E01006P1

(OPT)

H-11

Cab Harness

PM02C01357P1

(OPT)

H-12

Radio Harness

PM02C01499P1

(OPT)

H-13

Travel Alarm Harness

PW13E01032P1

OCEANIA (EU & USA : OPT)

H-14

Travel Alarm Switch Harness

PM13E01063P2

OCEANIA (EU : OPT)

23-1-28

4.3 COMPONENTS & HARNESS ARRANGEMENT 4.3.1 Upper Frame Portion (1/6)

23-1-29

4.3.1 Upper Frame Portion (2/6)

23-1-30

4.3.1 Upper Frame Portion (3/6)

23-1-31

4.3.1 Upper Frame Portion (4/6)

23-1-32

4.3.1 Upper Frame Portion (5/6)

23-1-33

4.3.1 Upper Frame Portion (6/6) â&#x20AC;¢

for USA (Hand Control : Nibbler & Slew / Swing)

23-1-34

4.3.2 Engine Portion

(Note) TIGHTENING TORQUE : M12 : 14.6 kgf•m (106 lbf•ft) M10 : 6.5 kgf•m (47 lbf•ft) M8 : 3.6 kgf•m (26 lbf•ft)

23-1-35

4.3.3 Instrument Panel Portion (1/2)

23-1-36

4.3.3 Instrument Panel Portion (2/2)

23-1-37

4.3.4 Fuel Tank Portion

23-1-38

4.3.5 Attachment Portion

4.3.6 Auto Air Bleed Portion (OPT)

23-1-39

4.3.7 Cab Portion (OPT)

4.3.8 Travel Alarm Portion (1/2) [OCEANIA] (EU • USA OPT)

(Note) PRESSURE SWITCH • APPLY SEAL TAPE THE SCREW • TIGHTENING TORQUE 2.2 kgf • m (16 lbf • ft)

23-1-40

4.3.8 Travel Alarm Portion (2/2) [OCEANIA] (EU â&#x20AC;¢ USA OPT)

23-1-41

4.4 DETAIL HARNESS & CABLE 4.4.1 (A) Instrument Panel & Main Harness (No. H-1) ----- (1/3) for EU

23-1-42

4.4.1 (A) Instrument Panel & Main Harness (No. H-1) ----- (2/3) for EU

23-1-43

4.4.1 (A) Instrument Panel & Main Harness (No. H-1) ----- (3/3) for EU

23-1-44

4.4.1 (B) Instrument Panel & Main Harness (No. H-1) ----- (1/3) for USA

23-1-45

4.4.1 (B) Instrument Panel & Main Harness (No. H-1) ----- (2/3) for USA

23-1-46

4.4.1 (B) Instrument Panel & Main Harness (No. H-1) ----- (3/3) for USA

23-1-47

4.4 DETAIL HARNESS & CABLE 4.4.1 (C) Instrument Panel & Main Harness (No. H-1) ----- (1/3) for OCEANIA

23-1-48

4.4.1 (C) Instrument Panel & Main Harness (No. H-1) ----- (2/3) for OCEANIA

23-1-49

4.4.1 (C) Instrument Panel & Main Harness (No. H-1) ----- (3/3) for OCEANIA

23-1-50

4.4.2 (A) Engine Harness (No. H-13) [EU & OCEANIA]

23-1-51

4.4.2 (B) Engine Harness (No. H-3) [USA]

23-1-52

4.4.3 Battery Cable + (No. H-4)

4.4.6 Boom Harness (No. H-7)

4.4.4 Battery Earth Cable - (No. H-5)

4.4.7 Auto Air Bleed Harness (No. H-9A)(OPT.)

4.4.5 Engine Earth Cable (No. H-6)

23-1-53

4.4.8 Connection Harness with Auto Air Bleed (No. H-9B) (OPT.)

4.4.10 Cab Main Harness (No. H-11) (OPT.)

4.4.11 Radio Harness (No. H-12) (OPT.)

4.4.9 Connection Harness with Cab (No. H-10) (OPT.)

23-1-54

4.4.12 Travel Alarm Harness (No. H-13) [OCEANIA]

4.4.13 Travel Alarm Switch Harness (No. H-14) [OCEANIA]

CONNECTORS SELECTION TABLE

HARNESS CONNECTION TABLE

23-1-55

NOTES

23-1-56

NOTES

Book Code No.

PW24 02E ➁

NEW HOLLAND EH35 Model Cross-reference: SK35SR-2 is NEW HOLLAND Model EH35

COMPONENTS SYSTEM TABLE OF CONTENTS I . HYDRAULIC COMPONENTS 1. Hydraulic Pump ............................................................................... I -1-1 2. Pilot Valve for Attachment................................................................ I -2-1 3. Pilot Valve for Travel ........................................................................ I -3-1 4. Control Valve ................................................................................... I -4-1 5. Slewing Motor ................................................................................. I -5-1 6. Travel Motor .................................................................................... I -6-1 7. Swivel Joint ..................................................................................... I -7-1 8. Cylinder ........................................................................................... I -8-1 II. ELECTRICAL EQUIPMENT 2.1 Electrical Equipment List .............................................................. II -1-1 2.2 Specifications of Electrical Equipment .......................................... II -2-1

24 -0-1 ➁

PW24

Revision First edition First revision Second revision

Date of Issue January, 2001 November, 2001 December, 2002

Remarks S5PW2402E A S5PW2402E ➀ A S5PW2402E ➁ A

Any use of editorial or pictorial content is strictly prohibited without express written permission from New Holland Construction, LLC. Carol Stream, IL 60188 U.S.A. Copyright © 2003 New Holland Construction, LLC. All Rights Reserved.

24-0-2 ➁

1.1 SUMMARY (1) GENERAL VIEW

Part I : HYDRAULIC COMPONENTS 1. HYDRAULIC PUMP

Hydraulic ports No.. Ports name S1 Suction port A1,A2 Delivery port A3 Delivery port A4 Pilot delivery port A1G,A2G Gauge port R1 Air bleeder port (with breather valve) Z Pilot port for cooler mode (OPT)

Size SAE 11/2 PF 1/2 PF 1/2 PF 3/8 PF 1/8 M10X1.0 PF 1/4

Fig. 1-1 General view of hydraulic pump (2) SPECIFICATIONS

% 3 .#* / !" #" $

!" #" $

% % . / 1 . / . / '(+4 . / 4" ). 0 4" )/ 0 . 01 / 0 . 0 %/ 0 . 0 / %0 . 011/ 4 .(! 4 / 0 .10 / %0 . 0%/ 0 . 0 / %01. 0 / 0 . 0 / 0 . 0 / # ! , " ! ( " "" , $ , " $ + % ." / 0 '(. /

2 & "' ( " " ! ) "* + , - " * ! " ) & ($

24 -I -1-1

1.2 CONSTRUCTION • FUNCTION

Section

X–X

Fig. 1-2

No.

NAME

No.

NAME

Shaft assy

Gear pump assy

Hanger assy

Housing assy

Rotary group

Trochoid pump assy

Cover assy

Spring assy

(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 the delivery oil acts on the hanger, resists the spring force, and tilts the hanger. As the piston stroke is changed by the tilting of the hanger, the flow rate varies. • The 3rd pump or pilot pump is installed on the same shaft with a coupling.

24 -I-1 -2

(2) Operation 1) Pump operation

Fig. 1-3

• The cylinder block is fitted on the spline and rotates with the drive shaft. • The piston fitted on the cylinder block follows the sliding surface of the hanger and moves to and from. • 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) • 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) • By changing the tilting degree of the hanger(sliding surface), the displacement varies. • The oil sucked from the inside port of the cylinder block is delivered from the delivery port inside of the control valve. • The oil sucked from the outside port of the cylinder block is delivered from the delivery port outside of the control plate.

24 -I -1-3

(2) Control

Fig. 1-4

• The piston sliding on the surface of the hanger acts on the hanger through the hydraulic pressure due to the delivery oil pressure P1 and P2. • The spring is located in the form which is in opposition to the delivery oil pressure. • When the hydraulic pressure acting on the hanger through the piston goes below the setting load of the spring, the hanger is fixed at the maximum tilt angle. • When the hydraulic pressure acting on the hanger through the position exceeds the setting load of the spring, the hanger is tilted and held tilting at the position where the hydraulic pressure balances the spring pressure. (Control line, Area A) • The control line is shifted after the hydraulic pressure P3 acts on the shift piston. • When external hydraulic pressure Pz=35 kgf/cm2 (500 psi) acts on the Z port, it is shifted to the air conditioning (air-con.) mode. When the Z port is not in service, it is to be connected to the drain piping.

24 -I-1 -4

3) Adjusting procedure of set torque

Fig. 1-5

â&#x20AC;˘ Adjusting procedure (1) Loosen the hexagon nut. (2) Set the power line by tightening or loosening the adjusting screw.

24 -I -1-5

1.3 INNER CONSTRUCTION Refer to Fig 1-2regarding the whole pump (1) Drive shaft

Fig. 1-6

NAME No. 1 Shaft 4 Ring 5 Snap ring (for Shaft)

Q’TY No. 1 6 Key 1 7 Shim 1 8 Shim

NAME

Q’TY 1 1 1

(2) Hanger

8 2

Fig. 1-7

No. 1 2 3 4

NAME Hanger Guide (Suction) Bushing (Suction) Guide (Delivery)

NAME Q TY No. 1 5 Bushing (Delivery) 1 6 O-ring 1 7 Back-up ring 1 8 Plug

24 -I-1 -6

Q TY 1 1 1 1

(3) Rotary group

Fig. 1-8

No. 1 2 3 4

NAME Piston Cylinder block Retainer Guide

NAME Q TY No. 10 5 Spring 1 6 Parallel pin 1 7 Spring seat 1 8 Snap ring(for hole)

Q TY 1 3 1 1

(4) Control spring

Fig. 1-9

No. 1 2 3 4 5 6 7

NAME Spring seat Spring seat Cover Setscrew Spring Spring O-ring

NAME Q’TY No. 1 8 Capscrew 1 9 Nut 1 10 Spring 1 34 Shim (t 1.0) 1 44 Shim (t 0.5) 1 54 Shim (t 0.3) 1

24 -I -1-7

Q’TY 2 1 1 2 2 2

(5) Cover

Section Z-Z Fig. 1-10

No. 1 2 3 4 5 6

NAME Cover Control plate Parallel pin Capscrew Packing Plug

NAME Q’TY No. 1 7 Bearing 1 8 Plug 1 9 Capscrew 1 10 Plug 12 Orifice 1 14 Plug 2

24 -I-1 -8

NAME Q’TY No. 1 15 Bushing 2 16 Packing 3 17 Steel Ball 3 18 Plug 1 1

Q’TY 1 1 1 1

(6) Gear pump

Fig. 1-11

No. 3 4 5 6 7 11

NAME Housing Cover Gear Gear Side plate assy Guide

Q’TY No. 1 12 1 14 1 15 1 16 2 17 2 18

NAME Coupling O-ring O-ring Square ring Square ring O-ring

24 -I -1-9

Q’TY No. 19 1 20 2 40 1 41 1 2 1

NAME Capscrew Capscrew Plate Plate

Q’TY 2 4 1 1

(7) Housing

Section Y-Y

Section X-X

Fig. 1-12

No. 1 2 3 4 5 6 7 8 9

NAME Housing Oil seal Bearing Piston Parallel pin Disk spring O-ring O-ring Distance piece

Q’TY 1 1 1 1 1 5 2 1 1

No. 11 12 13 14 15 16 17 18 19

NAME Parallel pin Guide Piston Plug Sleeve Sleeve Sleeve Shim Shim

24 -I -1 -10

Q’TY No. NAME 1 20 Shim 1 21 Shim 1 22 Distance piece 1 23 Snap ring 1 24 O-ring 1 30 Shim 1 31 Shim 1 32 Shim 1

Q’TY 1 1 1 1 2 1 1 1

(8) Trochoid pump

9 5

Fig. 1-13

No. 1 2 3 4

NAME Gear Casing Side plate(A) O-ring

Q TY No. 1 5 1 7 1 8 1 9

NAME Spring pin Side plate(B) Spring pin Plate

24 -I-1 -11

Q TY 2 1 1 1

NOTES

2. PILOT VALVE (ATT) 2.1 SUMMARY (1) General view

SINGLE OPERATION ANGLE (PORT 2,4)

SINGLE OPERATION ANGLE (PORT 1,3)

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 4.2 ± 0.3 kgf·m (30 ± 2.2 lbf·ft)

6-PF1/4 T=3.0 ± 0.2kgf·m (21.7 ± 1.4 lbf·ft)

VIEW A

T=Tightening torque

(2) Specifications

SPECIFICATIONS PA30V00002F2 PV48M1032B 2 70 kgf / cm (1,000 psi) 15 L/min (4.0 gal / min) 1.6 kg (3.5 lb)

ITEM Parts number Model(Type) Max. primary pressure Rated flow Weight

Fig. 2-1

(3) Performance Characteristics

(435) 30.6 (299±21) 21±1.5 (290) 20.4 (145) 10.2 (78±11) 5.5±0.75

Secondary pressure 3.0

3.0 2.06±0.15

2.0

1.74 1.29

1.0 0.54

1.0

±0.07

0 0

40.8 (2.95)

4.0

3.43

0.54

1.1

2 4 6 6.5 7 Push rod stroke mm

Operation torque (N•m)

(498) 35

Secondary pressure (MPa)

Secondary pressure kgf/cm2(psi)

4.0

(580) 40.8

30.6 (2.21) 20.4 (1.48) 18.9 (1.29) 10.4 (0.95)

10.2 (0.74) 5.5 (0.40)

Operation torque kgf•cm (lbf•ft)

Single operation torque

PORT 1,3

5 10 15 19 Operation angle (deg.)

(498) 35

(435) 30.6 (299±21) 21±1.5

(290) 20.4 (145) 10.2 (78±11) 5.5±0.75 0

Fig. 2-2

4.0

40.8 (2.95)

3.0

30.6 (2.21)

2.06±0.15

2.16

25.0 (1.60)

2.0

20.4 (1.48)

1.69

20.2 (1.25)

Single operation torque 3.43

10.8 (1.25)

1.0

1.0 0.54

0.78

±0.07

0 0

1.1

Secondary pressure

4 6 8 8.5 9.4 Push rod stroke mm

5 10 15 20 Operation angle (deg.)

24 -I -2-1

10.2 (0.74) 8.0 (0.58)

Operation torque kgf•cm (lbf•ft)

4.0 Secondary pressure (MPa)

Secondary pressure kgf/cm2(psi)

PORT 2,4 (580) 40.8

2.2 CONSTRUCTION

APPLY LOCTITE #277 (PART OF SLANT LINE) APPLY GREASE ON TOP

APPLY GREASE ON TOP

RIGHT PILOT VALVE

SECONDARY PRESSURE ADJUSTING SHIMS

NOT TO BE REUSED PORT 2,4

PORT 1,3

PORT NO.

OPERATION

1 2 3 4

BUCKET DIGGING BOOM LOWERING BUCKET DUMP BOOM RAISING

LEFT PILOT VALVE PORT NO.

OPERATION

1 2 3 4

SLEWING LEFT ARM OUT SLEWING RIGHT ARM IN

Fig. 2-3 Pilot valve-Sectional view

No. 101 111 121 122 125 126 131 151 201-1

NAME CASING PORT PLATE SEAL WASHER O-RING SOCKET BOLT SPRING PIN ø 5 X 10 BUSHING PLATE SPOOL

Q’TY 1 1 2 1 2 1 1 1 2

No. 201-2 211 212-1 212-2 213 214 216-1 216-2 217

NAME SPOOL PLUG PUSH ROD PUSH ROD SEAL O-RING ; 1B P20 SPRING SEAT SPRING SEAT WASHER 2

24 -I-2 -2

Q’TY 2 4 2 2 4 4 2 2 4

No. 221-1 221-2 241-1 241-2 301 302 312 501

NAME

Q’TY 2 SPRING 2 SPRING SPRING 2 SPRING 2 JOINT ; M14 1 DISK 1 ADJUSTING NUT ; M14 1 BOOTS (BELLOWS) 1

2.3 OPERATION (1) Lever in neutral position (See Fig. 2-4) In this case, the force of the secondary pressure setting spring (241-2) that determines the output pressure of the pilot valve is not transmitted to the spool (201-2). Accordingly, the spool (201-2) is pushed up by the return spring (221-2) and spring seat (216-2) permitting the output port 2, 4 to connect with the tank port T. This makes the output pressure equal to the tank pressure.

PORT 2,4

PORT 1,3

Fig. 2-4 Lever in neutral position (2) When the Lever is tilted (See Fig. 2-5) When the lever is tilted, the push rod (212-2) strokes. The spool (201-2) and spring seat (2162) 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.

PORT 2,4

PORT 1,3

Fig. 2-5 When Lever is tilted (3) The Lever being held (See Fig. 2-6) 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 (241-2) 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.

PORT 2,4

PORT 1,3

Fig. 2-6 Lever being held

24 -I -2-3

NOTES

3. PILOT VALVE (TRAVEL) 3.1 SUMMARY (1) General view

4-M8 X P1.25 T=16.7±1.5N·m 1.7±0.2kgf·m (12.3±1.4 lbf·ft)

T=Tightening Torgue

2-PF1/4 T=3.0±0.2kgf·m (21.7±1.4 lbf·ft) 4-PF1/4 T=3.0±0.2kgf·m (21.7±1.4 lbf·ft)

Fig. 3-1 (2) Specifications

ITEM Model(Type) Max. primary pressure Rated flow Weight

SPECIFICATIONS PVD6P4001 2 70kgf/cm (1000 psi) 10L/min(2.6gal / min) 3.9kg(8.6 lb)

(3) Performance Characteristics N.m

122.4 (8.85)

Operation torque

106.3(7.69)

(435) 30.6

91.8(6.64)

(340 ± 21) 24.0 ± 1.5

62.0(4.48)

61.2(4.43)

(290) 20.4

59.1(4.27) 49.5(3.58)

(145) 10.2 (78 ± 11) 5.5 ± 0.75

30.6(2.21) Secondary pressure

Push rod stroke (mm) Operation angle (deg.)

Fig. 3-2

24 -I -3-1

Operation torque kgf•cm (lbf.ft)

Secondary pressure kgf/cm2(psi)

MPa

(580) 40.8

• Required operating torque (damper) 131±20kgf.cm (9.5±1.45 lbf·ft) Push rod speed 0.0275m/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.)

3.2 CONSTRUCTION

472

Apply grease to bearing

501 471

413

Apply grease on top 214

402

210

203

414

Apply grease on top 202 271 201 212 224

213

336 102 218

225

311 211 252

324 335

217 313 251 261 301 101

Fig. 3-3 Pilot valve-Sectional view

kgf·m(lbf·ft) No.

NAME

101 102 201 202 203 210 211 212 213 214 217 218 224 225 251

Casing Casing(Damper) Cover Plug Grease cup Packing O-ring O-ring O-ring Push rod Shim Spring seat Piston Steel ball RO Plug

3.0 (22)

Q’TY 1 1 2 4 4 4 4 4 2 4 4 4 4 12 3

kgf·m(lbf·ft) No. 0.7 (5) 9.0 (65)

0.7 (5)

24 -I-3 -2

252 261 271 301 311 313 324 335 336 413 414 420 471 472 501

NAME Plug O-ring Capscrew Spool Spring seat Washer Spring Spring Spring Cam shaft Bushing Cam Steel ball Set screw Bots (Bellows)

Q’TY 2 3 4 4 4 4 4 4 4 2 4 2 4 2 2

3.3 OPERATION (1) Reducing valve 1) When the lever is at neutral position, (Refer to Fig 3-4.) 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

Port 2 (4)

Port 1 (3)

Fig. 3-4

Neutral position Full stroke

2) In case where the lever is tilted, (Refer to Fig3-5) 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.

24 -I -3-3

420 214

Oil

311 324 217 313

Port 2 (4)

Port 1 (3)

Fig. 3-5

(2) Dumping mechanism 1) 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. 3-3. 2) 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.

Cam

Push rod Orifice

Piston

Piston When stroking from the neutral position towards the mark ??? , the oil in the piston chamber on the right(left) side is discharged through the orifice, and the simultaneously generated pressure produces dumping force.

Steel ball

Port 2 (4)

Port 1 (3)

Fig. 3-6 Operation when the lever is stroked from the neutral position

24 -I-3 -4

3) 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 dumping piston chamber is discharged through restriction of piston, and the simultaneously generated pressure produces dumping force. On the other hand, the push rod on the port 1 side is moved up by the force of the return spring and dumping spring. Similarly oil is sucked from the tank into the dumping 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 dumping force.

Neutral position Full stroke

Cam The oil outside of the piston is flows out through the passage leading to port T on the casing top end. ( In operation in ?? direction)

Push rod

Piston

Oil

When tilting in reverse direction from the neutral position, the push rod is pushed up by the force of the dumping spring. ( In operation in ?? direction)

Damping spring

The oil in the piston chamber is discharged through the restriction, and the simultaneously generated pressure produces the dumping force. (IN operation in ? ? direction)

Oil in T line is sucked in the dumper chamber through three ball check valves.

Return spring When shifting the lever in reverse from ???direction to +- condition, the piston on the left side immediately performs the roles of the dumper piston. The dumping force is produced on both sides constantly.

Port 2 (4)

Port 1 (3)

Fig. 3-7 Operation when the lever is stroked or operated in reverse

24 -I -3-5

NOTES

4. CONTROL VALVE

LCa3 A3

LCa4 A4

LCa5

P1 LCc1

OR9

OR4

OR3

B10

LCb3

LCb2 LCc2

Bucket

Boom

Travel left

Travel straiht MR1

OR8

LCb1

Pb8

Pb7

C A1

LCa2

OR1

B1 LCa1

Pb6

Pb2

Pilot port Pa2 Pa5~Pa8 Pa10 Pp Pb2 Pb5~Pb8 Pb10 Pb10 13-PF1/4

Pb5

Travel right

Arm

Swing

Service (N&B)

Slewing

[EU • OCEANIA]

Dozer

4.1 GENERAL VIEW AND HYDRAULIC PORTS NO.

LCa6

LCb4

LCa7

A10

Manual operte

MR2

OR7

MR3

Pilot operae Pa2

Pa5

Actuator port A1~7 9 10 B1~8 10 18-PF3/8

Pa6

Pa7

Pa8 Pb8’

Pa10 Drain port Dra1 PF 1/4

Pump port Tank port P1 P2 P3 T1 T2 3-PF3/8 2-PF1/2

LCa5 A5

Bucket

Boom

Travel left

Travel straiht

B7 LCb3

LCb2

OR9

OR4

OR3

MR1

P1 LCc1

B10

LCa4

Pb8

LCa3

LCc2

C A2

LCb1

Pilot port Pa2 Pa5~Pa8 Pa10 Pp Pb2 Pb5~Pb8 Pb10 Pb10 13-PF1/4

Pb7

OR8

LCa2

OR1

Pb6

B1 LCa1

Travel right

Arm

Swing

Service (N&B)

Slewing

Pb5

Pb2

LCa6

LCb4

LCa7

A10

Manual operte

MR2

OR7

MR3

[USA]

Dozer

Fig. 4-1

Pilot operae Pa2

Actuator port A1~7 9 10 B1~8 10 18-PF3/8

Pa5

Pa6

Pa7

Pump port Tank port P1 P2 P3 T1 T2 Fig. 4-2 3-PF3/8 2-PF1/2

24 -I -4-1

Pa8 Pb8’

Pa10 Drain port Dra1 PF 1/4

4.2 SPECIFICATIONS [EU • OCEANIA]

Valve operation

Table. 4-1

Item

SK30SR-2

SK35SR-2

Model(Type)

BCV35-JD10

BCV35-JE10

Manual

Swing Service Dozer blade

Pilot

Travel straight Travel left Travel right Boom Arm Slewing

Flow rate

Setting pressure atmain relief valve P1 P2 P3

Settingpressure at over load relief valve

[USA]

P1 P2-31.1L/min P3

24.2L/min P1 P2-34.8L/min P3

25.2L/min

+5 2 P1 P2ÆÆÆ230 kgf/cm (3270 +71 0 0 psi) at31.1L/min(8.2gal/min)

+5 2 (3270 +71 P1 P2ÆÆÆ230 kgf/cm 0 0 psi) at34.8L/min(9.2gal/min)

2 +5 +71 P3ÆÆÆÆÆÆÆÆ180 (2560kgf/cm 0 0 psi) at24.2L/min (6.4gal/min)

2 +5 +71 P3ÆÆÆÆÆÆÆÆ200 (2840kgf/cm 0 0 psi) at25.2L/min (6.7gal/min)

B1 A5 B5 B10 port (OR1 OR7 OR8 OR9) 260 +50 Kgf/cm2 (3700 +71 0 psi) at5L/min (1.3gal/min) B8 A9 port (OR3 OR4) 280 +50 kgf/cm2(3980 +71 pis) at5L/min (1.3gal/min) 0

Table. 4-2

Valve operation

Item

SK30SR-2

SK35SR-2

Model(Type)

BCV35-JH10

BCV35-JI10

Manual

Service Dozer blade

Pilot

Travel straight Travel left Travel right Boom Arm Slewing,Swing

Flow rate

Setting pressure atmain relief valve P1 P2 P3

Settingpressure at over load relief valve

P1 P2-31.1L/min P3

24.2L/min P1 P2-34.8L/min P3

25.2L/min

+5 2 P1 P2ÆÆÆ230 kgf/cm (3270 +71 0 0 psi) at31.1L/min(8.2gal/min)

+5 2 (3270 +71 P1 P2ÆÆÆ230 kgf/cm 0 0 psi) at34.8L/min(9.2gal/min)

2 +5 +71 P3ÆÆÆÆÆÆÆÆ180 (2560kgf/cm 0 0 psi) at24.2L/min (6.4gal/min)

2 +5 +71 P3ÆÆÆÆÆÆÆÆ200 (2840kgf/cm 0 0 psi) at25.2L/min (6.7gal/min)

B1 A5 B5 B10 port (OR1 OR7 OR8 OR9) 260 +50 Kgf/cm2 (3700 +71 0 psi) at5L/min (1.3gal/min) B8 A9 port (OR3 OR4) 280 +50 kgf/cm2(3980 +71 pis) at5L/min (1.3gal/min) 0

24 -I-4 -2

4.3 CONSTRUCTION

Bucket

Boom

Travel left

Travel straiht

Arm 15

Travel right

18 15

Swing

Dozer

Slewing

Service (N&B)

(1) Control Valve : Overall composition [EU â&#x20AC;¢ OCEANIA]

20 19

Manual operte

Pilot operae 1

5 15

4-3 8Fgi.13

Table. 4-3

No. 1 2 3 4 5 6 7

NAME Dozer section Slewing P3inlet Service Swing Arm Travel right

Q TY 1 1 1 1 1 1 1

No. 8 9 10 11 12 13 14

Q TY NAME P1 P2 inlet&Travel straight 1 Travel left 1 1 Boom 1 Boom lock 1 Buckt P1 P2 Main relief valve 2 1 P3 Main relief valve

24 -I -4-3

No. 15 16 17 18 19 20

NAME Over load relief valve Over load relief valve Anti cavitation valve Plug assy Tie bolt Nut

Q TY 4 2 1 3 4 4

Bucket

Boom

Travel straiht

Arm 15

Travel left

Travel right

18 15

Swing

Service

Dozer

Slewing

[USA]

20 19

Manual operte

Pilot operae 1

5 15

9 8

Fgi. 4-4

No. 1 2 3 4 5 6 7

NAME Dozer section Slewing P3inlet Service Swing Arm Travel right

Table. 4-4 Q TY No. Q TY NAME P1 P2 inlet&Travel straight 1 1 8 1 1 9 Travel left 1 1 10 Boom 1 1 11 Boom lock 1 1 12 Buckt 1 13 P1 P2 Main relief valve 2 1 1 14 P3 Main relief valve

24 -I-4 -4

No. 15 16 17 18 19 20

NAME Over load relief valve Over load relief valve Anti cavitation valve Plug assy Tie bolt Nut

Q TY 4 2 1 3 4 4

(2) Component Parts The control valve consists of the following four major groups. • Manual operation : [EU • OCEANIA] Swing.Dozer blade. Service (Nibbler & breaker) [USA] Dozer blade, Service (Nibbler & breaker) • Pilot operation : [EU • OCEANIA] Travel straight ‚ Travel left&right ‚ Boom ‚ Arm ‚ Bucket ‚ Slewing [USA] Travel straight ‚ Travel left&right ‚ Boom ‚ Arm ‚ Bucket ‚ Slewing , Swing • Accessory : P1 ‚ P2 inlet (in common travel straight) ‚ P3inlet ‚ Boom overload • Accessory(Valve) : P1 ‚ P2 ‚ P3 main relief ‚ Overload relief ‚ Anti cavitation , Boom lock * For the operating section, some typical examples are described in the below. Refer to the Section for Con trol Valve in the Chart of Disassembling for the others. Table. 4-5 1) Manual operation : Swing (No.5) [EU] Note) Swing control of [USA] is operated by hyd. pilot line. 14

9 6

13 12

2a 2b 2c 2d 2e 2f 11 2g 10 5

4 3

1 Fig. 4-5

No. 1 2a 2b 2c 2d 2e 2f 2g 3 4 5 6 7 8 9 10 11 12 13 14

NAME Body SPool O-ring 1A P12 Dust wiper Oil seat retainer Spring seat Spring Spool end O-ring 1A P12 Dust wiper Oil sear retainer Load check valve Spring(for check valve) O-ring 1B P11 Plug Socket bolt M5X10 Cover Socket bolt M5X18 Anti cavitation valve O-ring 1BW G4

Q TY 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 2 1 2 1 1

Table. 4-6

No.

2) Pilot operation : Slewing (No.2)

1 2a 2b 2c 2d 2e 3 4 5 6 7 8 9 10 14

4 6

2d 2e 9 2c 2b

Fig. 4-6

24 -I -4-5

NAME Body Spool Spring seat Spring Spring seat Spool end Load chack valve Spring(for chack valve) O-ring 1B P11 Plug O-ring 1BS22 Pirot cover Pirot cover Socket bolt M5X20 O-ribg 1BW G4

Q TY 1 1 1 1 1 1 1 1 1 1 2 1 1 4 1

3) Main relief valve (P1‚P2‚P3) and Over load relief valve 15

Table. 4-7

Fig. 4-7

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

4) Anti cavitation valve 1

NAME Socket Pressure regulating Piston Plug Body Adjust valve Adjust valve Lock nut M14 Spring (Adjust valve) Spring (Adjust valve) O-ring 1B P15 O-ring 1B S10 O-ring 1A P7 Back up ring O-ring 1B P14 Spring guide

Q’TY 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1

Table. 4-8 2

Fig. 4-8

24 -I-4 -6

No. 1 2 3 4 5 6 7 8

NAME Anti cavitaion valve Body Plug Spring Back up ring O-ring 1A P10A O-ring 1B P14 O-ring 1B P15

Q’TY 1 1 1 1 1 1 1 1

4.4 HYDRAULIC CIRCUIT [EU • OCEANIA] Table. 4-9

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Fig. 4-9

24 -I -4-7

NAME Bucket spool Boom spool Travel left spool Travel straight spool Travel right spool Arm spool Swing spool Service spool Slewing spool Dozer spool P1 main relief valve P2 main relief valve P3 main relief valve B1‚A5‚B5‚B10 Over load relief valve B8‚A9 Over load relief valve P1 by-pass circuit P2 by-pass circuit P3 by-pass circuit P1 parallel circuit P2 parallel circuit P3 parallel circuit Plug (Over load relief) Anti cavitation Tank circuit Pilot passage Load check valve Load check valve Load check valve Load check valve Boom lock valve

[USA] Table. 4-10

. # $ / ' 0 1 ( ) * # $ / ' 0 1 ( ) #* # ## #$ #/ #' #0 #1 #( #) $* $

Fig. 4-10

24 -I-4 -8

! " # !#" $ !$" % & $ % & $ % & ' % & ' % & ( % & ) % & * % & +,-

# +,-

$ +,-

4.5 EXPLANATION OF OPERATION (1) Neutral position P1: The delivery oil from the hydraulic pump flows from the P1 port of the control valve (hereinafter named as C/V) into the left travel spool through the land of the travel straight spool. 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 delivery oil from the hydraulic pump flows from the (C/V) P2 port into the right travel spool through the land of the travel straight spool. At the spool neutral position, the entered oil passes through the by-pass of the spool for the right travel, arm and boom swing spool, 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. At the spool neutral position, the oil entered in the parallel circuit passes through the by-pass circuit of spool for dozer and slewing operation and the check valve on the P3 supply section, and flows out to the tank circuit through the by-pass circuit of spool for service and the by-pass circuit leading to the tank. 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, Arm, Swing, Service P3 line: Dozer, slewing Pp: The delivery oil from the gear pump flows from the (C/V) Pp port into the by-pass circuit through the orifie provided on P1 and P2 supply sections. At the spool neutral position, the delivery oil flows out to the tank circuit through the circuits provided on the right and left travel spools and boom spool. Therefore the pilot circuit pressure becomes equal to the tank pressure, the received pressure of the travel straight valve is equal to the tank pressure, and consequently the travel straight spool does not switch. 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 respective spool of dozer, service and swing (EU spec.) 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 -I -4-9

[EU]

Fig. 4-11 Operation at neutral position

24 -I -4 -10

[USA]

Fig. 4-12 Operation at neutral position

24 -I-4 -11

(2) Pilot operating section 1) Operating boom raise With the boom raise operation, the pilot secondary pressure enters into the Pa8 port, and moves the spool for the boom operation. 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 ravel operation into the tparallel 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 Pp port passes through the orifice provided on the P1 and P2 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 travel spool is not switched.

Boom cylinder

Bridge passege

Load check

Parallel passage pilot passage

Pilot secondary pressure

Pb8

Pa8 By-pass passage

Check valve From P1 pump Parallel passage

From P1 pump

The oil entered in through the Pp port flows out from the travel switching section into the tank circuit.

Travel left To tank

Boom Pa8

Pb8

Boom ORV section

To P9 port

Fig. 4-13 Operation at boom raising

24 -I -4 -12

(3) Manual operation section 1) Dozer raise operation With the dozer raise operation, the spool moves to the pushing direction. With the movement of the spool, the oil entered through the P3 port passes through the parallel circuit, and is cut off at the by-pass circuit of the dozer. With the movement of the spool, as the circuit from the B4 port to the bridge passage is open, the oil entered in the parallel circuit passes through the load check valve, flows into the B4 port through the bridge passage, and is fed into the swing cylinder head side. On the other hand, the return oil from the dozer cylinder rod side flows into through the A1 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 dozer cylinder extends, and the dozer raises.

Dozer cylinder

Bridge passage

Parallel passage

By-pass passage

Parallel pasage

Dozer

Slew From P3 P3 supplied

Fig. 4-14 Operation of Dozer raise

24 -I-4 -13

(1) Operation of relief valve 1) Operation at relief condition 1. 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.

Orifice “B”

Piston

Adjust valve spring

Tank Passage P

Body seat Socket

“A”cham ber Pressure regulating valve

Adjust valve

Fig. 4-15 2. 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.

Ring orifice “C”

Drilled hole“D”

Fig. 4-16 3. 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”.

Drilled hole “D”

Fig. 4-17

4. 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. 4-15).

24 -I -4 -14

(2) 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.

Fig. 4-18

(5) 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 circuit into the P port and the space fills with the oil.

Tank Passage

Body seat Socket

Fig. 4-19

24 -I-4 -15

(6) Function of Lock Valve 1) Piston Holding When the boom spool is at neutral position, the pilot piston chamber (a) is connected to the drain path through the pilot port (Pb8â&#x20AC;&#x2122;) for relasing lock valve. And the piston chamber (b) is also connected to the drain path through the drain port (Dr1). Therefore the piston (A) is held at the position shown in the sketch. And the hydraulic pressure to hold the boom cylinder is applied to the lock valve chamber as shown in the sketch, 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.

Boom cylinder

Piston chamber (b) Lock valve chamber

Piston A

Pilot piston chmber

Needle valve seat

Needle valve

Lock valve

Body seat

Fig. 4-20 Function of Lock Valve (piston holding)

24 -I -4 -16

2) Release When the pilot pressure is applied to the pilot port (Pb8â&#x20AC;&#x2122;) for releasing lock valve, the piston (A) is moved to the right side opening the needle valve through piston (B). 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.

To tank

Boom cylinder

Steel ball

Lock valve chamber Drilled hole

Piston A

Piston B

Needle valve

Lock valve

Throttle

Pilot piston chamber

Fig. 4-21 Function of Lock Valve (release)

24 -I-4 -17

(7) Travel Straight Function When shifting the travel for both right and left, and also shifting either of arm, boom, bucket or swing, though the oil flows into the pilot path from Pb port through throttle, the oil path between pilot path and tank path is closed, therefore the pilot path pressure becomes equal to the Pp port supply pressure. As the results, the Pp port supply pressure is applied to the travel straight spool. Then the spool is moved against the spring force up to hitting the pilot cover. When spool is shifted, the pressurized oil supplied through P1 and P2 passes through the notch provided on each spool and is supplied to the travel motors of right and left through respective bypass paths, and also supplied to each parallel path from the path provided in the spool through the check valve. Accordingly, because the pressurized oil supplied to P1 and P2 is distributed to the attachment shifting (arm, boom, bucket, swing or service) at a certain proportion, the machine is able to keep its straight traveling even though any of attachment shifting is activated while traveling. Fig. 4-22 shows the conditions when shifting both travel for right and left, and also shifting the arm.

Pump port of P2 side

To parallel path

Pump port of P1 side

Pp port Travel straight spool

Bypass path of P2 side

Parallel path of P2 side

Arm Right tavel

Bypass path of P1 side

Travel straight spool

Pilot path

From P1 pump

Check valve Supply from P1 and P2

Throttle

From P2 pump

Left tavel

Pilot cover Pilot path

Boom

Bypass path of P1 side

Parallel path of P1 side

Fig. 4-22 Operations at Oil Supply

24 -I -4 -18

5. SLEWING MOTOR 5.1 GENERAL VIEW

PG SH

PT1/8 port for grease piping A

M G6

5.2 HYDRAULIC CIRCUIT

G5 G6

Fig. 5-1

DB B

Table. 5-1

Port A B M DB PG SH G5 G6

Fig. 5-2

NAME

Gauge port

Model (Type)

PF1/8

SK30SR-2

SK35SR-2

MSG-27P-16E-5

MSG-27P-16E-6

24 (1.46)

26.1 (1.59)

Displacement

cc/rev(cuÆin/rev)

Rated flow

L/min(gal/min)

24.2 (6.39)

25.2 (6.66)

Parking brake torque

kgfÆm(lbfÆft)

89 (640)

103 (740)

Min20(280) Max65(920)

Parking brake releasing pressure kgf/cm (psi) Parking brake timing Relief valve Set pressure Weight

PF1/4

Table. 5-2

Applicable model

Reduction

PF3/8

Rotational direction : Inlet A port : CW Inlet B port : CCW (View from shaft end)

5.3 SPECIFICATICENS

Hydraulic motor

Size

Main port Main port Make up port Drain port Slewing parking brake release port Slewing parking brake pilot port

3.7–1.2

sec 2

kgf/cm (psi)

150(2130) at24L(6.3gal)/min 160(2280) at25L(6.6gal)/min 1/15.5

Reducing ratio kg(lb)

24 -I -5-1

38 (84)

5.4 CONSTRUCTION

Fig. 5-3 Table. 5-3 No. 1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

NAME Housing Pinion shaft Collar Plate Taper roller bearing Oil seal Taper roller bearing Shim t2 Shim t3 Shim Shim t4 select Shim t5 Shim t13 Shim t14 Collar Holder Thrust washer Inner race Needle bearing Planetary gear Thrust plate Drive gear Plug O-ring 1B P8 O-ring Casing Ball bearing Shaft Thrust plate

Q TY 1 1 1 1 1 1 1 2 2 2 2 2 2 1 1 3 3 3 3 1 1 1 1 1 1 1 1 1

No. 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 48-1 48-2 48-3

NAME Cylinder block Collar Spring Washer Snapring Pin Retainer holder Retainer plate Piston assy Disk Brake piston O-ring 1B G110 O-ring 1B G135 Spring seat Spring O-ring Cover Ball bearing Pin Valve plate Pin O-ring 1B P21 Socket bolt M12X30 Orifice Timer valve assy Sleeve O-ring 1B P10A O-ring 1B P12

24 -I-5 -2

Q TY No. NAME 1 48-4 O-ring 1B P14 1 48-5 Spool 49 Washer 1 50 Spring 1 51 O-ring 1B P18 1 52 Plug 3 53 Relief valve assy 1 54 Check valve 1 55 Spring 9 56 Plug 1 57 O-ring 1B P14 1 58 Plug 1 59 O-ring 1B P8 1 60 Plug 2 61 O-ring 1B P11 1 62 Socket bolt M12X30 1 63 Name plate 1 64 Rivet 1 65 Thrust plate 1 66 Sun gear 1 67 Screw 2 68 Planetary gear 2 69 Needle bearing 5 70 Inner race 1 71 Thrust washer 1 72 Holder 1 1 1

Q TY 1 1 1 1 1 1 2 2 2 2 2 2 2 1 1 2 1 2 1 1 4 4 4 4 4 1

Relief valve assy (No.53) Table. 5-4

No. 53-1 53-2 53-3 53-4 53-5 53-6 53-7 53-8 13 53-9 53-10 53-11 53-12 53-13 53-14 53-15

7 9

Fig. 5-4

NAME Body Poppet Seat Spring seat Spring Plug Set screw O-ring 1B P24 O-ring 1B P10 O-ring 1A P15 O-ring 1B P12 Back up ring Back up ring Piston Lock nut

Qâ&#x20AC;&#x2122;TY 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1

5.5 EXPLANATION OF FUNCTION AND OPERATION (1) Swash plate motor The cylinder block (24) is equipped with 9 pistons(32). And the end face of cylinder block (24) is in contact with valve plate (43) having two crescent ports C and D(high and low pressure switching distributor). (Principles of torque generation) On leading the high pressure oil (pressure P) to the A port, the grade is pushed by the force of each piston (F=PXA, A: Piston cross sectional area) and the piston receives the reaction force from the grade for the piston and the directional torque of the reaction rotation is generated. And the sum total of the rotation directional torque produces a turning force in cylinder block (24) and the torque is conducted to shaft (22) through the spline resulting in the piston rotation. And, the output torque and the rotation number are found from the following equation. Where,

Output torque (T) T=

D 2

m 100

Rotation number (N) N=

1000 D i

D P Q m v i G

: Displacement volume (cc/rev) : Effective driving pressure (kgf/cm2) : Flow rate (L/min) : Mechanical efficiency (motor) (% 10-2) : Volumetric efficiency (motor) (% 10-2) : Speed ratio of reduction unit : Reduction unit efficiency (% 10-2)

24 -I -5-3

Construction of slewing motor 32 24

Valve plate ‚ Viewed from X–X (Outline)

Fig. 5-5

24 -I-5 -4

(2) Parking brake The parking brake is of hydraulic release and chamber type multi-disc construction. 1) When parking brake is ON, When the pressure oil for releasing the brake is cut off, regarding the disk (33) joined to the exterior of the cylinder block with a spline, brake piston(34) which is secured with pin on the case is pushed by spring(38), and cylinder block(24) and casing (2) are fixed by the frictional force. Consequently the shaft is locked. 2) When parking brake is OFF, When the brake releasing pressure is led to brake cylinder chamber “C” through PG port, brake piston(34) operates resisting the force of spring(38), removing the friction with disk(33), and the shaft rotates freely. (3) Hydraulic timer (Specification with hydraulic timer only) The hydraulic timer is provided to protect the parking brake from dragging and plays to secure delay time so that the parking brake does not actuate when the hydraulic dynamic brake is absorbing swing inertia energy, and the delay time is set by restricting the delivery oil from the cylinder chamber with orifice and by controlling the flow rate . By returning the control valve from motor rotating condition to the neutral position, the valve switching pressure “SH” interlocking with switching signal for the control valve lowers, and for the valve, the brake cylinder chamber is interlocked with the drain port through the valve as shown in the figure. (In this condition, the energy of the upper structure is transformed into heat energy and absorbed by the relief valve and the hydraulic dynamic braking action.). On the other hand, the oil led to the brake cylinder chamber “C” tries to move in the direction to push the disk by the spring force acting on the brake piston, but as the flow rate of the delivery oil from the brake cylinder chamber is controlled by the orifice of the valve, the brake piston is not in contact with the disk before an elapse of the specified time and the brake does not work.

24 -I -5-5

Parking brake is ON condition

33 34 38

PG (Brake releasing pressure) OFF Fig. 5-6 Parking brake is OFF condition

33 34 38

C (Brake cylinder chamber)

20 PG (Brake releasing pressure) ON Fig. 5-7

24 -I-5 -6

Spring Drain To brake cylinder chamber C PG Valve SH

Orifice

Drain Brake cylinder chamber

Drain

Brake cylinder chamber PG

SH OFF

In P/B releasing

Fig. 5-8

In P/B operation

The above function is explained in the diagram shown below. Diagram

MAX Shuttle valve switching outer signal pressure SH 0

In this interval, main control valve is switched.

Time zone the flow is controlled by orifice.

MAX Pressure of parking brake cylinder chamber

Parking brake torque

C1 0

C2 In this interval, â&#x20AC;&#x153;PGâ&#x20AC;? supply pressure is acting on. t1

MAX

Timer set time

Releasing parking brake

0 In this interval, parking brake does not act on and does not draggs Upperstructure slewing speed

Set slewing speed 0 Acceleration

Uniform speed area

24 -I -5-7

Deceleration area Hydraulic pressure dynamic brake

Time (t)

(4) Operating principle of relief valve The relief valve is used to decide the driving power and brake force when slewing the hydraulic excavator and each is equipped with main port A and B. And it is constructed so that the relief valve return oil returns in a circuit to the main low pressure line on the other side. And, it is provided with a shockless function to reduce the shock produced when speeding up or down. The relief valve is made up of the a) Area difference & direct operated type relief valve b) Shockless piston. The installation of shockless type relief valve is effective for the reduction of the shock, reduction of the stress generated on the structure of the machine. Relation of the set pressure of relief valve and the adjusting volume Set pressure SK30SR-2···150 kgf/cm2 (2130 psi) SK35SR-2···160 kgf/cm2 (2280 psi) The set pressure changes approx.36kgf/cm2 (510psi) by a turn of the set bolt. Don’t adjust the set pressure unless it is truly necessary..

Area difference & direct operated relief valve Shockless piston

Construction of relief valve Fig. 5-9

24 -I-5 -8

The relief valve is operated by the following two steps. 1st step: When starting operation, the interior of the spring (5) is held in low pressure because shockless piston (14) moves. Consequently the pressure receiving area (S2) of poppet (2) becomes equal to the area(S1) of seat(3) and has a large pressure receiving area when compared with the area (S1-S2) for the regular relief set pressure. Therefore the low pressure holding time is decided by the diameter of the poppet orifice, the pressure receiving area of the free piston and the free piston stroke.

Construction of relief valve Fig. 5-10

24 -I -5-9

2nd step: After the movement of shockless piston(14), the pressure inside of spring chamber (5) rises and becomes equal to the pressure the front and behind of poppet(2). And the relief valve is operated by the regular set pressure.

2nd step:Operation of relief valve Fig. 5-11

The pressure wave forms in the conventional type and the shockless type are shown below.

Pressure

Shockless type

Pressure

Conventional type

Time

Comparison of pressure wave forms Fig. 5-12

24 -I -5 -10

(5) Make-up valve (check valve, No.54) The make-up valve performs the following two functions. The 1st function is to prevent the cavitation produced when overrunning to avoid the overrun of the upperstructure. The motor revolved by the inertia force of the upperstructure causing the pumping action, and when the motor speed is over the speed equivalent to the oil quantity fed into the motor, the shortage of oil is made up from the outside to the motor main circuit through the make-up valve to protect the circuit from the generation of vacuum. The 2nd function is, when the closed circuit is formed between the control valve and the motor as when braking, to protect the circuit from the generation of the vacuum by making up the shortage due to the motor drain and valve leak from the make up valve to maintain the braking function in the regular circuit condition.

Make-up valve

Fig. 5-13

24 -I-5 -11

(6) Reduction Unit (2-stage planetary) Refer to the cross sectional view. The motor shaft (22) is connected to the drive gear (16) with the spline on it. The driving power on the hydraulic motor is transmitted from the drive gear (16) to the planetary gear (14) which is engaged to the drive gear (16). The planetary gear (14) is engaged to the ring gear on the reduction unit housing (1). Then it revolves around the ring gear with its rotation. The planetary gear (14) is held on the holder (10) with the bearing, and the holder (10) transmits the revolving motion of planetary gear (14) to the sun gear (66) which is engaged to the holder (10) with the spline on it. The sun gear (66) is engaged to the planetary gear (68), and transmits the revolving motion to the planetary gear (68) as the same routing as the first stage. Since the planetary gear (68) is held on the holder (72) with the bearing, the holder (72) transmits the revolving motion of the planetary gear (68) to the pinion shaft (2) which is engaged to the pinion shaft (2) with the spline on it.

Fig. 5-14

24 -I -5 -12

6. TRAVEL MOTOR 6.1 SPECIFICATIONS

OIL LEVEL CHECK PORT (PF 3/8)

OIL FILLING PORT (PF 3/8)

(1) General View

DRAIN PORT (PF 3/8) PRESSURE GAUGE PORT (2-PT 1/8)

Rotating direction Oil inlet Oil outlet port port (View from X side) Clockwise

Counterclockwise

A Fig. 6-1 VIEW X

(2) Specifications

Table 5-1 Applicable Model

Item Model (Type) Reduction unit

Rated output revolution (1 st / 2 nd)rpm Output torque

motor

Reduction ratio Rated operating pressure Rated output revolution Rated frow 2-Speed shifting pressure

Parking Static friction torque brake Weight

Releasing pressure

SK35SR-2 [EU]

SK35SR-2 [USA]

GM04VN-B

GM04VN-C

GM04VN-A

34.4 / 59.1

34.7 / 59.7

31.2 / 53.7

(1 st / 2 nd) kgf·m (lbf·ft) 279 /155 (2020 / 1120) 309 /172 (2230 / 1240) 344 /191 (2490 / 1380)

Displacement (1 st / 2 nd) Hydraulic

SK30SR-2

1 / 45.5

1 / 50.4

1 / 56

1746 / 3010

cc/rev (cu·in/rev) 19.5 / 11.1 (1.19 / 0.68) kg/cm2 (psi)

230 (3270)

(1 st / 2 nd) rpm

1563 / 2690

1749 / 3010

liter/min (gal/min)

31.1 (8.2)

34.8 (9.2)

kg/cm (psi)

35 (500)

kgf·m (lbf·ft)

6.6 (48)

kgf/cm2 (psi)

9.1 (130)

kg (lb)

42 (93)

24-I-6-1

6.2 CONSTRUCTION (1) Construction (Outline)

REDUCTION UNIT (REG) HIGH SPEED LOW SPEED 2-SPEED CHANGE PISTON

HYDRAULIC MOTOR BRAKE VALVE (COUNTER BALANCE VALVE) PARKING BRAKE HIGH AND LOW SPEED CHANGE MECHANISM

PARKING BRAKE

2-SPEED CHANGE VALVE

CONTROL VALVE LOAD CHECK VALVE & ANTICAVITATION VALVE BRAKE VALVE (COUNTER BALANCE VALVE)

HYDRAULIC PUMP

24-I-6-2

(2)

Hydraulic Motor

Fig. 6-3 No. 102 103 104 105 106 107 108 109 110 112 113 114 115 116 132 135 139 145 149 150 151 161 162 167 169 177 190

NAME DRIVE SHAFT SWASH PLATE CYLINDER BLOCK PISTON SHOE RETAINER PLATE THRUST BALL TIMING PLATE WASHER PISTON SPRING SPRING FRICTION PLATE MATING PLATE OIL SEAL O-RING O-RING SNAP RING BEARING BEARING NEEDLE ROLLER PISTON SHOE PIVOT MATING PLATE PARALLEL PIN SPRING

Q’TY

No.

1 1 1 7 7 1 1 1 2 1 8 1 2 2 1 1 1 1 1 1 3 1 1 2 1 2 1

201 218 219 220 221 222 223 224 225 226 227 228 230 233 236 237 241 243 252 254 263 264 266 268 273 275 276 280 299

24-I-6-3

NAME REAR FLANGE VALVE SEAT VALVE SPRING PLUG RING SPOOL PLUG STOPPER PLUG VALVE SPRING SPRING O-RING O-RING O-RING PARALLEL PIN SOCKET BOLT SOCKET PLUG SOCKET PLUG SPOOL OIL STOPPER SPRING STEEL BALL O-RING ORIFICE ORIFICE PLUG NAME PLATE

Q’TY 1 1 1 1 2 1 1 2 2 2 2 2 2 1 2 2 2 6 3 6 1 1 1 1 2 3 1 1 1

(3)

Reduction Unit

Fig. 6-4

No. 1 2 3 4 6 7 8 9 12 17 18 19 20 21

NAME HUB SPINDLE HOLD FLANGE RV GEAR INPUT GEAR SPUR GEAR COVER CRANK SHAFT SPACER PIN RING REAMER BOLT SNAP RING BALL BEARING

Q’TY

No.

NAME

Q’TY

1 1 1 2 2 2 1 2 4 28 1 2 2 2

22 23 24 25 26 28 29 31 33 34 35 27 42

TAPERED ROLLER BEARING NEEDLE ROLLER BEARING SNAP RING SNAP RING O-RING O-RING O-RING FLOATING SEAL PLUG SOCKET PLUG BOLT O-RING PARALLEL PIN

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

24-I-6-4

6.3 EXPLANATION OF FUNCTION 6.3.1 Reduction Unit (1) Function This reduction unit is equipped with spur gears (Hereinafter referred as 1st reduction gear section) and differential gears (Hereinafter referred as 2nd reduction gear section), reduces the high rotation speed from the hydraulic motor, coverts it to low speed large torque and rotates hub (1)

SPUR GEAR (7)

(Casing.)

CRANK SHAFT (9)

(2) Explanation of function 1) 1st reduction gear section The rotation of hydraulic motor shaft is transmitted to input gear (6) which is linked with shaft (102) in spline.

SHAFT (102)

Then, the rotation speed of two spur gears (7) which are engaged with input gear is reduced. Also, the reduction rate of 1st reduction gear section is as follows. INPUT GEAR (6)

ZS i1= - ----------Zi i1= Reduction rate of 1st reduction gear section Zi=Number of teeth of input gear Zs=Number of teeth of spur gear

NEEDLE BEARING SPUR GEAR ECCENTRIC ROTATION REVOLVING

2) 2nd reduction gear section a) Two spur gears are engaged with crankshaft respectively to transmit the power from the 1st reduction gear section to 2nd reduction gear sec-

CRANK SHAFT ROTATION A

tion.

The eccentric bodies of crankshaft A and B revolve eccentrically (revolution) while rotating on its axis by rotating crankshaft. Also, these eccentric bodies A and B and RV gears (4) transmit only the eccentric revolution. And RV gears A and B revolve in the same direction and number of revolutions as spur gear

ECCENTRIC MOTION

RV GEAR RV GEAR

and crankshaft.

24-I-6-5

b) Tooth surface ZR of RV gear is always engaged with ZP pins (17) rotating and changing the mesh part in order, by eccentrically revolving RV gear. By eccentrically revolving RV gear one turn, the

HUB PIN (17)

pin revolves in the same direction of eccentrical revolution in the portion of difference between number of teeth ZR and number of pins ZP [(ZP

RV GEAR

- ZR) / ZP].

CRANK SHAFT REVOLVING BODY SECTION

This revolution of pin is transmitted to hub, producing output rotation of reduction unit. At this point, the speed ratio of 2nd reduction gear section is as follows. (ZP - ZR) 12 = ----------------------------ZP i2 = Speed ratio of 2nd reduction gear section ZR = Number of RV gear ZP = Number of pins At half rotation (180ยบ) Then, the output revolution is as follows, when the hydraulic motor shaft rotates one time. i = i1

i1 = Speed ratio of 1st reduction gear section I2 = Speed ratio of 2nd reduction gear sec(ZP - ZR) ZS tion ZP Zi 12 = - -------------

-----------------------------

6.3.2 Hydraulic Motor Section (Brake valve, parking brake, high and low speed change mechanism) (1) Function 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

24-I-6-6

at travel motor operation, and close the port at a standstill.

Fig. 6-7

At one rotation

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 2-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. (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 3 or 4 pistons (105), generating the power (F1 kgf = P kgf / cm2

A cm2). This power enters

on swash plate (103), but swash plate (103) is fixed having an angle (

) 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

ri) against

line Y1 - Y2. The total torque [T = Ă? (F3

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 (102) to transmit torque.

24-I-6-7

Fig. 6-8

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

112

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 (223) leads pressure oil to port (P). The pressure oil led to port (P) moves piston (112) of parking brake, and re-

Fig. 6-9

leases parking braking force. (For details, refer to item â&#x20AC;&#x153;Parking brakeâ&#x20AC;?.) 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. b) Self-traveling 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-traveling (Overrun). While self-traveling, 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 back 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.

Fig. 6-10

24-I-6-8

c) 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 enertia 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 enertia 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 enertia 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-I-6-9

Fig. 6-11

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 9.1 kgf / cm2 (130 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), (169) 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).

Fig. 6-12

b) Stopping If pressure oil from brake valve is cut, and the pressure in cylinder chamber (a) lowers 9.1 kgf / cm2 (130 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), (169) 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 6.6 kgfâ&#x20AC;˘m (48 lbfâ&#x20AC;˘ft) to hydraulic motor shaft. And since oil is controlled through the proper oil passage, it results in smooth operation.

Fig. 6-13

24-I-6-10

4) High / Low 2-speed shifting mechanism a) Low speed When the pilot pressure 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 (motor case) through the valve (263). Accordingly, the tilt angle of the swash plate (103) becomes the maximumÉÐ1 resulting the maximum stroke volume and low speed rotation of the hydraulic motor.

PILOT PRESSURE D PLANE Y CHAMBER P

DRAIN Fig. 6-14 b) High speed When 30 kgf / cm2 (430 psi) of the pilot pressure is supplied through the port (D), 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 minimumÉÐ2 resulting the minimum stroke volume and high speed rotation of the hydraulic motor.

PILOT PRESSURE D

PLANE X

CHAMBER P

DRAIN Fig. 6-15

24-I-6-11

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 185 kgf / cm2 (2630 psi), it excesses the pilot pressure of 30 kgf / cm2 (430 psi), and the valve (263) is pushed up to upper position, and oil in the chamber (P) is released into the drain (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 become the maximumĂ&#x2030;Ă?1 and is maintained at its position resulting low speed rotation.

PILOT PRESSURE D PLANE Y CHAMBER P

DRAIN Fig. 6-16

24-I-6-12

7.SWIVEL JOINT

7.1 GENERAL VIEW

Fig.7-1 General view

7.2 SPECIFICATIONS

Table7-1

Model (Type)

YV-7200

Port No.

A, B, C, D

Max. working pressure kgf/cm2 (psi) Pressure test Flow Revolution Weight

kgf/cm2 (psi) liter/min (gal/min)

250 (3560)

210 (2990)

5 (71)

375 (5330)

315 (4480)

10 (142)

60 (15.9)

E, F

30 (7.9)

5 (1.3) Less than 15

rpm

Approx 22 (48)

kg (lb)

24-I-7-1

7.3 CONSTRUCTION

Fig.7-2 Construction Table 7-2 Swivel joint Parts No. 1 2 3 4 5 6 7 8

NAME SHAFT BODY FLANGE THRUST RING PIN SLIPPER SEAL O-RING O-RING

Q’TY

No.

1 1 1 1 1 7 1 1

9 10 11 12 13 14 15

7.4 FUNCTION The swivel joint is installed at the slewing center of machine, and is to maintain the connection of hydraulic oil circuits regardless to the slewing angle on the upper frame. On the body (2) and shaft (1) which are able to independently rotate with each other, the necessary number of ports (3) are provided corresponding to the number of circuits. The necessary number of grooves is machined on both of the body (2) at its inner periphery and the shaft (1) at its outer periphery, and these grooves are sealed at upper and lower portions with the seal (4) The hydraulic oil flowing into the shaft from the port (3) is able to keep its flowing along through the hydraulic circuit (5) which is provided between the body (2) and shaft (1), and the circuits maintained without any hindrance due to the independent rotation of the body (2) and shaft (1).

24-I-7-2

NAME DUST SEAL DUST SEAL SNAP RING BOLT PLUG SPRING WASHER BACK-UP RING

Q’TY 1 1 1 2 1 4 4

8. CYLINDER 8.1 SPECIFICATIONS (1)

General View

HB GT A N E TH L G D EN DE DL EN E T CT EX RA LY T L E FU YR LL U F

PART NO. AND MANUFACTURING NO. STAMP POSITION

Fig. 8-1 General view of cylinder

(2) Specifications

Cylinder

Unit : mm (ft•in)

Table 8-1

SK30SR-2 Cylinder Bore / Rod Dia.

Stroke

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

Dry Cushion weight kg (lb)

Canopy Boom [NEW ZEALAND] ø80 / ø45 (3.15” / 1.77”) 518 (1’8.4”) 1380 / 862 (4’6.3” / 2’9.9”) Rod side [ø80 / ø45 (3.15” / 1.77”)] [538 (1’9.2”)] [1400 / 862 (4’7.1” / 2’9.9”)] Cab

33 (73) [34 (75)]

Arm

ø75 / ø45 (2.95” / 1.77”)

541 (1’9.3”) 1398 / 857 (4’7.0” / 2’9.7”)

None

30 (66)

Bucket

ø65 / ø35 (2.56” / 1.38”)

487 (1’7.2”) 1240 / 753 (4’0.8” / 2’5.6”)

None

20 (44)

Swing

ø80 / ø45 (3.15” / 1.77”)

488 (1’7.2”) 1331 / 843 (4’4.4” / 2’9.2”) Both sides 37 (82)

Dozer

ø80 / ø45 (3.15” / 1.77”)

173 (6.8”)

701 / 528 (2’3.6” / 1’8.8”)

None

21 (46)

Note) • The dimensions in [ ] are only applicable for the machines with canopy specification which are delivered for aoceanian district. Table 8-2

SK35SR-2 Cylinder

Cylinder Bore / Rod Dia.

Stroke

Unit : mm (ft•in) Center distance of mounting pins Full extend B / Full retract A

Dry Cushion weight kg (lb)

Canopy Boom [NEW ZEALAND] ø85 / ø50 (3.35” / 1.97”) 531 (1’8.9”) 1417 / 886 (4’7.8” / 2’10.9”) Rod side [ø85 / ø50 (3.35” / 1.97”)] [556 (1’9.9”)] [1442 / 886 (4’8.8” / 2’10.9”)] Cab

37 (82) [37 (82)]

Arm

ø80 / ø45 (3.15” / 1.77”)

560 (1’10.0”) 1432 / 872 (2’8.4” / 2’10.3”)

None

34 (75)

Bucket

ø65 / ø35 (2.56” / 1.38”)

487 (1’7.2”) 1240 / 753 (4’0.8” / 2’5.6”)

None

20 (44)

Swing

ø80 / ø45 (3.15” / 1.77”)

488 (1’7.2”) 1331 / 843 (4’4.4” / 2’9.2”) Both sides 37 (82)

Dozer

ø90 / ø45 (3.54” / 1.77”)

150 (5.9”)

690 / 540 (2’3.2” / 1’9.3”)

None

23 (51)

Note) • The dimensions in [ ] are only applicable for the machines with canopy specification which are delivered for aoceanian district.

24-I-8-1

8.2 CONSTRUCTION AND FUNCTION 8.2.1 Construction (1) Boom cylinder SK30SR-2 • SK35SR-2

Fig. 8-2 Construction of boom cylinder

No.

NAME

Q’TY

No.

NAME

Q’TY

No.

NAME

Q’TY

CYLINDER TUBE ASSY

HOLDER

STEEL BALL

PISTON ROD ASSY

CUSHION SEAL

PIN BUSHING

CYLINDER HEAD

COLLAR

WIPER RING

BUSHING

BACK-UP RING

PIPE ASSY

U-RING

CUSHION BEARING

PIPE ASSY

WIPER RING

PISTON

GREASE NIPPLE

O-RING

SEAL RING ASSY

GREASE NIPPLE

BUCK-UP RING

SLIDE RING

CAP

O-RING

SETSCREW

SPACER

24-I-8-2

(2) Arm cylinder SK30SR-2 • SK35SR-2

15 16

Fig. 8-3 Construction of Arm cylinder

No.

NAME

Q’TY

No.

NAME

Q’TY

No.

NAME

Q’TY

CYLINDER TUBE ASSY

BUCK-UP RING

PIN BUSHING

PISTON ROD ASSY

O-RING

WIPER RING

CYLINDER HEAD

PISTON

PIPE ASSY

BUSHING

SEAL RING ASSY

GREASE NIPPLE

U-RING

SLIDE RING

CAP

WIPER RING

SETSCREW

O-RING

STEEL BALL

24-I-8-3

(3) Bucket cylinder SK30SR-2 • SK35SR-2

Fig. 8-4 Construction of bucket cylinder

No.

NAME

Q’TY

No.

NAME

Q’TY

No.

NAME

Q’TY

CYLINDER TUBE ASSY

BUCK-UP RING

PIN BUSHING

PISTON ROD ASSY

O-RING

WIPER RING

CYLINDER HEAD

PISTON

PIN BUSHING

BUSHING

SEAL RING ASSY

PIPE ASSY

U-RING

SLIDE RING

GREASE NIPPLE

WIPER RING

SETSCREW

CAP

O-RING

STEEL BALL

24-I-8-4

(4) Swing cylinder SK30SR-2 • SK35SR-2

Fig. 8-5 Construction of swing cylinder

No.

NAME

Q’TY

No.

NAME

Q’TY

No.

NAME

Q’TY

CYLINDER TUBE ASSY

CUSHION SEAL

PISTON ROD ASSY

COLLAR

SNAP RING

CYLINDER HEAD

BACK-UP RING

STOPPER

BUSHING

CUSHION BEARING

PIN BUSHING

U-RING

PISTON

WIPER RING

SEAL RING ASSY

NIPPLE

O-RING

SLIDE RING

PIPE ASSY

BACK-UP RING

SETSCREW

GREASE NIPPLE

O-RING

STEEL BALL

CAP

CUSHION BEARING

SPACER

10 HOLDER

24-I-8-5

(5) Dozer cylinder SK30SR-2 • SK35SR-2

Fig. 8-6 Construction of dozwe cylinder

No.

NAME

Q’TY

No.

NAME

Q’TY

No.

NAME

Q’TY

CYLINDER TUBE ASSY

BUCK-UP RING

PIN BUSHING

PISTON ROD ASSY

O-RING

WIPER RING

CYLINDER HEAD

PISTON

GREASE NIPPLE

BUSHING

SEAL RING ASSY

GREASE NIPPLE

U-RING

SLIDE RING

CAP

WIPER RING

SETSCREW

O-RING

STEEL BALL

24-I-8-6

8.2.2 Function (Example for boom cylinder) BACK-UP RING

BACK-UP RING O-RING

O-RING HOLDER

CYLINDER HEAD (3)

WIPER RING (6)

CYLINDER TUBE

PISTON ROD (2)

BUSHING (4)

SPACER

U-RING (5)

CUSHION SEAL COLLAR

Fig. 8-7 Cylinder head assy

(1) Fundamental Function

position of the cylinder, a high oil pressure is

This is of a kind of hydraulic actuator, and con-

generated to ease the cylinder shock at the fully

verts the energy in pressurized oil supplied by

extended position. And the cylinder head has

the hydraulic pump to a large force linear direc-

another function of charging and discharging

tion by means of the piston, as well as changing

highly pressurized oil from the inside of cylinder

over the operating direction for either extension

tube to the port.

or retraction by means of actuating the valve lever to change over the direction of pressurized

â&#x20AC;˘ Bush (4)

oil flow. Such conversion of energy force and

The bush (4) is pressed into the bore on cylinder

change over the operating direction are of the

head to support the piston rod. Along with the

fundamental function of this cylinder.

slide ring installed outer periphery of the piston, the bush (4) bears radial load imposed on the

(2) Function of each Parts

cylinder, and performs linear movement against

The following description is based on a cylinder

the piston rod at high facial pressure, and mini-

with a typical structure (Boom cylinder).

mized the eccentricity of piston rod that badly affects to the sealing effect by supporting its one

1) Cylinder Head Assy

end.

The cylinder head assy also works as a bearing by means of pressing the bush (4) into the cylin-

â&#x20AC;˘ Wiper Ring (6)

der head (3). The oil leakage is prevented by

The wiper ring (6) is located at the entrance

insersion of the U-ring (5) into the bore of cylin-

where the piston rod comes in and out. Its func-

der head. The dust invasion is protected by

tion is to protect invasion of dust and water into

pressing the wiper ring (6) into the bore of cylin-

the cylinder to secure good sealing effect of the

der head. By means of fitting with the cushion

U-ring (5), as well as to remove dust and mud

bearing (14) at adjacent to the fully extended

adhered on the piston rod.

24-I-8-7

Fig. 8-8 Piston assy

2) Piston Assy

the eccentricity of piston rod that badly affects to

The piston assy has the seal ring (16) which is

the sealing effect by supporting it at one end.

inserted at the center portion of the piston (15),

And the slide ring has another function of bury-

to prevent leakage of pressurized oil from either

ing and catching contaminations between the

chamber of left or right to the other chamber. The

cylinder tube and the slide rings.

slide rings (17) are inserted in both sides of the seal ring (16) to bear radial load imposed on the

â&#x20AC;˘ Cushion Bearing (14)

cylinder, and also to catch contaminations.

The cushion bearing (14) is located between the piston and the stepped portion of piston rod.

â&#x20AC;˘ Seal Ring (16)

Along with the cylinder head, it has the functions

The location of seal ring (16) is the center of pis-

to form a circular gap adjacent to the fully ex-

ton. The seal ring (16) is to seal the circular gap

tended position, and to throttle the oil to ease

between the piston and the cylinder tube utiliz-

the collision speed of cylinder at the fully ex-

ing a tension of the O-ring, to from both cham-

tended position to soften the shock.

bers of high pressure side and low pressure side isolating from each other making the piston as the border. â&#x20AC;˘ Slide Ring (17) Two slide rings are provided at both sides of the seal ring (16) directly getting in touch with the cylinder tube. Along with the bush (4), the slide rings (17) bear radial load imposed on the cylinder, perform linear movement against inside face of cylinder at high facial pressure, and minimize

24-I-8-8

Part II : ELECTRICAL EQUIPMENT

[

]

D-1 D-2 D-3 D-5 D-7 D-12 D-13 D-14

SE-1 SE-2

E-2

Electical Fittings

E-3 E-4 E-6 E-7 E-8 E-10 E-12 E-13 E-14 E-15 E-20

Light

L-1 L-2 L-3 L-4 M-1

Motor

M-2 M-3 M-4 M-6

Relay

R-1 R-2 R-3 R-6 R-7 R-8 R-9 R14 R-22 R-23 [R-24] [R-25]

YN02D01001P1 2475U38

Sensor

2475U38

Part Name FUEL SENSOR ENGINE THERMO SENSOR

Part No. PW52S00002P2 PA24S00003P1

Solenoid

E-1

DIODE DIODE DIODE DIODE DIODE DIODE DIODE DIODE

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

Switch

Diode

2.1A ELECTRICAL EQUIPMENT LIST Applicable Machines SK30SR-2 : PW08-20001~ SK35SR-2 : PX09-08001~ Group Code Part Name Part No. Group Code

SW-23 SW-24 SW-25 SW-26 SW-27 SW-28 SW-30 SW-31 [SW-33] [SW-34]

KEY SWITCH WORKING LIGHT SW. 2-SPEED SELECT SW. WIPER WASHER SW. E/G COOLANT TEMP. SW. E/G OIL PRESSURE SW.

(Note) • The Code Nos. in [ ] are applicable for the following Machine Nos. SK30SR-2 : PW08-20995~ SK35SR-2 : PX09-08585~ • The Part Nos. before the improvement / change are put in [ ].

24-II-1-1

2.1B ELECTRICAL EQUIPMENT LIST Applicable Machines SK30SR-2 : PW10-22001~ SK35SR-2 : PX11-08901~

[

PM73E00004F6 E/G accessory (119836-77201) PH53S00001P1 PH73S0001P1 EU•OCE PM59S00002F2 GAUGE CLUSTER USA PV59S00001F2 POWER SOCKET [EU] PF81S01001P1 AIR HEATER E/G accessory (129120-77501) RADIO (OPT) Cab accessory (PY54S00001P1) HEATER (OPT) PM21M00005F1 BATTERY PU72S00001P1 SEQUENCE BOX PA24S00002P3 FUSE BOX (OPT) PH73E00004F1 (FOR COOLER) TRAVEL ALARM PM50S00001S001 [OCEANIA] ROOM LAMP Cab accessory (PM80S00006P1) BOOM WORKING LIGHT (LH) PM80S00005F1 CAB WORKING LIGHT (OPT) PY80S00002F1 CAB WORKING LIGHT (OPT) STARTER MOTOR E/G accessory (129698-77010) WIPER MOTOR Cab accessory (PM76S00001F1) WASHER MOTOR PE54C00002S002 DECELERATION MOTOR PW20S00005F1 [EU•USA] (OCE:OPT) FUEL PUMP (OPT) PM22P0001P1 (AUTO AIR BLEED) BATTERY RELAY PH24S00001P1 SAFETY RELAY PH24S00002P1 DECELERATION PM24S00001P1 RELAY (OPT) TIMER UNIT PH25S00002P1 E/G STOP RELAY PH24S00001P1 CHARRGE INDICATOR PA24E01001P1 RELAY OPT. WORK LIGHT RELAY PM24S00001P1 SLEW / SWING PA24E01001P1 SELECT RELAY [USA] S.W. SELECT RELAY [USA] PM24S00001P1 SLEW/SWING PRESERPA24E01001P1 VATION RELAY [USA] NIBBLER OPEN RELAY [USA] PM24S00001P1 NIBBLER CLOSE RELAY [USA] PA24E01001P1

Electical Fittings

E-6 E-7 E-8 E-10 E-12 E-13 E-14 E-15

L-2 L-3 L-4 M-1 M-2 M-3 M-4 M-6 R-1 R-2 R-3 R-6 R-7 R-8 R-9 R14 R-22 R-23 R-24 R-25

YN02D01001P1

Part Name

Part No.

SE-1 SE-2

FUEL SENSOR ENGINE THERMO SENSOR

PW52S00002P2 PA24S00003P1

SV-1 SV-2 SV-3

[USA] YN02D01001P1

Solenoid

FUSE BOX GENERATOR (ALTERNATOR) HORN FUSIBLE LINK

2475U38

Sensor

E-1 E-2

L-1

Light

Group Code

DIODE DIODE DIODE DIODE DIODE DIODE DIODE

E-20

Motor

Part No.

D-1 D-2 D-3 D-4 D-12 D-13 D-14

E-3 E-4

Relay

Part Name

SV-5 SV-9 SV-10 SV-12

SW-1 SW-2 SW-3 SW-4 SW-5 SW-6 SW-7 SW-9 SW-10 SW-11 SW-12

Switch

Diode

Group Code

]

24-II-1-2

SW-23 SW-24 SW-25 SW-26 SW-27 SW-28 SW-30 SW-31 SW-33 SW-34

KEY SWITCH WORKING LIGHT SW. 2-SPEED SELECT SW. WIPER WASHER SW. E/G COOLANT TEMP. SW. E/G OIL PRESSURE SW.

2.3 SPECIFICATIONS ELECTRICAL EQUIPMENT Code No. Parts Name Parts No. Use Applicable Machine

Specifications

A : D-1 2 3 7 12 B : D-1,2,3,12 Diode

Model

Description

PM210-02031

Rated current

1.1A or less

Breakdown

800V or more

2475U38 Horn E/G stop solenoid E/G stop relay Working light relay Battery relay

Mating connector YAZAKI Connector 7123-6026-60 Terminal 7116-2871 Rear holder 7157-6222-50

{ PW08-20001~ PX09-08001~ PW10-22001~ B { PX11-08901~ A

A : D-5,13 B : D-4,13,14 Diode

Type Max rated

7321-9822-30

Current

Breakdown

400V

YN02D01001P1 Travel 1 2speed Slew/Swing relay [USA] E/G stop solenoid

{ B { A

PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

Mating connector Maker

Terminal

2poles 4poles

D-14 Diode

Housing

Type Max rated

7321-9332-60

Current

2.5A

Breakdown

600V

2475R132 Housing YAZAKI 7122-2228-60

E/G stop solenoid PW08-20001~ PX09-08001~ Maker

Housing

Terminal

YAZAKI

7123-2228

7 11 6 - 2 0 9 0

24 -II -2 -1

Diode YAZAKI 7157-1208 HITACHI UO5G

SECTION AA

Terminal

YAZAKI 7114-2020

Code No. Parts Name Parts No. Use Applicable Machine

Specifications

Spare fuse

E-1 Fuse box

10A one 30A two

With Connector [OCEANIA Only] Applicable Machines : PW08-20001~ : PX09-08001~

]

PM73E00004F3 [OCE] PM73E00004F6 [EU¥USA]

30A

Circuit protection

30A

PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

30A

30A 10A

10A

30A

10A

30A

10A 10A

E-2

YANMAR Part No.

119836-77201

Generator (Alternator)

Voltage

12V

Rated revolution

4500r.p.m

119836-77201

10A

[

Description

Current

40A (13.5V)

Weight

3.5kg (7.7lb)

Wiper Heater Deceleration relay Solenoid Working light Deceleration motor Horn Room lamp Engine stop Solenoid Gouge clusor Battery relay

IC TERMINAL

M5 BAT TERMINAL L TERMINAL ing n tat ctio o R ere d

Generator PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~ P TERMINAL YAZAKI 7115-1050-02

CHARGE LAMP CONDENSER DIODE

DIODE DIODE

BATTERY

COIL

KEY SWITCH

ALTERNATOR IC REGULATOR

E-3 Horn PH53S00001P1 Warning sound

Maker Part No.

BG62-66-790A

Rated Voltage

DC12V

Rated current

Max 3.5A

Basic frequency

390–20Hz

Sound level

110–5dB

Insulation resistance 1M‰ or more/500VMegger

PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

Drain 2holes

24 -II -2-2

Code No. Parts Name Parts No. Use Applicable Machine E-4

Specifications

Description

Allowable current

45A

Operating voltage

12V

Fusible link PH73S00001P1 Fuse PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

E-6

CONNECTOR TABLE

Gauge Cluster [EUÂĽOCE] PM59S00002F2

No. 1 2 3

Monitor Panel

4 5

PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

6 7 8

Connection Illumination (+) E/G oil press (-) Charge (-) E/G coolant temp (-) Lamp power source-1 (+) [E/G coolant, Fuel, Travel, 1, 2 speed] Fuel (-) Travel 2speed (-) Lamp power source-2 (+) [E/G oil press., Charge, Hour, meter]

9 10 11 12 13 14 15

Fuel level sensor/water temp.sensor (+) Fuel sensor Fuel sensor/water temp.sensor illumination(-)

16 17

Front side

Reverse side

Connector

Hour meter (-)

18 19 20

Water temp. sensor

Housing :174977-2 Terminal :173682-1

20MA-040MLI

24 -II -2 -3

Code No. Parts Name Parts No. Use Applicable Machine E-6

Specifications

CONNECTOR TABLE No. 1 2 3

Monitor Panel

4 5

PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

12V

Operating voltage

Gauge Cluster [USA] PV59S00001F2

Description

6 7 8 9

10 11 12 13 14 15

Fuel level sensor/water temp.sensor (+) Fuel sensor Fuel sensor/water temp.sensor illumination(-)

16 17

Front side

Reverse side

Connector

Hour meter (-)

18 19 20

Water temp. sensor

Housing :174977-2 Terminal :173682-1

20MA-040MLI E-7

Operating voltage

DC 12V

Operating current

15A (Max)

Power socket [EU] YN81S00001P1 Power Souce PW08-20001~ PX09-08001~

E-7 Operating voltage

DC 12V (Water-proof type)

Power socket [EU] PF81S01001P1 Power Souce Conector Housing : 174354-2 Terminal : 171661-1

PW10-22001~ PX11-08901~

24 -II -2-4

Code No. Parts Name Parts No. Use Applicable Machine E-8 Air heater 129100-77500

Specifications

YANMAR Part No.

Description

M6 TERMINAL TIGHTENING TORQUE 0.35 ~ 0.5 kgf•m (2.5 ~ 3.6 lbf•ft)

129100-77500

Rated voltage

DC11V

Rated current

36.5A

Rated output

400W

Insulation resistance 3M‰ or more / 500V megger

E/G starter PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

EARTH

E-10

Maker

CLARION

Voltage

12V

Tuner

Display

Display button

PY54S00001P1 Radio(OPT) PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

Speaker

Preset button Power/volume 1~6 Tune/time adjust

E-12 3PM

Heater PM21M00005F1

Electric circuit

Vinyl tube LR

Heating(OPT)

DC12V

10AFuse LW

PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

Machine side

24 -II -2 -5

Code No. Parts Name Parts No. Use Applicable Machine E-13 Battery PU72S00001P1

Specifications

Type

Description

FZG-B24R

Rated voltage

DC12V

Capacity

38Ah/5HR

Amount of electrolyte

3.2L

Rated voltage

DC12V

Power source PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

E-14 Relay PA24S00002P3 Sequence(Holding circuit) PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

Input/output operation GND Decel.relay solenoid

Decel.SW

Travel1,2speed solenoid

Electric circuit

E-15

Maker’s Part No. Fuse

AMP : 0-175783-1 Mating connector : 0-174923-1 Terminal : 175027-1

Travel1,2 speed SW

Pin arrangement

1406-2000 20A blade

Fuse box (For cooler) PH73E00004F1 Fuse (OPT) PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

E-20 Travel alarm[OCEANIA] (EU ¥ USA : OPT) PM53S00001S001

Maker’s Part No.

TMKSL-0004-01

Rated voltage

DC12V¥24V

(Usage range) Rated current

(9~36V) Max 50mA at rated voltage

Warning sound PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

SUMITOMO CONNECTOR : 090 HOUSING : 6187-2311 TERMINAL : 1500-0105 HARNESS SEAL : 7180-8234

24 -II -2-6

Code No. Parts Name Parts No. Use Applicable Machine

Specifications

L-1

Model

Light

Description

17030-01700

Rated voltage

12V

Bulb

12V10W

Rated voltage

12V

Bulb

12V10W

2456U114 Room light (Cab Spec.) PW08-20001~ PX09-08001~

L-1 Light PM80S00006F1 Room light (Cab Spec.) PW10-22001~ PX11-08901~

L-2

¥A Maker s P/No.

DS U023

Light

Effective area of lens

102 cm2

A : 2456R243F2 B : PM80S00005F1

Bulb

Halogen12V-55W

Maker s P/No.

BL84-150

Effective area of lens

82 cm

Bulb

Halogen12V-55W

Bulb

12V-55W

Boom working light (L.H.) ¥B

{ B { A

PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

L-3, 4

Light PY80S00002F1 Working light (OPT) (Cab Spec.) PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

24 -II -2 -7

M12 Bolt

CA104

Code No. Parts Name Parts No. Use Applicable Machine

Specifications

M-1 S TERMINAL

Motor

Description

M8 B TERMINAL TIGHTENING TORQUE 0.88 ± 0.12 kgf•m (6.4 ± 0.9 lbf•ft) PINION

M8 M TERMINAL

129698-77010 E/Gstarter PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

129698-77010

Rated voltage

DC12V

Rated output

1.2 kW

Rated time

Rotating direction

YANMAR Part No.

30 Sec 3.0 kg (6.6 lb)

Weight Rotating dinection Number of pinion teeth

Clockwise as seen from pinion 11 View Z

M-2 Motor

Maker s P/No.

S16WMT10165

Rated volt age

12V 106¡ –3¡

Wiping angle

YJ76S00001P1 Wiper (Cab Spec.) PM05-05001~ PV08-20001~ PW08-20001~ PX09-08001~

M-2 Motor

YAZAKI7122-2045

Maker s P/No.

S49100-5120

Rated volt age

12V 105¡ –3¡

Wiping angle

PM76S00001F1 Wiper (Cab Spec.)

R (+1)

Y(S)

PM06-05601~ PV09-22001~ PW10-22001~ PX11-08901~

CONNECTOR YAZAKI 7322-2045

24 -II -2-8

Code No. Parts Name Parts No. Use Applicable Machine M-3

Specifications

Rated volt age

Description

DC12V

Motor PE54C00002S002 Wiper washer (Cab Spec.) PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

M-4 Motor [PM20S00001F1] PM20S00004F1 Deceleration [EU¥USA] (OCEANIA : OPT) PW08-20001~ PX09-08001~

side

side (at shipping) Stroke

Rated voltage

12V

Working force

15kg or more

Spring tension

Setting16–2kg

Working time

1or less

Stroke

35 +1.0 -0.4 mm

24 -II -2 -9

Plug

BS YAZAKI Connector Pin arrangement

Code No. Parts Name Parts No. Use Applicable Machine

Specifications

Description

M-4 10

Motor

PW20S00005F1 42

Deceleration [EU¥USA] (OCEANIA : OPT)

P1 P2 36 Stroke

PW10-22001~ PX11-08901~

AMP Connector Type : 174264-2 plug

Switch Rated voltage

12V

Stroke

36 – 2 mm

Working force

11Kg or more

Working time

1or less

Working current

3.5A or less

(

—)

(—)

Relay

PTC Themistor

M-6 Fuel pump

Rated voltage

DC12V

Max.working current

1.5 A or less

Delivery rate

At open condition 400cc/min or more

PM22P00001P1 Auto air bleed (OPT) PM05-05001~ PV08-20001~ PW08-20001~ PX09-08001~

YAZAKI water proof connector BS-2M 7118-3320-30 (Black)

Mating connector YAZAKI No.7319-3320

AEX 0.5B(Black) AEX 0.58R (Red) Vinyl tube (Blue)

INLET

24 -II -2 -9A

OFF : P2 ON : P1

OUTLET

Code No. Parts Name Parts No. Use Applicable Machine

Specifications

Description

This page is blan because of editing convenience.

24 -II -2 -9B

Code No. Parts Name Parts No. Use Applicable Machine R-1 7 Relay PH24S00001P1 Battery relay E/G stop relay

Specifications

Maker s P/No.

VF7-41F11

Rated voltage

DC12V

Coil resistance

72‰–10%

Insulation resistance

20M‰ (500V)

Applicable connector Applicable terminal

PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~ R-2 Safety relay PH24S00002P1

Description

VCF7-1000(P&B) AMP280756-4 AMP280755-4 AMP42281-1

Connection diagram YANMAR Part No.

129136-77101

TIGHTENING TORQUE OF S, B TERMINAL 0.3 ~ 0.4 kgf•m (2.2 ~ 2.9 lbf•ft)

DC12V

Rated voltage

Continuous

Rated Temperature range

-30 ~ 80…C (-22 ~ 176 …F)

CONNECTOR YAZAKI 7222-6244-40

B TERMINAL

0.5 kg (1.1 lb)

Weight Protection of starter PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~ R3 8, 9,14, 22, 23, 24, 25 Relay

WHITE ACC

YELLOW P S TERMINAL E BLACK

C BLACK / WHITE

Maker s P/No.

RC-5103

Rated voltage

DC12V

Insulation resistance 1‰ or more/20A,20¡C PM24S00001P1 (R3, 9, 22, 23, 24) PA24E01001P1(R8,14, 23, 25) Deceleration relay (OPT) Charge indicator relay Work light relay (OPT) Select relay [USA] Nibbler relay [USA]

PM05-05001~ PV08-20001~ PW08-20001~ PX09-08001~ R-6 Relay PH25S00002P1

4 Circuit diagram

YANMAR Part No.

129211-77920

Rated voltage

12V

Exciting current

Timer

1sec

Timer Unit

3 With braket (P/No. PA24E01001P1)

Connector YAZAKI 7122-2446 Red (Acc)

PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

Red / White (Relay)

Black (GND) View Z

24 -II -2 -10

Yellow (Relay)

Code No. Parts Name Parts No. Use Applicable Machine SE-1 Sensor PW52S00002P2

Specifications

Description

Rated voltage

12V

Float position Resistance(‰) Allowable(‰)

Fuel sensor AFTER MATING 2

PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

8 MAX Meter

WARNING LAMP THERMISTOR

FUEL UNIT

GND.

Circuit diagram

SE-2

Rated voltage

DC12V

Type

Thermistor type

Sensor PA24S00003P1 E / G thermo sensor PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

Temperature (¡C)

(50)

100 (120)

Resistance value (‰) (153.9) 51.9 27.4 (16.1) The figures in parentheses are reference values

24 -II -2 -11

Code No. Parts Name Parts No. Use Applicable Machine SV-1 2

Specifications

Rated voltage

DC12V

Relief valve set pressure

35kgf/cm2 (500psi)

Solenoid Flow rate PH35V00001F2

Description

2-speed select

Lever lock

15L/min 4.0 gal/min (P port)

Safty lever lock Travel 2-speed select PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

T=Tightening torque T=4.5 – 0.5 kgfÆm T=0.8 – 0.1 kgfÆm (33 – 4 lbfÆft) (5.8 – 0.7 lbfÆft)

SUMITOMO Connector Hw090, 2PM Housing : 6181-0070 Terminal : 1500-0105

T=4.5 – 0.5 kgfÆm (33 – 4 lbfÆft)

SV-3

YANMAR P/No.

119233-77931

Rated voltage

DC 12V

Solenoid Rated current 119233-77931

Pull coil : 36.5Amps

Stroke7.4mm GND(Black)

Hold coil : 98Amps

E/G stop connector YAZAKI 7222-6234-40

PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

Pull coil (White) Hold coil (Red)

24 -II -2 -12

Code No. Parts Name Parts No. Use Applicable Machine SV-5 Solenoid YJ35V00004F1

Specifications

Description

Type

AGCD

Rated voltage

DC12V

Capacity

12W

Operating pressure Max. flow

50kgf/cm (710psi) 160 /min (42gal/min)

Power shift (Cooler spec.) PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

SV-9, 10 Solenoid

Rated voltage

DC12V

Consumption power

12W

Rated pressure

50kgf/cm (710psi)

PY35V00005F1

SOL. A SOL. B

Nibbler open SOL. [USA] Nibbler close SOL. [USA]

AMP Conector Housing : 174354-2

PW08-20995~ PX09-08585~ PW10-22001~ PX11-08901~

Terminal : 173706-1

Solenoid

P HYDRAULIC CIRCUIT

SV-12

Rated voltage

DC12V

Consumption power

12W

Rated pressure

50kgf/cm (710psi)

PE35V00001F1

SUMITOMO Connector HW090 (2P) Housing : 6181-0070 Terminal : 1500-0105

Slew/Swing select [USA] PV08-20001~ PW08-20001~ PX09-08001~ HYDRAULIC CIRCUIT

24 -II -2 -13

Code No. Parts Name Parts No. Use Applicable Machine

Specifications

4MY -312

SW-1

4MY -CNA

Description

CONNECTION TABLE

Switch PM50E00001F1

TO N AU TUR RE

TO AU RN TU E R

Key switch PM05-05001~ PV08-20001~ PW08-20001~ PX09-08001~

¿5 DRAIN HOLE

SW-1

CONNECTION TABLE

Switch PH50E00007S001

TO N AU TUR RE

TO AU RN U T RE

Key switch PM06-05601~ PV09-22001~ PW10-22001~ PX11-08901~

¿5 DRAIN HOLE

SW-2

M Switch PV24E01001P1

(E)

OFF ON

L:70WX2 lamps L

Working light

( Unconnected )

PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

SW-3

OFF

Connection table

M Type

Buried in right travel lever

Switch YN03M01286S002 (Right travel lever) Trvel 1 2speed PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

24 -II -2 -14

(E) Switch & Maks

Code No. Parts Name Parts No. Use Applicable Machine SW-4 Switch PY50S00004P1

Specifications

Description

Type

0850-00596

Insulation resistance

1M‰ or more (DC500V Megger)

Connection table

Auto return Auto return

Load 2A

Wiper washer (Cab only)

3A (Peak10A) 3A (Peak10A) 5A (Peak10A)

PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

Wiper motor

Cam switch, Wiper Washer, Motor

SW-5

YANMAR Part No.

Switch

Operating temperature

PM50S00006P1

Electric capacity Insulation resistance

E/G water temperature Tightening torque

121250-44901 ON : 110 – 3¡C, OFF : 100¡C or less DC12V 1A 100M‰ or more/ 500V Megger 2.8 kgf¥m (20lbf¥ft)

PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~ SW-6 Switch 114250-39450

Connector YAZAKI 7323-2446

Identification : Gray Paint

YANMAR Part No.

114250-39450

Rated voltage

DC6V, 12V, 24V

Rated load

5W (Lamp load)

HEX 24

49 – 1 kPa Operating pressure

E/G oil pressure

0.5 – 0.1 kgf/cm2 (7.1 – 1.4 psi)

PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~ SW-7 [EU¥OCE] Type Switch YN50E01001P1

MIYAMA DS-257 OFF-(ON) momentary

Rated

125V 3A (AC)

Insulation

100M‰ or more /

resistance

500V Megger

Horn switch SUMITOMO Housing 6090-1031 Terminal 8230-4282

PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

24 -II -2 -15

Code No. Parts Name Parts No. Use Applicable Machine

Specifications

Description

SW-7 [USA] Grip & Switch LF03M01005F1 Horn Switch PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~ SW-8 [EU ¥ OCE] SW-9

Rated voltage

DC12V

Rated current

15A

Switch

Insulation resistance

1M‰ or more

PA50S00001P1

Stroke

CA104 (With sleeve)

M20 X 1.5

Switch ON :2–1mm Full stroke :10–2mm

Lever lock SW. (RH,LH) PW08-20001~ PX09-08001~ PW10-22001~ SW-9 Only PX11-08901~

CB104 (With sleeve)

}

SW-10

Maker s part No.

0850-00595 Load

Switch PY50S00003P1 Heater switch (OPT) PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

PLUG Connector YAZAKI 7323-2446

SW-11 Rated voltage Switch

DC12V

Connection table

(MAX:DC16V)

Insulation resistance 1M‰ or more(500VMegger)

PM50S00005P1 Deceleration switch (OPT) PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

6242-1061(SUMITOMO) Mating connector 6242-5061(SUMITOMO)

24 -II -2 -16

Code No. Parts Name Parts No. Use Applicable Machine SW-12

Specifications

Type

REX 801001

Type

RBX 002252

Description

Switch [USA] YR11P00008S005 Air filter clogging switch PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~ SW-12

Air Filter

Switch [OCEANIA] 2446U336S8 Air filter clogging switch PW10-22001~ PX11-08901~ Switch SW-23

Rated voltage

Select Switch [OCE] (EU : OPT)

Insulation resistance

DC12V ¥ 24V 1M‰ or more/ 500V Megger

2479U1190F16 Travel Alarm PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~ SW-24,25,26,27[OCE] SW-30,31[USA]

Contact rating

Switch Insulation resistance GB50S00049F1

Voltage : 18 ~ 30V Current : 10mA ~ 3.5 A 100M‰ or more/ DC 500V Megger

Travel alarm [OCE] Slew/Swing lever [USA] pressure switch PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

24 -II -2 -17

PT 1/8

SUMITOMO 090 type water proof connector Housing : 6187-2311 equivalent

Code No. Parts Name Parts No. Use Applicable Machine

Specifications

SW-28, 33, 34 [USA] Grip & Switch LF03M01005F3 Slew/Swing select SW. Nibbler open SW. Nibbler close SW. PW08-20001~ PX09-08001~ PW10-22001~ PX11-08901~

24 -II -2 -18

Description

Book Code No.

PW31 02E ➀

NEW HOLLAND EH35 Model Cross-reference: SK35SR-2 is NEW HOLLAND Model EH35

WHOLE DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS 1. EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY 1.1 Form for Chapter of Disassembly & Assembly ................................. 1-1 1.2 Indication of Tightening Torque ........................................................ 1-1

PW31

31 -0-1 ➀

Revision First edition ------Second revision

Date of Issue January, 2001 December, 2002

Remarks S5PW3102E A S5PW3102E ➀ A

Any use of editorial or pictorial content is strictly prohibited without express written permission from New Holland Construction, LLC. Carol Stream, IL 60188 U.S.A. Copyright © 2003 New Holland Construction, LLC. All Rights Reserved.

31-0-2 ➀

1. EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY 1.1

FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY This chapter is consist of 3-Section as follows.

(1) ATTACHMENT .............................................................................................................Code No. ; PW32 Part I ; Removing and Installing Assy Part II ; Disassembling and Assembling Components 1) Hydraulic cylinder (2) UPPER SLEWING STRUCTURE .................................................................................Code No. ; PW33 Part I ; Removing and Installing Assy 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 ........................................................................................................Code No. ; PW34 Part I ; Removing and Installing Assy Part II ; Disassembling and Assembling Components 1) Travel Motor 1.2

INDICATION OF TIGHTENING TORQUE Tightening torque is indicated as follows, for example; T = 10 kgf·m (72 lbf·ft) Tolerance is ± 10% unless specified. • Refer Code No. PW11 TOOLS for standard tightening torque.

31-1-1

PE3

NOTES

Book Code No.

PW32 02E ➀

NEW HOLLAND EH35 Model Cross-reference: SK35SR-2 is NEW HOLLAND Model EH35

ATTACHMENTS TABLE OF CONTENTS PART I ; REMOVING AND INSTALLING ASSY 1. ATTACHMENT ASSY AND NAME ....................................................... I-1-1 2. BUCKET............................................................................................... I-1-2 3. ARM ..................................................................................................... I-1-4 4. BOOM .................................................................................................. I-1-6 5. SWING ................................................................................................. I-1-8 6. DOZER ................................................................................................. I-1-10 PART II ; DISASSEMBLING AND ASSEMBLING COMPONENTS 1. CYLINDER ............................................................................................II-1-1

PW32

32 -0-1 ➀

PREFACE 1.

This manual covers all the procedures required for the dis/re-assembling of the machine in compilation by items.

This manual consists of Part I ; REMOVING AND INSTALLING ASSY, and Part II ; DISASSEMBLING AND ASSEMBLING COMPONENTS.

Though general dis/re-assembling procedures are able to carry out nearly in the order of Table of Contents, some items may be omitted because of the circumstances at the actual repair work or the purpose of time saving.

Please understand that it is impossible to accord the descriptions with all cases of the actual process for the removal/installation of the assembled components, because of difference in the field conditions or defective section and the convenience in compilation of this manual.

Please be aware the importance to establish the working order. Prior to carry out the removal/installation and dis/re-assembling works, select the sections presumably required, fully understand the description, and itemize the working procedures, then start up the work.

Revision First edition Second revision

Date of Issue January, 2001 December, 2002

Remarks S5PW3202E A S5PW3202E ➀ A

Any use of editorial or pictorial content is strictly prohibited without express written permission from New Holland Construction, LLC. Carol Stream, IL 60188 U.S.A. Copyright © 2003 New Holland Construction, LLC. All Rights Reserved.

32-0-2 ➀

Part I : REMOVING AND INSTALLING ASSY 1. ATTACHMENT ASSY AND NAME

(N) SWING CYLINDER HEAD PIN

(M) SWING CYLNDER ROD PIN

(L1) (UPPER) (L2) (LOWER) SWING CENTERPIN

(A) BOOM FOOT PIN (B) BOOM CYLINDER HEAD PIN

(F) BOOM TOP PIN (E) ARM CYLINDER ROD PIN

(G) BUCKET CYLINDER HEAD PIN

(I) IDLER LINK PIN

(Q) (K) DOZER CYLINDER BUCKET HEAD PIN ATTACHING PIN

(H) BUCKET CYLINDER ROD PN

(J) BUCKER DRIVE PIN

Fig. 1-1 Attachment name and position

32 -I -1 -1

(P)DOZER PIN

(R) DOZER CYLINDER ROD PIN

2. BUCKET 2.1 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. Fig. 2-2 To place Bucket on ground

(3) In order to remove pin (K) which links arm and

bucket, remove the ring (2) and the pin (3) by means of straight driver, and draw out pin (K).

• If the pin does not come off easily, the pin is loaded. Take off the load by manipulating the operating lever.

2 B

• 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.

PIN FOR BUCKET LINK

DUST SEAL

1 SECTION BB

DAST SEAL

(5) Remove the ring (2) and pin (1) then pull out the pin (J). (6) Remove bucket assy. Weight : 89kg (196lb) --- SK30SR-2 92kg (203lb) --- SK35SR-2

PIN FOR ARM

Fig. 2-3Assembly of pin (SECTION A-A)

2.2 INSTALLATION OF BUCKET Installation is performed in the reverse order of removal, including the following workings : • When aligning the pin borees, 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) Adjust the clearance between the bucket and the arm according to Item 2.3. (4) Replace the worn pins and bushings according to the Section "ATTACHMENT DIMENSIONS" of "SPECIFICATIONS".

Fig. 2-4 Installation of bucket (5) When inserting the pin, coat the shaft with

32 -I -1 -2

grease. • The bucket can be mounted easily if the bucket link is installed in the beginning.

2.3 PROCEDURE FOR ADJUSTMENT OF CLEARANCE BETWEEN BUCKET AND ARM • Clearance shall be checked at every 120-hour operation in case of normal working.

10 3 (TEMPORARY POSITION)

• Shorten the checking interval according to work conditions. • Prior to adjusting work, wash the bucket hinge portion to remove adhered mud and grease, etc. (1) Move O-ring (3) toward the bucket boss, using a spatula, to see gap (B). (2) When adjusting clearance (B), bring the non-adjusting side of the bucket in contact with the arm. (3) Measure clearance (B) and check that it is within 0.5mm (0.02in). (4) Adjust clearance (B) where it is more than 0.5mm (0.02in). (5) Several shims (10) of 0.5mm (0.02in) thickness are set in each of the three capscrews (8). The clearance can be decreased by 0.5mm (0.02in) if one each shim is removed. (6) After adjusting by required shims, tighten 3capscrew (8) evenly. By the above procedure, bushing (A) is pushed toward inside, and then clearance is adjusted within 0.5mm (0.02in). : 17mm T=6.7kgf·m(48lbf·ft) • Specified clearance is required between bushing (A) and arm. (7) Operate the bucket and confirm that the total of both clearances are within 0.5mm (0.02in). (8) Reinstall O-ring (3) to its original position.

32 -I -1 -3

A B Fig. 2-5 Adjustment of clearance between bucket and arm

3. ARM 3.1 REMOVAL OF ARM (1) Making the arm cylinder and bucket cylinder to the most retracting conditions, get touch the arm tip with the ground. (2) Depressing the air breather on the hydraulic oil tank, release the pressure in the tank. (3) Disconnect the 2 hoses connected to the bucket cylinder. Then apply a blinding plug to the openings. : 22 mm

Fig. 2-5 Arm removing Posture

(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. : 17mm (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).

PIN (F) PORTION

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

PIN (E) PORTION

Fig. 2-6 Sectional view of Installing Pin

: 24mm (9) Remove the arm assy paying attention to the stability of arm.

BUCKET CYLINDER

Weight of arm assy: approx. [EU]

[USA] SK30SR-2 : 105kg (230lb) SK35SR-2 : 110kg (240lb) (10) Removal of Bucket Cylinder

120kg (265lb) 125kg (275lb)

1) Remove the capscrew that is preventing the rod pin (H) from coming out, then pull off the pin (H). : 24mm

Fig. 2-7 Removal of Arm assy

SHIM

PIN (H) PORTION

PIN(G)PORTION

2) Remove the capscrew and nuts that are preventing the head pin (G) from coming out, then pull off the pin (G). : 17mm 3) Apply a nylon sling to the tube of bucket cylinder, and remove the cylinder. Weight ; approx. 21kg (46lb)

32 -I -1 -4

Fig. 2-8 Sectional view of Installing Pin

3.2 INSTALLATION OF ARM Installation is performed in the reverse order of removal, including the following workings.

BOSS

â&#x20AC;˘ At the alignment of pin bores, never insert your finger into the bores. â&#x20AC;˘ Make sure to align them with visual confirmation.

DUST SEAL

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

(2) Check the dust seal for damages, and replace the faulty dust seal to new one (referring to Fig. 2-9 for the installing procedures). (3) Referring to the Section "ATTACHMENT DIMENSIONS" 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. 2-10, install the capscrew and nuts to prevent the pin from coming out.

Fig. 2-9 Dust seal installation

(6)Make sure to provide an appropriate clearance for thrust direction at the installation of pin referring to Fig. 2-10. (7)For the adjustment for clearance, insert resin (plastic) shim first, then adjust the clearance with steel shims.

: 17 mm

G H

F The sum of both cleamncesto be within 0.1mm(0.004in) to 0.5mm(0.02in) The sum of both clearances: To be from 0.6mm(0.024in)to 1.0mm(0.039in) after shim adjustment

The sum of both clearances: To be from 0.5mm(0.020in)to 0.9mm(0.035in) after shim adjustment

SHIM The sum of both clearances : less than0.5mm(0.020in) after shim adjustment

SHIM

The sum of both clearances: To be from 0.5mm(0.020in)to 0.9mm(0.035in) after shim adjustment

SHIM

1.0~1.5 (0.04"~0.06")

SHIM

1.0~1.5 (0.04"~0.06")

2.0 (0.08")

SHIM The clearance to be from 0.1mm(0.004in) to 0.5mm(0.02in)

PIN (H) PORTION

PIN (G) PORTION

PIN (F) PORTION

Fig. 2-10 Sectional view of Installing Pin

32 -I -1 -5

PIN (E) PORTION

4. BOOM D

4.1 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 a blinding plug to all the openings. : 22 mm

C B

(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. 2-11 Removal of Boom Cylinder

2) Removing the capscrew and nuts that are preventing the rod pin (C) from coming out, remove the pin (C). : 17 mm 3) Retract the rod, then put the cylinder on a stable stand. 4) Removing the capscrew that is preventing the head pin (B) from coming out, remove the pin (B).

PIN (C) PORTION

PIN (B) PORTION

Fig. 2-12 Sectional view of Installing Pin

5) Remove the boom cylinder. Weight : 36kg (79lb) --- SK30SR-2 40kg (88lb) --- SK35SR-2 (5) Removal of Boom Assy

1) Temporarily lift up the boom assy in order not to exert any load to the boom foot pin (A). Weight of boom assy : approx. 190kg (420lb) --- SK30SR-2 220kg (485lb) --- SK35SR-2

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

Fig. 2-13 Removal of Boom Assy

(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). : 17 mm 2) Applying a nylon sling to the tube of arm cylinder, remove the arm cylinder. Weight : 31kg (68lb) --- SK30SR-2 36kg (79lb) --- SK35SR-2

PIN (D) PORTION

32 -I -1 -6

PIN (A) PORTION

Fig. 2-14 Sectional view of Installing Pin

4.2 INSTALLATION OF BOOM Installation is performed in the reverse order of removal, including the following.

BOSS

â&#x20AC;˘ At the alignment of pin bores, never insert your finger into the bores. â&#x20AC;˘ Make sure to align them with visual confirmation.

DUST SEAL

(1) Make clean the welded area on each of structure to inspect any cracks there.

BUSHING

(2) Check the dust seal for damages, and replace the faulty dust seal to new one (referring to Fig. 2-15 for the installing procedures). (3) Referring to the Section "ATTACHMENT DIMENSIONS" of Specifications, replace the worn-out pin and bush to new ones. (4) Before inserting the pin, apply grease to the shaft area. (5)Referring to Fig. 2-16, install the capscrew and nuts to prevent the pin from coming out. : 17 mm

Fig. 2-15 Dust seal installation

(6) Make sure to provide an appropriate clearance for thrust direction at the installation of pin referring to Fig. 2-16. (7) For the adjustment for clearance, insert resin (plastic) shim first, then adjust the clearance with steel shims.

C Apply grease SHIM The sum of both clearances to be from 0.1mm(0.004in) to 0.5 (0.02in) after shim adjustment

Apply Loctite #242 equivalent PIN (A) PORTION

The sum of both clearances: To be from 0.5mm (0.020in) to 0.9mm (0.035in) after shim adjustment

SHIM

1.0~1.5 (0.04"~0.06")

The sum of both clearances to be from 0.1mm (0.004in) to 0.5 (0.02in) after shim adjustment SHIM

The sum of both clearances to be from 0.1mm(0.004in) to 0.5 (0.02in) after shim adjustment SHIM

1.0~1.5 (0.04"~0.06")

2.5 (0.1")

PIN (C) PORTION

PIN (B) PORTION

Fig. 2-16 Sectional view of Installing Pin

32 -I -1 -7

PIN (D) PORTION

5. SWING 5.1 REMOVAL OF SWING BRACKET AND CYLINDER

(4) Remove the swing bracket (A9). Weight of Swing Bracket: 66kg (146 lb) 5.1.2 Removal of Swing Cylinder (C11)

(1) Preparation for Removal

(1) Disconnect 2 connecting hoses for the swing cylinder. : 22 mm

1) To make the removing work easy, swing by around 30Â° for leftward. 2) Remove cover(A1)then disconnect the hoses of bucket cylinder,arm cylinder and boom cylinder,and apply plugs to all the openings. : 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

5.1.1 Removal of Swing Bracket (A9)

(3) Take out the swing cylinder (C11) from the front side. Weight of Swing Cylinder : 34kg (75 lb)

(1) Removing the capscrew (C4) that is preventing the rod side pin (M) of swing cylinder (C11) from coming out, remove the pin (M). : 17 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). : 17 mm

N C11

A A9

C4 L2

Fig. 2-18 Removal of Swing Bracket

B8 A B8

Fig. 2-17 Swing Portion

32 -I -1 -8

5.2 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 bush to new ones. (3) Before inserting the pin, apply grease to the shaft area. (4) Refer to Fig. 2-19 for the shim adjustment at pin installing portion.

Set this upperside washer with the oil groove side positioned towards the ground.

A D

A C

C SECTION C-C

The sum of both clearances: To be from 0.5mm(0.020in)to 0.9mm(0.035in) SHIM after shim adjustment

4.5 (0.18")

The sum of both clearance : To be within 0.1mm(0.004in) to 0.5mm(0.02in) after shim adjustment SHIM

1.0~1.5 (0.04"~0.06")

Apply Loctite #242 equivalent SECTION D-D SECTION A-A

SECTION B-B Fig. 2-19 Sectional view of Pin Installing

32 -I -1 -9

6. DOZER 6.1 REMOVAL

B2, B3

Q C3, C4

(1) Put a support 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).

C1 R

(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.

SUPPORT

Fig. 2-20 Removing/Installing Dozer

(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 the cylinder (C1) with a timber, etc. : 17 mm

(6) Gradually move the machine to backward to remove the dozer.

(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).

Weight of dozer assy with : Standard

with Cutting edge (OPT)

SK30SR-2

145kg (320 lb)

155kg (340 lb)

SK35SR-2

163kg (360 lb)

173kg (380 lb)

(7) If necessary, remove the dozer cylinder by means of removing the pin (R) of head side. Weight of dozer cylinder: 21kg (46lb) --- SK30SR-2 23kg (51lb) --- SK35SR-2

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 "ATTACHMENT DIMENSIONS" of Specifications, replace the worn-out bushings and dust seals to new ones. (2) Before installing pin (P), (Q) and (R), apply grease to their shaft area. (3) Refferring to Fig. 2-21, install the nuts for capscrew to prevent the pin from coming out. : 17 mm

32 -I-1 -10

1.0 ~ 1.5 mm (0.04 ~ 0.06 in)

Fig. 2-21 Tightening Procedures for Nuts

Part II : DISASSEMBLING AND ASSEMBLING COMPONENTS 1. CYLINDER

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 1-1.

Table 1-1 List of Tools and Jigs Remarks

Tool/Jig Hammer Screwdriver Chisel Vise Wrench

Remarks

Tool/Jig

1. Steel hammer 2. Wooden or plastic hammer 2 ~ 3 kinds of minus driver of small and large sizes Flat chisel Capable to hold outer dia. of cylinder head and tube installing pin portion 1. Special wrench 2. Extension pipe for wrench

Gimlet Jig

Measuring Device

A sharp-point tool may be used in place of gimlet 1. For installing seal ring 2. For pushing seal ring into groove 3. For reforming seal ring 4. For pressing bushing 1. Slide calipers 2. Micrometer 3. Cylinder gauge 4. V-block

• For the details of special jigs, refer to Item 1.7 of this section.

1.2 GENERAL PRECAUTIONS • Carry out the disassembly and assembly works in a clean work shop, and always keep disas-

• After the installation of O-ring, confirm there is no twist on it. • Apply clean hydraulic oil to each sliding por-

sembled parts at clean conditions. • Prior to disassembly, thoroughly clean the cyl-

tion before the installation. • Confirm each sliding portion for no burr and

inder externally. • Use caution not to give any damages to the parts while carrying out the disassembly / as-

defect, and its smooth sliding operation. • This manual describes mainly for the swing cylinder as an typical example.

sembly works. • Thinly apply grease or hydraulic oil to seals

Confirm referring to the construction drawings in the [24-I-8]

prior to installation.

32-II-1-1

1.3 CYLINDER CONSTRUCTION (EXAMPLE OF SWING CYLINDER) • See [24-I-8] CYLINDER for the others.

24 25

25 24

7,8 10 13,7 2 12 11

No.

NAME

Q’TY

No.

1 2 3 4 5 6 7 8 9 10

CYLINDER TUBE ASSY PISTON ROD ASSY CYLINDER HEAD BUSHING U-RING WIPER RING O-RING BACK-UP RING O-RING HOLDER

1 1 1 1 1 1 2 1 1 1

11 12 13 14 15 16 17 18 19 20

17 16

18,19

22 21 20 23

NAME CUSHION SEAL COLLOR BACK-UP RING CUSHION BEARING PISTON SEAL RING ASSY SLIDE RING SETSCREW STEEL BALL CUSHION BEARING

Q’TY

No.

1 1 1 1 1 1 2 1 1 1

21 22 23 24 25 26 27 32 33 34

NAME CUSHION SEAL SNAP RING STOPPER PIN BUSHING WIPER RING NIPPLE PIPE ASSY GREASE NIPPLE CAP SPACER

Fig. 1-1 Construction of swing cylinder

1.4 DISASSEMBLY • The numbers in ( ) following to each part name are the numbers corresponding to those in Fig. 1-1 "Swing cylinder" except for notes. (1) Disassembly of cylinder assy 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 piston rod so that the hydraulic oil does not spout out. Fig. 1-2 Disassembling cylinder assy

32-II-1-2

Q’TY 1 1 2 2 4 1 1 1 1 1

3) Make straight the locking fin for the cylinder head. • Use cautions bending / straightening of locking fin, because locking fin and cylinder tube are made with one-piece.

Fig. 1-3 Unlocking cylinder head 4) Loosen the cylinder head (3). • Prior to loosening the cylinder head, pull out the piston rod (2) by 100 ~ 200 mm (4 ~ 8 in). • Cover the rod with an appropriate material to prevent it from unexpected bruises. 5) Pull off the piston rod assy from the tube. • Pull the piston rod in straight not to give any damages on the sliding surface. (2) Disassembly of piston rod assy

Fig. 1-4 Disassembling cylinder head

1) Fix the piston rod assy in level. 2) Disassembly of the piston a. Remove the setscrew (18), then remove the steel ball (19). • Since the setscrew is caulked at 2 positions with a punch, take off the caulked portion with a hand drill. b. Remove the piston (15) assy. c. Remove the cushion bearing (14) (for boom cylinder and swing cylinder only). 3) Disassembling of cushion bearing of retraction side (Only for swing cylinder)

Fig. 1-5 Disassembling piston rod

THREAD

PISTON ROD

14 24

15 19

18 23 19

SNAP RING (22)

CUSHION SEAL (21) One split portion

CUSHION BEARING (20)

STOPPER (23) Separated into 2 pieces

32-II-1-3

Fig. 1-6 Removing piston assy

4) Remove cylinder head (3) and holder (10). (Only

boom and swing cylinders for the holder) 10

Fig. 1-7 Removing cylinder head and holder

(3) Disassembly of piston assy: 1) Remove the slide ring (17) from the piston (15). â&#x20AC;˘ Expand the split on the slide ring (17) as minimum as required to pull it off for axial direction. (2 Points) 2) Remove the seal ring assy (16). â&#x20AC;˘ Cut off the seal ring (16) or remove it using a

minus screw driver. Fig. 1-8 Disassembling piston assy (4) Disassembly of cylinder head assy: 1) Remove the O-rings (7) (9) and back-up ring (8) from the outer periphery of cylinder head (3).

2) Disassembling holder (Only boom and swing cylinders) a. Remove collar (12). b. Remove cushion seal (11).

Fig. 1-9 Disassembling cylinder head assy

c. Remove spacer (34). d. Remove O-ring (7) and back-up ring (13) of outer diameter.

HOLDER BACK-UP RING (13)

O-RING (7)

CUSHION SEAL (11) COLLAR (12) SPACER (34)

Fig. 1-10 Disassembling holder

32-II-1-4

3) Removal of U-ring Remove the U-ring (5).

SECTION A-A Fig. 1-11 Disassembling cylinder head

4) Remove the wiper ring (6). â&#x20AC;˘ Alternately tap inside of the metal ring of wiper ring at several positions, as shown in the figure, to push it out step by step from the groove.

Fig. 1-12 Removing wiper ring

5) Remove the bushing (4) using a removal jig.

Fig. 1-13 Removing bushing

32-II-1-5

(5) Disassembly of clevis portion: 1) Remove the wiper ring (25) from the clevis por-

tion of tube (1) and piston rod (2).

25 Fig. 1-14 Removing wiper ring

2) Remove the pin bushing (24). â&#x20AC;˘ Using a metal block, push it out with a press machine.

METAL BLOCK

Fig. 1-15 Removing pin bushing

32-II-1-6

1.5 ASSEMBLY (1) Assembling Clevis Portion 1) With the installing jig (B) shown Item 1.7, press the bushings (24) into the piston rod assy (2) and tube assy (1).

B 24

• Prior to the work, apply hydraulic oil on the surface of parts.

Fig. 1-16 Installing pin bushing 2) With the setting tool, install the wiper ring (25). SETTING TOOL

Fig. 1-17 Installing wiper ring (2) Assembling Cylinder Head 1) With installing jig (A) shown Item 1.7, press-fit the bushing (4). • Prior to the work, apply hydraulic oil on inner periphery of the cylinder head (3). • At press-fitting the bushing (4) into the cylinder head (3), make the top surfaces of them in level without step. Fig. 1-18 Assembling cylinder head

2) Installing U-Ring Install the U-ring (5).

SECTION A-A Fig. 1-19 Installing U-ring

32-II-1-7

3) Assembling holder (Only for boom and swing cylinders) HOLDER

a. Install spacer (34).

BACK-UP RING (13)

b. Install cushion seal (11). c. Install collar (12). d. Install back-up ring (13)

COLLAR (12)

O-RING (7)

CUSHION SEAL (11) SPACER (34)

and O-ring (7)

Fig. 1-20 Installing holder 4) Using the setting tool, install the wiper ring (6).

SETTING TOOL

Fig. 1-21 Installing wiper ring 5) Install the back-up ring (8) and O-rings (7) (9).

Fig. 1-22 Installing back-up ring and O-ring

32-II-1-8

(3) Assembly of piston portion :

O-ring

1) Install the O-ring for the seal ring assy (16).

Fig. 1-23 Installing O-ring

2) Set the sliding jig (C) shown Item 1-7 on the pis-

ton (15), then quickly push the seal ring (16) onto the piston (15) with the pushing jig (D) shown Item 1-7.

Fig. 1-24 Assembling seal ring

O-ring 3) Since the seal ring (16) is extremely stretched at the installation, reform it with the reforming jig (E) shown Item 1-7.

Fig. 1-25 Reforming seal ring

32-II-1-9

4) Install the slide ring (17).

• Expand the split on the slide ring (17) as minimum as required to install it toward the axial direction. (2 points)

15 Fig. 1-26 Installing slide ring

(4) Installation of piston rod assy : 1) Fix the piston rod (2) in level, and install the cylinder head assy and holder onto it. 2) Installing procedures for cushion bearing of retraction side. THREAD

Fig. 1-27 Installing head assy and holder

PISTON ROD

SNAP RING (22)

CUSHION SEAL (21) One split portion

CUSHION BEARING (20)

STOPPER (23) Separated into 2 pieces

3) Install the piston assy. a. Install the cushion bearing (14) (for boom cylinder and Swing Cylinder only) and piston (15) on the piston rod (2), and tighten them up.

• Tightening torque for piston : Refer to Table 1-4

15 b. Put the steel ball (19) into the threaded bore, and securely tighten it with the setscrew (18). And

18 19

caulk the setscrew (18) with a punch at two points.

Fig. 1-28 Installing piston assy

• Tightening torque for setscrew : Refer to Table 1-4

32-II-1-10

(5) Assembly of cylinder : 1) Fix the tube in level, and install the piston rod assy into it. • At the installation, align the center of piston rod to the center of tube and install the piston rod in straight, paying attention not to damage seals.

Fig. 1-29

2) Install the cylinder head (3). • Apply hydraulic oil on the packings (seals)prior to install. • Tightening torque for cylinder head ; Refer to Table 1-4

Fig. 1-30

3) Bend the locking fin on the tube to lock the cylinder head.

Fig. 1-31 Locking cylinder head

32-II-1-11

1.6 MAINTENANCE STANDARDS (1) Inspection after disassembly 1) Inspection item Table 1-2 Parts Name Piston rod

Inspecting Portion

Inspection Item

Remedy

Presence of crack

Replace

2. Stepped part to which piston is attached Presence of crack

Replace

1. Neck of rod

3. Threads

Presence of seizure, etc. Recondition or replace

4. Bend

Measure amount of bend Refer to Rod Bend

5. Plated surface

1) Wearing off of plating

1. Replace

2) Rust on plating

2. Replace

3) Presence of defect

3. Recondition or replace

6. Rod

Wear of outside

Recondition or replace

7. Bushing at mounting part

Wear of inside

Replace

Cylinder tube 1. Welded part of bottom

Presence of crack

Replace

2. Tube at mounting part

Presence of crack

Replace

3. Tube inside

Presence of defect

Replace if oil leak is seen

4. Bushing at mounting part

Wear of inside

Replace

1. Bushing

1) Wear of inside

Replace

Rod cover

2) Defect of inside

(2) Repair procedure Replace sliding parts and seal parts according to the followings. ( i ) Bushing ·································

Where 1/4 of circumference is worn in copper color.

( ii ) Seals and slide rings ·············

Replace them when cylinder is disassembled.

(iii) Pin bushing ····························

Where severe scuffing is appeared.

(iv) Piston rod ······························

Where the bent 0.5 mm/m or more is appeared.

32-II-1-12

(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 :

1 ^2

Fig. 1-32 Measuring method

Replace the bushing if the clearance between the piston rod and the rod bushing exceeds 0.25 mm (0.01 in). 2) Bend of piston rod : The allowable bend of the rod is maximum 0.5 mm / 1 m (0.02 in / 39.4 in). 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 V-blocks turn the pis-

Table 1-3 shows an example of measurement Table 1-3 Example of measurement

ton rod, and read the difference between the maximum and minimum oscillations on the dial indicator. • Even if the bend is within the tolerable limit, the cylinder may not operate smoothly because of localized bend. Beware of it during function test

Distance between V-blocks m (in)

Deflectional value of the dial gauge mm (in)

Remedy

1 (39.4)

1 (0.04)

Replace

2 (78.7)

2 (0.08)

Replace

after installation. Replace the rod if the cylinder makes a squeeking noise or dose not operate smoothly.

(4) Tightening torque A : Cylinder head B : Piston assy Fig. 1-33

C : Setscrew

Table 1-4 Tightening torque Model

SK30SR-2

SK35SR-2

Unit : kgf•m (ft•lbs)

Cylinder

Cylinder head A

Piston B

Boom

46 (330)

123 (890)

Arm

43 (310)

109 (790)

Bucket

35 (250)

49 (350)

Swing

46 (330)

123 (890)

Dozer

46 (330)

78 (560)

Boom

50 (360)

152 (1100)

Arm

46 (330)

123 (890)

Bucket

35 (250)

49 (350)

Swing

46 (330)

123 (890)

Dozer

54 (390)

98 (710)

32-II-1-13

Setscrew C 1.7 (12) 0.7 (5) 1.7 (12) 1.7 (12) 0.7 (5) 1.7 (12)

(5) Inspection after installation Unloaded performance test 1) Put the cylinder horizontally at unloaded condition. 2) Apply pressure slowly and alternately through the ports at both ends to operate the piston rod 5 or 6 times. 3) Check that the cylinder operates normally. Leakage test • External leakage 1) Apply test pressure for 3 minutes each to the rod retraction side and to the rod extension side of the cylinder. 2) Confirm that rod seals, cylinder head tightening part, and each weld are free from abnormalities, such as external leakage and permanent deformation. • Internal leakage 1) Disconnect the hose from the rod extension side of the cylinder. 2) Apply test pressure to the rod retraction side of the cylinder for 3 minutes. 3) Measure the leakage from the rod extension side. • Leakage should be below 1 cc (0.06 cu•in) / 3 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) Repoat the step of extending and retracting the cylinder 4 or 5 times at slow speed of engine. • Move the piston rod 100 mm (3.9 in) short of its stroke end. Take care never to operate the relief valve. 3) Perform the above 2) procedures at high idling speed, then move the piston rod to its stroke end at low idling speed to operate the relief valve.

32-II-1-14

PUMP CONTROL VALVE

HYDRAULIC CYLINDER

TANK

Fig. 1-34 Unloaded teat

PUMP CONTROL VALVE

HYDRAULIC CYLINDER

Fig. 1-35 Leakage teat

1.7 JIG LIST (1) Installing Jig (A) for Press Fitting of Head

(2) Installing Jig (B) for Press Fitting of Pin Bushing.

Bushing.

(

) (

Unit : mm (in)

Unit : mm (in) Applicable Cylinder SK30SR-2

Bucket

Rod dia ; ø45 Boom Arm Arm Swing Swing Dozer Dozer Rod dia ; ø50 ----------

Dimension

SK35SR-2

Rod dia ; ø35 Bucket

)

øB 0 0 -0.1 -0.004

øA ± 0.2 ( ± 0.008)

+0.25 +0.010 0 0

Boom

Applicable Cylinder SK30SR-2

Dimension

SK35SR-2

I. D. of Pin bushing ; ø40

49.0 (1.93)

34.5 (1.36)

39.5 (1.56)

25.0 (0.98)

10.0 (0.39)

67.0 (2.64)

5.0 (0.20)

54.5 (2.15)

30.0 (1.18)

44.5 (1.75)

60.0 (2.36)

25.0 (0.98)

54.0 (2.13)

67.0 (2.64)

44.5 (1.75

59.5 (2.34)

10.0 (0.39)

49.5 (1.95)

5.0 (0.20)

25.0 (0.98)

30.0 (0.18)

67.0 (2.64)

65.0 (2.56)

42.0 (1.65)

Bucket

I. D. of Pin bushing ; ø45 Boom

Boom

Arm

Swing

Dozer

32-II-1-15

(3) Sliding Jig (C) for Seal Ring

(4) Pushing Jig (D) for Seal Ring

) ±0.05 (±0.002)

(

+0.2 +0.008 +0.1 +0.004

)

2 (0.08)

(

-0.3 -0.012 -0.1 -0.004

5 (0.20) 45 (1.77)

35 (1.38)

83 (3.27)

2 (0.08)

65 (2.56)

Material ; Nylon or Acrylic

Unit : mm (in) Applicable Cylinder SK30SR-2

SK35SR-2

I. D. of Tube ; ø65 Bucket

Bucket

I. D. of Tube ; ø75 Arm

----------

I. D. of Tube ; ø80 Swing Boom Dozer

Arm Swing

I. D. of Tube ; ø85 ----------

Boom

I. D. of Tube ; ø90 ----------

Dimension

Dozer

14.4 (0.57)

øB

65.5 (2.58)

øC

63.8 (2.51)

øD

46.0 (1.81)

16.4 (0.65)

øB

75.5 (2.97)

øC

73.8 (2.91)

øD

62.0 2.44)

16.4 (0.65)

øB

80.5 (3.17)

øC

78.8(3.10)

øD

66.0 (2.60)

17.4 (0.69)

øB

85.5 (3.37)

øC

83.8 (3.30

øD

(66.0 (2.60)

16.4 (0.65)

øB

90.5 (3.56)

øC

88.8 (3.50)

øD

66.0 (2.60)

Unit : mm (in) Applicable Cylinder SK30SR-2

I. D. of Tube ; ø65 Bucket

Bucket

I. D. of Tube ; ø75 Arm

----------

I. D. of Tube ; ø80 Swing Arm Boom Swing Dozer I. D. of Tube ; ø85

32-II-1-16

----------

Boom

I. D. of Tube ; ø90 ----------

Dimension

SK35SR-2

Dozer

70.0 (2.76)

68.0 (2.68)

60.0 (2.36)

80.0 (3.15)

78.0 (3.07)

70.0 (2.76)

85.0 (3.35)

83.0 (3.27)

75.0 (2.95)

90.0 (3.54)

88.0 (3.46)

80.0 (3.15)

95.0 (3.74)

93.0 (3.66)

90.0 (3.54)

(5) Reforming Jig (E) for Seal Ring Unit : mm (in) 20 (0.79)

Applicable Cylinder SK30SR-2

I. D. of Tube ; ø65

) (R 0.12)

(

)

+0.1 +0.004 0 0

2 .1

Bucket

50 (1.97)

Bucket

I. D. of Tube ; ø75 Arm

----------

I. D. of Tube ; ø80 Swing Arm Boom Swing Dozer I. D. of Tube ; ø85 ----------

Boom

I. D. of Tube ; ø90 ----------

32-II-1-17

Dimension

SK35SR-2

Dozer

80.0 (3.15)

65.0 (2.56)

90.0 (3.54)

75.0 (2.95)

95.0 (3.74)

80.0 (3.15)

100.0 (3.94)

85.0 (3.35)

105.5 (4.15)

90.0 (3.54)

1.8 POSSIBLE CAUSES FOR TROUBLE AND REMEDY

Trouble Conditions

Major Possible Causes

Remedy

Oil leakage from sliding • Foreign material is caught by U-ring or wiper • Remove foreign material. face of piston rod.

ring at its inside periphery.

(A ring shape oil is formed • Scuffing or fault on U-ring or wiper ring at • Replace each part with new one. on piston rod and en-

its inside periphery.

larged resulting dripping • Scuffing on sliding face of piston rod. 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 U-ring, etc. with new ones. • If leakage is not stopped by replacing seals, replace piston rod. • Re-plating of hard chrome on pis-

• Peeling off of hard chrome plating. Oil leakage from outer periphery of cylinder head. Oil leakage from welded portion.

ton rod.

• Damages on O-ring.

• Replace the part.

• Damages on back-up ring.

• Replace the part.

• Damages on welded portion on tube.

• Replace the part.

Piston movement due to • Foreign material is caught by sliding face • Remove foreign material. leakage.

of slide ring.

(For the case when static load that is equivalent to product of multiplication of • Scuffing or faulty condition on sliding face • Replace the part. max. working pressure

of slide ring.

and cylinder area, is applied to rod, max. movement of piston is larger • Scuffing on sliding face of seal ring assy.

• Replace the part.

than 0.5mm (0.02 in)) per 10 minutes.

• Damages on O-ring.

32-II-1-18

• Replace the part.

Book Code No.

PW32 02E ➀

NEW HOLLAND EH35 Model Cross-reference: SK35SR-2 is NEW HOLLAND Model EH35

PW32

32 -0-1 ➀

PREFACE 1.

This manual covers all the procedures required for the dis/re-assembling of the machine in compilation by items.

This manual consists of Part I ; REMOVING AND INSTALLING ASSY, and Part II ; DISASSEMBLING AND ASSEMBLING COMPONENTS.

Revision First edition Second revision

Date of Issue January, 2001 December, 2002

Remarks S5PW3202E A S5PW3202E ➀ A

Any use of editorial or pictorial content is strictly prohibited without express written permission from New Holland Construction, LLC. Carol Stream, IL 60188 U.S.A. Copyright © 2003 New Holland Construction, LLC. All Rights Reserved.

32-0-2 ➀

Part I : REMOVING AND INSTALLING ASSEMBLY 1. CANOPY / CAB

A12

[A] before BU SK30SR-2 : PW08-20001~ SK35SR-2 : PX09-08001~

A.1.1 CANOPY REMOVAL

(1) Remove the floor mat (A12).

(2) Removing the cover (7) Only when removing the handrail in Step (4) described below, unscrew one M8X20 SEMS bolt (6) and one M8X25 SEMS bolt (10) to remove the cover (7).

Fig. 1-1 Floor mat and cover removal

: 13mm (3) Removing canopy assembly

Unscrew one M16X60 capscrew (7) and three M16X100 capscrews (10) to remove the support (2), (4) and the canopy (1) in one piece. : 24mm Canopy weight : 84 kg (185 lb)

(4) Removing handrail (12)

Unscrew one M10X40 SEMS bolt (13) and two M10X25 SEMS bolts (15) to remove the hand-

rail (12). : 19 mm

(5) Install the canopy in reverse order of the removal.

13 A.1.2 CAB REMOVAL (Option) A.1.2.1 Removal preparation (1) Remove the floor mat (A13). (2) Removing cab harness connector 1) Disconnect 12-pin connectors of cab connecting harness and cab harness from the right-side rear control stand (See ELECTRICAL SYSTEM for details). 2) Disconnect 3-pin radio coupler at the left-side rear control stand (optional).

Fig. 1-2 Canopy assembly and handrail removal

33-I-1-1

A13

Fig. 1-3 Floor mat removal

1.2.2 Cab removal (1) Removing cover installed on rear of cab Unscrew three M6 SEMS bolts (23) to remove the cover (22). : Plus screwdriver (2) Removing mounting screws on rear of cab Unscrew one M16 capscrew (25) fastening the guard bracket to the cab to remove the shims (8) of 1.6, 2.3, and 3.2 (optional) in thickness and

the spacer (24). : 24 mm

Cross-section B-B

View I

Fig. 1-4 Outside of cab

2 (3) Removing mounting screws inside cab 1) Unscrew M10X30 capscrew (3) fastening the cab

to the floor plate. : 17mm 2) Unscrew one M16X85 capscrew (1) and two M16X50 capscrews (2) fastening the cab to the

2 Fig. 1-5 Cab assembly fastening positions

upper frame. : 24 mm

(4) Lifting cab Put slings through the lifting eyes on the cab top. Cab weight: 194 kg (428 lb)

2 1

(5) Installing cab Install the cab in reverse order of the removal. Tighten screws to the torque specified below. For M6: T=0.45 kgf•m (3.3 lbf•ft) For M10: T=4.7 kgf•m (34 lbf•ft) For M16: T=19.5 kgf•m (141 lbf•ft)

2 Fig. 1-6 Lifting cab

33-I-1-3

1. CANOPY / CAB

[B] after BU SK30SR-2 : PW10-22001~ SK35SR-2 : PX11-08901~ B1.1 CANOPY REMOVAL (1) Remove the floor mat (7).

(2) Removing handrail (12) Unscrew two M10X35 SEMS bolt (13) to remove the handrail (12). : 17 mm Fig. 1-7 Floor mat and cover removal

(3) Removing handrail (20) Unscrew two M12X35 capscrew (21) to remove the handrail (20). : 19 mm (4) Removing canopy assembly Unscrew one M16X60 capscrew (7), one M16X100 capscrews (10) and two M16X70 capscrew (16) to remove the support (2), (4) and the canopy (1) in one piece. : 24mm Canopy weight : 84 kg (185 lb) (5) Install the canopy in reverse order of the removal. Tighten screws to the torque specified below. For M10 : T=4.7 kgf•m (34 lbf•ft) For M12 : T=8.1 kgf•m (591 lbf•ft) For M16 : T=19.5 kgf•m (141 lbf•ft)

B.1.2 CAB REMOVAL (Option) B.1.2.1 Removal preparation (1) Remove the floor mat (12). (2) Removing cab harness connector Respectively disconnect 6P connectors of cab harness and cab connecting harness, 2P connector of washer motor, 3P connector of radio (optional) and so on.

• The figure shows standard. Fig. 1-8 Canopy assembly and handrail removal

Fig. 1-9 Floor mat removal

33-I-1-2A

B.1.2.2 Cab removal (1) Removing cover installed on rear of cab Unscrew three M6 SEMS bolts (20) to remove the cover (17). : Plus screwdriver (2) Removing mounting screws on rear of cab Unscrew one M16 capscrew (1) fastening the guard bracket to the cab to remove the shims (13) of 1.6, 2.3, and 3.2 (optional) in thickness and the spacer (12). : 24 mm

Fig. 1-10 Outside of cab

(3) Removing mounting screws inside cab 1) Unscrew M10X30 capscrew (3) fastening the cab to the floor plate. : 17mm 2) Unscrew one M16X85 capscrew (16) and two M16X50 capscrews (2) fastening the cab to the

Fig. 1-11 Cab assembly fastening positions

upper frame. : 24 mm

(4) Lifting cab Put slings through the lifting eyes on the cab top. Cab weight: 194 kg (428 lb) (5) Installing cab Install the cab in reverse order of the removal. Tighten screws to the torque specified below. For M6: T=0.45 kgf•m (3.3 lbf•ft) For M10: T=4.7 kgf•m (34 lbf•ft) For M16: T=19.5 kgf•m (141 lbf•ft) Fig. 1-12 Lifting cab

33-I-1-2B

2. GUARD 1 2.1 REMOVAL (1) Removing cover assembly (1) Unlock the cover assembly (1) to open it. Then unscrew four M8X20 (yellow) SEMS bolts to re-

47 19 47

move the cover (1) from the hinge (19). : 13mm

Fig. 2-1 Cover assembly (1) removal

(2) Removing panel assembly (2) Unscrew one M8X25 (green) SEMS bolt (26), one M8X20 (yellow) SEMS bolt (47), and two MX20 (green) SEMS bolts (25).

47 25 26 2

: 13mm

Fig. 2-2 Panel assembly (2) removal

(3) Removing panel assembly (3) Unscrew one M8X20 capscrew (52) and two MX20 (yellow) SEMS bolts (47).

: 13mm

Fig. 2-3 Panel assembly (3) removal

33-I-1-3

(4) Removing bonnet assembly (4) Unlock the bonnet assembly (4) to open it. Then unscrew two M10X25 SEMS bolts (24) to remove

(before BU only)

20 47

the bonnet assembly (4) from the hinge portion.

: 17mm

(5) Removing bonnet assembly (5) Remove two grommets (20), two M8X20 (yellow) SEMS bolts (47) to remove the bonnet assembly (5). : 13mm

24 Fig. 2-4 Bonnet assemblies (4) (5) removal (6) Removing cover assembly (6) Unscrew two M10X35 capscrews (23) and three

M10X25 SEMS bolts (24) to remove cover assembly (6). : 17mm

(7) Removing cover assembly (7) Unscrew three M10X35 capscrews and three M10X25 SEMS bolts (24) to remove the cover

assembly (7). : 17mm

24 23

23 Fig. 2-5 Cover assemblies (6) (7) removal

33-I-1-4

(8) Removing cover (36) Unscrew four M8X20 SEMS bolts (27) to remove the cover (36). : 13mm

9 48 27 24

(9) Removing bracket assembly (9) Unscrew two M10X30 capscrews (48) to remove the bracket assembly (9).

: 17mm

Fig. 2-6 Cover (36) and bracket assembly (9) removal

52 (after BU)

47 (before BU) (10) Removing cover assembly (17) • (before BU) Unscrew three M8X20 (yellow) SEMS bolts (47)

to remove the cover assembly (17). • (after BU) Unscrew two M8X20 (yellow) SEMS bolts (47) and one M8X20 capscrew (52) to remove the cover assembly (17). : 13mm

• The figure shows before BU. Fig. 2-7 Cover assembly (17) removal

(11) Removing support (10) Unscrew four M12X45 capscrews (21) to

remove the support (10).

: 19mm

2.2 INSTALLATION Install the above assemblies in reverse order of the removal.

33-I-1-5

• The figure shows before BU. Fig. 2-8 Support (10) removal

3. FLOOR PLATE ASSEMBLY 6 2

Remove floor plate together with the travel pilot valve assembly and the swing pedal in one piece 3.1 REMOVAL PREPARATION (1) Remove the floor mat. (2) Remove the floor cover (7). (3) Remove the canopy.

(See Section 1.)

(4) Remove the cover assembly (2).

FLOOR PLATE

: 13mm (5) Remove the cover assembly (7) of the deck under the floor [see Step 2.1-(7)]. • This section is only applicable for before BU. (6) Disconnect electrical wiring for travel 2-speed selector switch from the connector portion. In advance, disconnect the minus terminal of the battery to prevent danger of short circuit, etc.

• The figure shows before BU. Fig. 3-1 Cover assembly (2) removal

A10 4 2

P 1 3

C/V ƒ Pb7

C/V Pb6

C/V

Pa7

2.7 (20)

Pa6

Tightening torque kgf·m (lbf·ft)

1/4

ƒ S/V A13 S/V A2

C/V

Thread size Spanner used O-ring type 30 … flare type (PF) (mm) fitting fitting

Fig. 3-2 Pilot piping disconnection

3.0 (22)

SWING PEDAL [EU • OCEANIA] N&B PEDAL [USA]

(Note) Take care of the tightening torque as the pilot valve is made of aluminum.

22 36

(8) Removing cable of Swing pedal [EU • OCEANIA] and N&B pedal [USA]. 1) Unscrew two M8X20 SEMS bolts (36) to pull out the bracket (24) upward. 2) Pull out pin (11) and unscrew the adjusting nut to disconnect the swing cable (22).

(122) 11

ADJUSTING NUT

Fig. 3-3 Swing cable disconnection

33-I-1-6

(9) Removing N&B pedal rod [EU â&#x20AC;˘ OCEANIA] 1) Loosen 2 nuts (14) and remove rod (4).

Fig. 3-4 Removing pedal rod (10) Removing cover assembly (19) in front of stand Unscrew M8X16 SEMS bolts (26) to remove the cover assembly (19). â&#x20AC;˘ SEMS bolts : 2 (before BU) : 4 (after BU)

19 26

(11) Remove the left-side rear cover assembly (17) [see Step 2.1-(10)]. Fig. 3-5 Cover assembly (19) removal

3.2 DISASSEMBLY (1) Remove the plate (3). : 13mm

before BU 1

(2) Remove governor motor cable and the grommet (4A) from the plate (3) (optional).

(3) Remove dozer lever cable and the grommet (4B) from the floor plate (1).

4A 6

(4) Remove cover (36) [see Step 2.1-(8)].

after BU

(5) Unscrew one M12X55 SEMS bolt (43) and one M16X40 capscrews (45) fastened together with the stand.

: 19 mm and 24 mm

4A 3 6

(6) Pull out the floor plate (1) forward and remove it. 3.3 ASSEMBLING FLOOR PLATE (1) Assemble the floor plate in reverse order of the disassembly.

33-I-1-7

Fig. 3-6 Floor plate (1) removal

4. BATTERY

4.1 REMOVAL PREPARATION (1) Incline the seat forward and remove the cover (27).

iIncline j

SEAT

â&#x20AC;˘ The figure shows before BU. Fig. 4-1 Removal preparation 4.2 REMOVAL (1) Disconnect the minus side terminal of the cable.

(2) Then, disconnect the plus side terminal of the cable

STRAPS : 12mm

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. (3) Unscrew the nut (4) to remove the bracket (2) and the rod (3).

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

4.3 INSTALLATION Install the battery in reverse order of the removal.

33-I-1-8

Fig. 4-2 Battery removal

5. SEAT STAND 38 5.1 REMOVAL PREPARATION (1) Remove the canopy and the handrail (see Section 1). (2) Remove the cover (36) and the cover assembly (17) for the guards (see Section 2). (3) Remove the cover assembly (19) in front of the seat stand [see Step 3.1-(9)]. (4) Remove the plate (3) on the rear of the floor plate [see Step 3.2-(1)]. (5) Disconnect the minus side terminal of the battery (see Section 4).

5.2 REMOVAL (1) Removing dozer lever assembly (61) Unscrew M8X16 SEMS bolts (38) and displace dozer cable to the front of the machine without disconnection.

• The figre ahows before BU. Fig. 5-1 Dozer lever assembly and cover assembly removal 5

before BU

: 13mm

(2) Removing cover assembly (62) Unscrew two M8X16 SEMS bolts (38) to remove

12 (Raise)

CN-60 CN-61

the cover assembly (62).

: 13mm (3) Disconnecting harness a) before BU Incline the seat forward and disconnect two connectors (CN-4 and CN-5) for body harness and instrument panel harness inside the relay box (see ELECTRICAL SYSTEM for details). b) after BU Unscrew two M8X20 SEMS bolts (8). Then move out the relay box assembly as assembly.

RELAY BOX 5 1

after BU

: 13mm T=2.4 kgf•m (17 lbf•ft) (4) Removing key switch cover (1) Raise the relay box forward and then unscrew two M6X20 SEMS bolts (5) and two M6X16 SEMS bolts (6) to remove the key switch cover

8 6 RELAY BOX

(1). : 10mm T=4.6 kgf•cm (0.33 lbf•ft) (5) Disconnect connectors for instrument panel harness and engine harness under the key switch (see ELECTRICAL SYSTEM for details).

Fig. 5-2 Key switch cover (1) removal

33-I-1-9

(6) Removing throttle cable Unscrew two M8X20 SEMS bolts (10) to remove the throttle lever assembly (1). Then unscrew the adjusting nut for the throttle cable to disconnect

the throttle lever from the cable. : 13mm

T=2.4 kgf•m (17 lbf•ft) 1

ADJUSTING NUT THROTTLE CABLE

Fig. 5-3 Throttle cable removal (7) Remove covers of the right and left control boxes and disconnect connectors for the left switch panel and the right gauge cluster. Then disconnect the terminal for the lever lock limit switch circuit (see ELECTRICAL SYSTEM for details). Move forward

(8) Movement of right and left control boxes With the electrical wiring disconnected, unscrew three M8X20 SEMS bolts (37) on the left side and four M8X20 SEMS bolts (37) on the right side of the control box. Then move the control box forward with the control valve piping connected, to a place where the seat stand can be lifted freely. : 13mm

• The figure shows before BU. Fig. 5-4 Right and left control boxes movement (9) Disconnecting battery cable Disconnect the plus side cable of the battery from the terminal B of the starter (see Step 11.2).

11 (M8X25, 2 PCS.)

(10) Removing deceleration motor (optional) Unscrew two M8X25 SEMS bolts (11) to remove the deceleration motor.

3 (before BU)

11 (M8X20, 3 PCS.) 3 (after BU)

: 13 mm, T=1.1kgf•m (8.0 lbf•ft)

(11) Removing heater hose (optional) Disconnect two heater hoses from the engine. Fig. 5-5 Deceleration motor removal

33-I-1-10

(12) Removing seat stand a) before BU Unscrew one M12X55 SEMS bolt (43), two M12X40 SEMS bolt (44), and one M16X40

before BU

43 44

capscrew (45) to remove the seat stand. Weight of the seat stand including the seat: approx. 55 kg (121 lb)

45 a) after BU Unscrew one M12X55 SEMS bolt (31), two M12X40 SEMS bolt (A7), and one M16X40 capscrew (32) to remove the seat stand. : 19 mm and 24 mm • Tightening torque M12 : 8.1 kgf•m (59 lbf•ft) M16 : 19.5 kgf•m (141 lbf•ft) Weight of the seat stand including the seat: approx. 55 kg (121 lb) after BU

Fig. 5-6 Seat stand removal

5.3 INSTALLATION Install the seat stand in reverse order of the removal.

33-I-1-11

6. COUNTERWEIGHT

6.1 REMOVAL PREPARATION (1) Remove the panel assembly (3), the bonnet assembly (4), and the cover assembly (17) (see Section 2). (2) Lifting tools preparation • Lifting jigs for counterweight (see Tool list) • Two M20X35 screws (A)

SCREW(A)

SLING

Lifting jig for counterweight

• Wire rope (nylon sling)

9 6.2 REMOVAL (1) Remove the plate (9) 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 : 330 kg (730 lb) for SK30SR-2 560 kg (1,230 lb) for SK35SR-2 (3) Unscrew one M16X130 capscrew (2) and two

5,6,7

M16X45 capscrews (3). : 24mm (4) Remove the shims (5), (6) and (7). (5) Remove counterweight (1).

6.3 INSTALLATION (1) Install the counterweight in reverse order of the removal. (2) Reinstall the shims (5), (6), and (7). (3) Lifting counterweight Make sure that all the three fixing bolts can be manually screwed. (4) Apply Loctite #262 on the capscrews (2) and (3) and tighten them together with the washer (11) and (4).

Fig. 6-1 Counterweight removal

5,6,7

Tightening torque: 28.5 kgf•m (206 lbf•ft)

: 24mm (5) Remove lifting jigs.

3,2 Fig. 6-2 Counterweight installation

33-I-1-12

7. FUEL TANK

A1-3 B13 A1

B11

7.1 DISASSEMBLY PREPARATION (1) Remove the cover assembly (1), the panel assembly (2), and the cover assembly (6) (see Section 2).

before BU B4

B4 B15

7.2 DISASSEMBLY (1) Open the cap (A1-3) and loosen the drain plug (B7) to drain fuel. Tank capacity: 38 liters (10 gal) (2) Disconnect the hoses connected to the fuel inlet and outlet ports. (3) Unscrew two M10X20 SEMS bolts (B16) to re-

DRAIN HOSE

B16

CLIP B8 B7

move the boss (B8) together with the drain hose. : 17 mm (4) Disconnect connector (B11) for the level sensor. (5) Remove two capscrews (B4) and one SEMS bolt (B15). : 17 mm (6) Remove the fuel tank.

A1-3

after BU

B13 B11

B4 B15 DRAIN HOSE

7.3 INSTALLATION Assemble the fuel tank in reverse order of the removal and tighten the screws at the specified torque shown in the following table:

CLIP

B16 CLIP B8 B7

CLIP DRAIN HOSE

No.

Name

Tool Tightening torque (mm) kgf¥m (lbf¥ft)

Capscrew (M10)

4.7 (34)

B15 SEMS bolt (M10)

4.7 (34)

B16 SEMS bolt (M10)

3.6 (26)

Note: Apply Loctite #262 to the screws.

Fig. 7-1 Fuel tank removal

33-I-1-13

8. HYDRAULIC OIL TANK

8.1 DISASSEMBLY PREPARATION (1) Swing approximately 90 degrees to the right to facilitate to remove the tank. (2) Remove the fuel tank according to the procedures described in Section 7. (3) Remove the undercover under the hydraulic oil

CAP BOOT

A1-9

tank. : 17 mm T=4.7 kgfâ&#x20AC;˘m (34 lbfâ&#x20AC;˘ft) B3

(4) Remove the panel assembly (3) [see Step 2.1(3)].

B3 A1

8.2 DISASSEMBLY (1) Releasing tank pressure Press the cap boot of breather assembly (A1-9) with a finger to release the internal pressure.

A1-14

Press and hold the boot until air-relieving sound stops. (2) Remove plug (A1-14) to drain hydraulic oil.

Fig. 8-1 Releasing tank pressure and draining hydraulic oil

: 22 mm Tank capacity: about 37 liters (9.8 gal)

(3) Disconnecting suction hose From the opening under the hydraulic oil tank: 1)

Remove the clip (10). : Minus screwdriver

Remove the hose (5). : Minus screwdriver

Fig. 8-2 Suction hose removal

33-I-1-14

(4) Removing return oil hose Disconnect each hose from the position marked withÅ¶. : 19, 22, and 36 mm Å¶

Å¶ S/J H

S/M DB Å¶

Å¶

COOLER, OIL

S/M M

Fig. 8-3 Return oil hose removal

ƒ S/V S/V T

T Fig. 8-4 Return oil hose removal

(5) Removing hydraulic oil tank Unscrew one M10X20 capscrew (B1) and two M10X25 capscrews (B3) to remove the hydraulic oil tank (A1). : 17 mm

A1-15

B3 B3

Weight: about 31 kg (68 lb)

A1-14

Fig. 8-5 Hydraulic oil tank removal

33-I-1-15

8.3 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: No.

Name

B1 and B3 Capscrew (M10) A1-14

Plug (PF 3/8) Clip

Tool (mm)

Torque kgf¥m (lbf¥ft)

4.7 (34)

7.5 (54)

Minus screwdriver

0.55 (4.0)

• Apply Loctite #262 to B1 and B3.

Tightening torque kgf¥m (lbf¥ft) Thread size Spanner used O-ring type 30 … flare type (PF) (mm) fitting fitting 1/4

3/8 1/2 3/4

19 22 27 36

3.7 (27)

3.0 (22)

7.5 (54)

5.0 (36)

11 (80)

8.0 (58)

16.5 (119)

12.0 (87)

(3) After assembling, fill the tank with the designated hydraulic oil and check the oil level with the level gage (A1-15) (see Fig. 8-5). Oil quantity: about 37 liters (9.8 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 in the circuit.

ARM CYLINDER

BUCKET CYLINDER

BOOM CYLINDER SWING CYLINDER

(5) Pressurizing hydraulic oil tank 1) Fully extend each cylinder to the stroke end as shown in Fig. 8-6. 2) In this condition, press the cap boot of breather assembly (A1-9) with a finger to release the internal pressure.

DOZER CYLINDER

Fig. 8-6 Posture for hydraulic oil tank pressurization

Press and hold the boot until air-relieving sound stops. 3) Move the attachment and retract the cylinder rods to pressurize the tank. (6) Rechecking oil level Stop the engine in the posture shown in Fig. 8-7 to recheck oil level. In addition, ensure no oil leakage is found on each part.

33-I-1-16

Fig. 8-7 Posture for stopping engine

9. AIR CLEANER 9.1 DISASSEMBLY PREPARATION Open the rear bonnet assembly. 9.2 DISASSEMBLY (1) Unscrew the capscrew (9) fastening the clip (6). 9

: 8 mm

(2) Loosen the clip (5) to remove the air hoses (2) and (3).

: Minus screwdriver (3) Unscrew two SEMS bolts (7) to remove the air

cleaner assembly (1). : 13mm

5 3 5

9.3 ASSEMBLY Assemble the air cleaner in reverse order of the disassembly. • Tightening torque SEMS bolt (7) : 2.4 kgf•m (17 lbf•ft) capscrew (9) : 4.7 kgf•m (34 lbf•ft)

Fig. 9-1 Air cleaner removal

10. GENERATOR 2

10.1 DISASSEMBLY PREPARATION (1) Remove the radiator hose and hydraulic return hose to facilitate to remove the generator (see Sections 8 and 14). (2) Disconnect the minus side terminal of the battery.

10.2 DISASSEMBLY (1) Disconnect connector (CN-302).

Fig. 10-1 Generator removal (2) Remove the capscrews (1), (2), and (3).

GENERATOR

: 13mm (3) Remove the V-belt and the generator (1). 10.3 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 to 15 mm (0.39 to 0.59 inch)

CRANK PULLEY

33-I-1-17

Fig. 10-2 V-belt tension

11. STARTER 38

11.1 REMOVAL PREPARATION (1) Remove the cover assembly (62) in front of the seat stand [see Step 3-1, (8)]. (2) Remove the plate (3) on the rear of the floor plate [see Step 3-2, (1)]. (3) Unscrew two M8 SEMS bolts (38) to remove the cover assembly (62).

SEAT STAND

: 13mm • SEMS bolt (38) : M8X16 (before BU) : M8X20 (after BU) (4) Disconnect the minus side terminal of the battery. • Remove the canopy to facilitate to remove the starter.

•The shows before BU. Fig. 11-1 Cover assembly removal 11.2 REMOVAL (1) Disconnect the terminal B of the starter.

ÅF13 mm (2) Disconnect connector on the terminal S of the starter. (3) Unscrew two fastening bolts (1) to remove the 1

starter.

STARTER

: 19 mm

TERMINAL B TERMINAL S

TO BATTERY

E/G HARNESS Starter-terminal details

Fig. 11-2 Starter removal

11.3 INSTALLATION Install the in reverse order of the removal.

33-I-1-18

12. MUFFLER

12.1 DISASSEMBLY PREPARATION (1) Slew about 30 degrees to the right. (2) Remove the undercover (B3) under the muffler. : 17mm Tightening torque: 4.7 kgf•m (34 lbf•ft)

B3 Fig. 12-1 Undercover removal 12.2 DISASSEMBLY (1) Remove three nuts (9) on the exhaust tube (2) side through the opening for the undercover.

2 9 5

: 13 mm (2) Loosen two capscrews (14) to remove the two clamps (5).

9 9

1 5 9

: 13 mm 14

(3) Pull out the muffler (1) downward to remove it.

Fig. 12-2 Muffler removal Welded joint of shell 9 14

9 5

No.

Name

Tool (mm)

Torque kgf•m (lbf•ft)

Capscrew

2.4 (17)

Nut

2.4 (17)

50Å

12.3 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:

Fig. 12-3 Muffler installation

33-I-1-19

13. PUMP

13.1 REMOVAL PREPARATION (1) Remove the cover assembly (17) (see item 2). (2) Remove the counterweight (see item 6). (3) Depressurize the hydraulic oil tank and drain the hydraulic oil (see item 8). 13.2 REMOVAL (1) Disconnecting hoses and fittings connected to the pump • Attach a tag to each hose for identification. 1) Remove the pilot discharge oil hose (B16).

: 22 mm 2

2) Remove the clip (10) to disconnect the suction hose (6). : Minus screwdriver 3) Unscrew four M12X35 capscrews (14) to remove the tube (12).

14 4 6

: 10 mm 4) Remove the main pump discharge oil hoses (2), (3), and (4).

B16

: 27 mm Fig. 13-1 Pump removal (2) Unscrew two M12X30 capscrews (C4) to remove the pump (B1). : Ball joint type 10 mm Pump weight: 38 kg (84 lb) 13.3 INSTALLATION Install the pump in reverse order of the removal according to the tightening torque and sealant instructions.

T=8.5 to 9.4 kgf¥m (61 to 68 lbf¥ft) Apply no Loctite as microcapsule coating has been applied. Apply grease

(1) Apply grease to the spline part of the pump input shaft. Grease: Shell Retinax AM Grease or equivalent (Molybdenum disulfide extreme pressure multipurpose grease) C4 T=8.7 kgf¥m (63 lbf¥ft)

(2) Insert the pump spline part to the coupling.

T=6.6 kgf¥m (48 lbf¥ft) Apply Loctite #262

(3) Fix the pump by the capscrew (C4). : Ball joint type 10 mm

Fig. 13-2 Pump installation

33-I-1-20

(4) Install the main pump discharge oil hoses (2), (3), and (4), and the pilot discharge oil hose (B16) (see Fig. 13-1).

Tightening torque kgf·m (lbf·ft) Thread size Spanner used O-ring type 30 … flare type (PF) (mm) fitting fitting

3/8 1/2

22 27

7.5 (54) 11 (80)

5.0 (36) 8.0 (58)

(5) Tighten the capscrew (14) to install the suction tube (6). : 10 mm (6) Apply the sealant on the inserted portion of the suction hose (6) and fix the tube by clip (10). : Minus screwdriver T=0.55 kgf•m (4.0 lbf•ft) (7) Reinstall each component removed in the above removal preparation. (8) Feed hydraulic oil [about 37 liters (9.8 gal)] and then bleed air to pressurize the tank (see item 8).

33-I-1-21

14. RADIATOR

A10 A9 A3 B2

before BU

14.1 DISASSEMBLY PREPARATION (1) Remove panel assembly (3) (see item 2).

A1 B1

A10

(2) Remove the counterweight (see item 6). B2

(3) Remove the undercover under the radiator. â&#x20AC;˘ In order to facilitate the work, remove the related covers and components if necessary. A9

14.2 DISASSEMBLY (1) Draining water from radiator 1) Remove the radiator cap. 2) (before BU) : Loosen the drain cock (A7) to drain water. (after BU) : Loosen the clip (A8), then remove the plug (A14) to drain water. Volume: Approx. 1.5 liters (0.4 gal)

A2 A4

A9 A14 A6

A11 A7

after BU

A10 A10 A5

A9 A3

(2) Draining hydraulic oil in oil cooler 1) Release the pressure in the hydraulic circuit. 2) Remove the oil cooler hoses (8) and (24), and then plug the inlet/outlet ports of the oil cooler and the openings of the hoses.

B1 B2 A9

(3) Disconnect the connection hose (A5) of reservoir (A6) by removing the clip (A10). (4) Remove the radiator hoses (A2) and (A3) fixed by clip (A9). Tools: Cutting pliers and minus screwdriver

A8 A2 A9

(5) Unscrew the capscrew (B2) to remove the stay (B1). : 17 mm (6) Unscrew the capscrew (A14) to remove the hose (A4) together with the boss (A11). This section is only applicable for before BU. : 17 mm (7) Unscrew two capscrews (B3) to remove the radiator assembly (A1). : 17 mm Weight: 11 kg (24 lb)

33-I-1-22

A4 A14

Fig. 14-1 Radiator disassembly

Fig. 14-2 Draining hydraulic oil in oil cooler

14.3 ASSEMBLY (1) Assemble the radiator in reverse order of the disassembly.

Position the fan at a distance of 19 mm from radiator shroud.

(2) Apply Loctite #262 on the capscrews (B3) to fix

SHROUD

the radiator by them.

(3) Install the fan and shroud, adjusting their positions according to Fig. 14-3.

Tightening torque for related parts

No.

Name

Tool (mm)

Torque kgf·m (lbf·ft)

A13

Capscrew (M8)

2.4 (17)

A14 Capscrew (M10) B2 and B3

Adjust the clearance between the fan and radiator shroud so that it is set to 15 mm around the circumference. FAN

4.7 (34)

(4) Feed cooling water (LLC)

Fig.14-3 Radiator installation

See Section 4 (Maintenance) of the OPERATION & MAINTENANCE MANUAL for the mixing ratio of LLC.

33-I-1-23

15. ENGINE

15.1 REMOVAL PREPARATION (1) Remove the canopy (see item 1). (2) Remove the seat stand (see item 5). (3) Remove the counterweight (see item 6). (4) Remove the radiator (see item 14). (5) Remove the pump or the pump connecting hose (see item 13). (6) Disconnect the grounding side terminal of the

Å¶

battery (see item 4).

Åö

15.2 REMOVAL (1) Disconnecting fuel hose Disconnect each hose from the position marked with Å¶ or Åö. Note that the positions marked with Åö are only for automatic air bleed type (optional). (2) Removing fuel pump (24) (optional). 1) Disconnect the connector (2FY-BS) of the automatic air bleed harness (for details, see ELECTRICAL SYSTEM). 2) Unscrew the capscrews (25) to remove the fuel pump (24).

Fig. 15-1 Fuel hose and fuel pump removal

9 6

: 10 mm 5

(3) Disconnecting air cleaner (1) 1) Remove the bolts (9) fixing the clips (6).

: 17 mm 2) Loosen the clip (5) to disconnect the hose (2) from the air cleaner (1). Then disconnect the connector of the indicator (10).

Fig. 15-2 Air cleaner removal

: Minus screwdriver 10

(4) Removing support (10) Unscrew four M12X45 capscrews (21) to remove the support (10) together with the air cleaner.

: 19 mm (5) Disconnecting cable connector (for details, see ELECTRICAL SYSTEM). 1) Disconnect the terminal B of the starter motor (M-1) on the plus cable of the battery (see Step 11.2). 2) Disconnect the grounding cable of the engine.

33-I-1-24

Fig. 15-3 Support removal

3) Place the engine stably on the worktable.

Prepare a worktable capable of enduring the weight of the engine and stably receiving the removed engine.

15.3 INSTALLATION (1) Install the engine in reverse order of the removal. See the following table for the tightening torque and the sealant:

(6) Removing engine 1) Unscrew four M12 X 110 capscrews (12) fixing the engine on the rubber mount (6) to remove the engine. : 22 mm 2) Lifting engine Pass a wire rope through the two lifting eyes at the top of the engine and lift the engine. Weight: Approx. 150 kg (330 lb)

No.

12 1

Name

Tool (mm)

Torque kgf·m (lbf·ft)

9 and 10 Capscrew (M10) 19

4.7 (34) Apply Loctite #262.

11 and 12 Capscrew (M12) 22

8.1 (59) Apply Loctite #262.

11 7 12

• Use the rubber (6) with identification color of “gray” (three positions). • Use the rubber (7) with identification symbol of “A” (one position).

6 12 9

6 11

6 6 10

Fig. 15-4 Engine removal

33-I-1-25

16. CONTROL VALVE

16.1 REMOVAL PREPARATION (1) Remove the canopy (see item 1). (2) Remove the floor plate assembly (see item 3). (3) Remove the cover assembly (7) [see item 2.1, (7)]. (4) Release the residual pressure in the circuit and the pressure in the hydraulic oil tank.

16.2 REMOVAL (1) Disconnecting hoses Disconnect all the hoses connecting to the control valve, and attach blind plugs and tags recording the installation place.

A24 A5

A9 (NIBBLER & BREAKER) A10

A13

NIBBLER & BREAKER (R)

A1 A3

SELECT VALVE

6 A7

CONTROL VALVE

A15 A6 A12 A23 A1

4 3 8 17 2 12

â&#x20AC;¢ The figure shows before BU. Fig. 16-1 Main hydraulic hose disconnection

33-I-1-26

FOR EU • OCEANIA

P/V : Pilot valve C/B : Control block

A6 B16

B6 A7

B30 B28

B29 B18 A1

A1 A3

A1 B4 • The figure shows before BU. Fig. 16-2A Pilot hydraulic hose disconnection [EU • OCEANIA]

FOR USA

• The figure shows before BU. Fig. 16-2B Pilot hydraulic hose disconnection [USA] SWING CABLE [EU • OCEANIA] N&B CABLE [USA]

(2) Disconnecting cable Turn the rod end (35) to disconnect the control valve from the cables (22) and (21). [USA] specification is equipped the cable for N&B in place of the swing cable (22). Remove N&B cable in the same way.

DOZER CABLE

21 22 35

Fig. 16-3 Cable disconnection

33-I-1-27

(3) Removing N&B rod [EU • OCEANIA] Loosen nut (13) and (15), remove rod (17) from control valve.

(4) Removing control valve 1) Unscrew three M10X50 capscrews (2) to remove the control valve (10) with the bracket (1). : 17 mm Weight of removed parts: Approx. 33 kg (73 lb)

Fig. 16-4 Removing rod

2) Unscrew three M10X25 capscrews (4) to remove the control valve (10). : 17 mm Dozer Slewing Supply Service (N&B) Swing Arm Travel Supply and Travel straight Travel Boom Bucket

Weight: Approx. 25 kg (55 lb) 10

16.3 INSTALLATION (1) Install the control valve in reverse order of the removal.

(2) Attach the capscrews (4). Clean the mounting surface and take care to prevent deformation of the valve. : 17 mm

2 4

(3) Tighten the hose fittings with the following torque: Tightening torque kgf·m (lbf·ft) Thread size Spanner used O-ring type 30 … flare type (PF) (mm) fitting fitting

1/4 3/8 1/2 3/4 1

19 22 27 36 41

2.7 (20) 7.5 (54) 11 (80) 16.5 (119) 26.0 (188)

3.0 (22) 5.0 (36) 8.0 (58) 12.0 (87) ---

(Note) Take care of the tightening torque for the pilot port (PF1/4) of the control valve as the port is made of aluminum. (4) Pressurize the hydraulic tank (see item 8.3). (5) Operate the attachment to check the performance. (6) Check the tank and piping for oil leakage and oil level.

33-I-1-28

• The figure shows before BU. Fig. 16-5 Control valve removal

17. SOLENOID VALVE 17.1 REMOVAL PREPARATION (1) Disconnect hoses. 17.2 REMOVAL (1) Disconnecting hoses Disconnect all the hoses connected to the solenoid valve. Then attach a plug and a tag recording the connecting port to each of their openings. (2) Disconnecting connector Disconnect the connector connected to the harness for the main body. (3) Removing solenoid valve Unscrew two M8 X 25 SEMS bolts (B23) to remove the solenoid valve (B26).

B26

: 13 mm, T=3.0 kgf•m (22 lbf•ft)

B23

17.3 INSTALLATION (1) Install the solenoid valve in reverse order of the

B26

removal. Thread size Spanner used Tightening torque for O-ring type (PF) (mm) fitting in kgf·m (lbf·ft)

1 /4 3 /8

19 22

2.7 (20) 5.0 (36)

Fig. 17-1 Solenoid valve removal

(Note) Take care of the tightening torque as the solenoid valve is made of aluminum.

33-I-1-29

18. PILOT VALVE

8.1 PREPARATION FOR REMOVAL

34 34-134-234-3

Since the same method applies to the right-hand and the left-hand pilot valve, only the method for the right-hand is described.

BOOTS

(1) Disconnect the minus side terminal of the bat-

tery. (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 monitor panel. (4) Unscrew SEMS bolts (55) and (56) to remove

• The figure shows before BU.

the cover assembly (33) and (34) (see Fig. 17-

Fig. 18-1 Cover removal (Right control box)

1). : Plus screwdriver

18.2 REMOVAL 1) Disconnect each hose at the position marked with Å¶ and attach a plug and tag to facilitate installation.

2) Shift the boot and remove four capscrews (B5). : 10 mm

3) Remove the pilot valve (A1).

ƒ ƒ S/V ƒ C/B A2 ƒ C/B 2 ƒ C/B 3 C/B 4 2

18.3 INSTALLATION (1) Install the pilot valve in reverse order of the removal at the following tightening torque: 1) Attaching sems bolts (9) (10).

S/V

: Screwdriver (+)

T=0.27 kgf•m (2.0 lbf•ft) 2) Installing hoses, etc.

Fig. 18-2 Hose removal Arm (R)

Tank Tightening torque kgf·m (lbf·ft) Thread size Spanner used O-ring type 30 … flare type (PF) (mm) fitting fitting

1/4 3/8

19 22

2.7 (20) ---

3.0 (22) 5.0 (36)

Slew (R)

Slew (L)

Solenoid

Arm (H)

(Note) Take care of the tightening torque as the pilot valve is made of aluminum. (2) Pressurize the hydraulic tank (see item 8.3). (3) Operate the attachment to check the performance. (4) Check the tank and piping for oil leakage and oil level.

33-I-1-30

Left side (LH) Boom (R) Tank Bucket (R)

Bucket (H)

Solenoid

Boom (H) Right side (RH)

Fig. 18-3 Pilot valve port location

19. SLEWING MOTOR

19.1 REMOVAL PREPARATION (1) Remove the floor plate assembly (see item 3). (2) Release the residual pressure in the circuit and the pressure in the hydraulic tank.

19.2 REMOVAL (1) Disconnect four hoses (A7), (A8), (1) and (3) connected to the slewing motor (see Fig. 19-1 and 2).

: 22 and 27 mm

Fig. 19-1 Main hose disconnection

Fig. 19-2 Main hose disconnection

(2) Remove two pilot hoses (B19) and (B20) connected to the slewing motor.

B19

B20

: 19 mm

Fig. 19-3 Pilot hose removal

33-I-1-31

(3) Unscrew five M12X40 capscrews (3) to remove the slewing motor. 3

: 10 mm [a long type approx. 200 mm (7.9 inch) in length required]. Weight: about 38 kg (84 lb)

Fig. 19-4 Slewing motor removal 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. 2) Install the capscrews (3) for fixing the motor. : 10 mm T= 11.7 kgf•m (85 lbf•ft) Apply Loctite #262 to the capscrew. 3) Connect the hoses

Tightening torque kgf·m (lbf·ft) Thread size Spanner used O-ring type 30 … flare type (PF) (mm) fitting fitting

1/4 3/8 1/2

19 22 27

3.7 (27) 7.5 (54) 11 (80)

3.0 (22) 5.0 (36) 8.0 (58)

(2) Pressurize the hydraulic tank (see item 8.3). (3) Check the slewing operation. (4) Check the tank and piping for oil leakage and oil level.

33-I-1-32

20. SWIVEL JOINT

20.1 REMOVAL PREPARATION (1) Lift the machine by approx. 30 cm (12 inch) and insert support blocks at four places of the crawler shoes, namely, front, rear, right and left, to secure working space under the machine. (2) Remove the cover assembly (2) of the floor plate [see item 3.1, (4)]

Fig. 20-1 Lifting machine

(3) Unscrew four M10 X 16 capscrews (A5) to remove the under cover (A4). : 17 mm (4) Release the residual pressure in the circuit and the pressure in the hydraulic tank (5) Disconnect the hose of the slewing motor (see item 19).

â&#x20AC;˘ Remove the canopy to facilitate to remove the swivel joints.

Fig. 20-2 Undercover removal

20.2 REMOVAL (1) Remove the upper-side drain hoses (12) and (33), the tee (6) and the connector (B3).

12 33 6

: 19 mm B3

(2) Disconnect all the other hoses connected to the swivel joint. â&#x20AC;˘ Attach a plug and tag to each of the openings. Fig. 20-3 Drain hose disconnection

A7 A9

B3 A10

A1 A5

A12

A1 A13

A24 A4

Fig. 20-4 Upper side hose disconnection

Lower side hose disconnection

33-I-1-33

(3) Removing stopper Unscrew two M12X50 capscrews (7) to remove the stopper (3).

: 19 mm [a long type approx. 300 mm (12 inch) in length required].

Fig. 20-5 Stopper removal

C2 (4) Removing swivel joint Unscrew two M12X40 capscrews (C2) to remove the swivel joint (C1) downward.

: 19 mm Weight: 22 kg (49 lb)

Fig. 20-6 Swivel joint removal 20.3 INSTALLATION (1) Install the swivel joint in reverse of the removal at the tightening torque shown below. 1) Install the capscrews (C2).

DOZER (H)

DOZER (R)

: 19 mm T= 10.4 kgf•m (75 lbf•ft) P Apply Loctite #262 on the capscrews. A (UPPER) FORWARD 2) Install the capscrews (7). : 19 mm

TRAVEL MOTOR (LEFT)

Thread size Spanner used O-ring type 30 … flare type (PF) (mm) fitting fitting

3.7 (27) 7.5 (54)

A (LOWER) BACKWARD

Tightening torque kgf·m (lbf·ft)

19 22

B (UPPER) FORWARD

B (LOWER) BACKWARD

T= 11.7 kgf•m (85 lbf•ft) 3) Connect the hoses.

1/4 3/8

3.0 (22) 5.0 (36)

(2) Reinstall all the removed parts. (3) Pressurize the hydraulic tank. (4) Check the performance.

33-I-1-34

TRAVEL MOTOR (RIGHT)

Fig. 20-7 Connecting port relation

21. UPPER FRAME 21.1 REMOVAL PREPARATION (1) Remove the floor plate assembly (see item 3). (2) Remove the guards (see item 2). (3) Remove the counterweight (see item 6). (4) Drain hydraulic oil from the hydraulic tank (see item 8.2). (5) Disconnect the upper-side hoses for the swivel joint (see item 19-2). (6) Remove the stopper for the swivel joint (see Fig. 20-5). (7) Remove the attachment (see the “BOOM” item of the section of ATTACHMENT). (8) Remove the swing bracket (see the “SWING” item of ATTACHMENT).

21.2 REMOVAL (1) Providing match marks to slewing bearing Provide match marks between the upper frame and the outer race of slewing bearing. (2) Lifting upper frame temporarily Temporarily lift the upper frame at three points applying wire ropes on a position of the swingbracket mounting hole for the front side and on two positions of the rear end of the upper frame.

UPPER FRAME

OUTER RACE OF SLEWING BEARING

Fig. 21-1 Slewing bearing and upper frame (3) Removing bolt for mounting upper frame Unscrew one reamer bolt (6) and fifteen capscrews (5) fixing the outer race of the slew bearing to the upper frame. : 19 mm (4) Removing upper frame Lift the upper frame a little to ensure safety. Then remove it and place on a worktable capable of enduring the weight. Weight : Approx. 1,100 kg (2,430 lb) for SK30SR-2 Approx. 1,200 kg (2,650 lb) for SK35SR-2

33-I-1-35

Fig. 21-2 Lifting rear side

21.3 INSTALLATION (1) Install the upper frame in reverse of the removal. (2) Cleaning contact surface Clean the bottom surface of the upper frame and the top surface of the slewing bearing.

Apply Loctite #515 Only circumference hatched portion UPPER FRAME

•

Apply Loctite #515 over the entire circumference of the outer race inside of the capscrew.

(3) Lifting method 1) Apply wire ropes to the upper frame and lift up horizontally. 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.

OUTER RACE OF SLEWING BEARING

Fig. 21-3 Slewing bearing installation REAMER BOLT POSITION

(4) Installing slewing bearing and upper frame 1) Apply Loctite #262 on a reamer bolt (6) and fifteen capscrews (5) and temporarily tighten them. 2) Tighten the reamer bolt and capscrews at the specified torque at the front, rear, right and left positions apart from each other by 180 º alternately. : 19 mm, T= 11.7 kgf•m (85 lbf•ft) Apply Loctite #262 to the bolt and capscrews. 3) Fill the grease bath portion surrounding the gear teeth of the slewing bearing with about 2.5 kg (5.5 lb) of “Lithium grease.” (5) Install the components removed in the above removal preparation to the original position and check the performance.

33-I-1-36

OUTER ZONE S

• The figure shows before BU. Fig. 21-4 Reamer bolt position

Part II : DISASSEMBLING AND ASSEMBLING COMPONENTS 1. HYDRAULIC PUMP 1.1 CONSTRUCTION

SECTION X-X

No.

NAME

No.

NAME

Shaft assy

Gear pump assy

Hanger assy

Housing assy

Rotary group

Trochoid pump assy

Cover assy

Spring assy

Note) Refer to section 1.HYDRAULIC PUMP in COMPONENTS SYSTEM PV 24 for ditail.

33-II-1-1

1.2 DISASSEMBLY AND ASSEMBLY (1) Tools and Jig 1) Tools

Q’ty

Size(Nominal)

Torque wrench

Possible to tighten to the specified torque

Size(Nominal)

Plastic hammer

Medium type

Socket wrench

Snap ring plier

For hole(for snap ring 22)

Grease

Snap ring plier

For shaft(for snap ring 20) Adhesive agent

Little

2) Jig 1. Working bench Plate which is used to raise the pump facing downward If it does not contact with the shaft end, the square timber is available instead of it. 2. Jig for removing and installing cover Used to assemble and disassemble to preserve the shaft.

55 OR MORE (2.17")

ø35~ø55 (1.38"~2.17")

ø110 OR MORE (4.33") Working bench

ø17 (0.67")

<Assembly> Install the cover on the housing keeping it horizontal. The right Figure shows the construction of jig. This is of the construction to push the cover applying the machined end of hexagon socket set screw (M16 X 150)(Note 1) to the adjusting screw

(2) General precautions 1) Carry out the disassembly and assembly in a clean area, and prepare clean containers to put the removed parts in. 2) Before disassembling, clean around the ports, and remove the coating on every connection with wire brush. 3) Clean the removed parts with wash oil.

ø8 (0.31")

20 (0.79")

SET SCREW (M16)

NUT

66 (2.60")

320 (12.6")

<Disassembly> Prevent the cover from rising diagonally due to the control spring when removing 4 hexagon socket head bolts(M12).

130 (5.12")

ø103~ø105 (4.06"~4.13")

Jig cover

55 OR MORE (2.17")

(Note 1) When the hexagon socket set screw is used, machine 15mm from the top end in ø8.

Little Loctite high tack sealant #98

135 (5.31")

One each 6.8.10

Name

Hexagon spanner

Q’ty

(0.59")

Name

4) Put a matchmark on every part and assemble it meeting the matchmark. 5) Replace all seals with new ones by disassembly and apply grease to them. 6) Check that every part is free from wear and seizure, and remove burr, etc. with sand paper. 7) Don’t touch each adjusting screw unnecessarily.

33-II-1 -2

(3) Disassembly 1) Removing gear pump 1-1) Remove 2 capscrews (M10 X 25). : 8mm Pay attention not to miss O-ring (2 places) fitted on the housing.

â&#x20AC;˘

1-2) Remove the coupling.

2) Removing trochoid pump 2-1) Remove side plate(A) and the plate.

2-2) Remove the ring from the cover.

33-II-1-3

2-3) Take the gear out of the cover.

2-4) Remove side plate(B) from the cover.

2-5) Remove the key of the shaft

3) Disassembling main pump 3-1) Removing cover Since the control spring is strong, remove 3 capscrews (M 12 X 40) and one (M12 X 55) while pressing the cover with jig. : 10mm

33-II-1 -4

3-2) Removing cover Loosen hexagon socket set screw of jig slightly keeping the cover horizontal with jig and remove the jig. Pay attention not to â&#x20AC;˘ drop the control plate attached on the back side.

3-3) Remove the packing.

3-4) Removing the control spring section 1 Remove 2 springs (inside and outside) and the guide.

2 Remove the spring seat.

33-II-1-5

3-5) Removing rotary group 1 Remove the shim and then remove the C-snap ring (20 for shaft). Snap ring plier (for snap ring 20 for shaft)

2 Place the pump laterally and remove the rotary group from the shaft.

3-6) Removing shaft Wind protective tape on the spline section, and draw the shaft out straight taking care not to damage the oil seal.

3-7) Removing hanger section 1 Remove the hanger.

33-II-1 -6

2 Remove the guide. Direction: Put marks to avoid directional errors, like right and left, etc.

â&#x20AC;˘

3-8) Disassembling cover section 1 Remove the control plate.

2 Remove two socket bolts (M8X30) to remove cover of control spring.

3 Remove the spring seat.

33-II-1-7

4 Disassembling shuttle valve Remove the plug. : 8mm

5 Remove plug, ball and packing. : 10mm

3-9) Disassembling housing section 1 Remove piston, coned disk spring, distance piece and shim of P3 shift side.

2 Remove parallel pin and sleeve (Ă¸6) of P3 shift side.

33-II-1 -8

3 Remove piston of Pz shift side.

4 Remove parallel pin and sleeve (Ă¸10) of Pz shift side.

5 Removing min. flow stopper Remove snap ring (22 for hole), and then remove the min. flow stopper. Snap ring plier (for snap ring 22 for hole)

6 Remove the guide, disk spring, distance piece and shim.

33-II-1-9

7 Remove sleeve.

3-10) Disassembling gear pump (GSP2) 1 Loosen 4 socket bolts (M10 X 20). : 8mm

2 Remove the cover.

3 Remove the square ring.

33-II-1 -10

4 Remove 2 plates, guide and O-ring.

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

33-II-1 -11

(4) Assembly Assemble the main pump by the procedure reverse of the disassembly. 1-1) Assembly of main pump 1. Assembling housing section 1 Place the sleeve in.

2 Install prallel pin and sleeve (ø6) of P3 shift side into housing.

3 Install piston, coned disk spring, distance piece and shim of P3 shift side into housing. Pay attention to the direction of the disk spring.

•

4 Install parallel pin and sleeve (ø10) of Pz shift side.

33-II-1 -12

5 Install piston of Pz shift side.

6 Placing the min. flow stopper Place the guide, disk spring, distance piece and shim in the housing.

7 Place snap ring(22 for hole) in. Snap ring plier (for snap ring 22 for hole)

1-2) Placing hanger section in 1 Place the guide in the housing. Place in paying attention to the match mark put on when disassembling.

â&#x20AC;˘

33-II-1 -13

2 Place the hanger.

1-3) Placing the shaft in Wind protective tape on the spline section taking care not to flaw on the oil seal and place the shaft in straight.

â&#x20AC;˘ Check that the shim is placed on the bearing.

1-4) Assembling rotary group 1 Place 10 pistons in the retainer.

2 Apply grease on the spherical section of the guide.

33-II-1 -14

3 Placing guide between retainer and cylinder block, install pistons into bores on cylinder block.

â&#x20AC;˘ Apply grease on the shoe end.

1-5) Placing rotary group in 1 Place the rotary group meeting it to the spline of the shaft.

2 Fit snap ring(20 for shaft) and place the shim in. Snap ring plier (For snap ring 20 for shaft)

1-6) Placing control spring section in 1 Apply grease on the spherical section of the spring seat and place it in.

33-II-1 -15

2 Fit 2 springs(inside and outside) and the guide in.

1-7) Assembly of cover 1 Assembling shuttle valve Place the ball, packing and plug in. : 10mm Torgue : 1~1.3kgf路m (7.2~9.4 lbf路ft)

2 Attach and tighten the plug. : 8mm Torgue : 4~5.2kgf路m (29~38 lbf路ft)

3 Install spring seat to cover.

33-II-1 -16

4 Install and fix cover of control spring. : 6mm Tightening torgue : 2.9~3.6kgfÂˇm (21~26 lbfÂˇft)

5 Apply grease on the rear surface of the control plate to prevent it from dropping and place it in the cover meeting the hole for positioning pin.

1-8) Installing cover 1 Fit the packing.

2 Tighten the set screw of the jig slightly keeping the cover horizontal and install the cover.

33-II-1 -17

3 Tighten the socket bolts of the jig slightly keeping the cover horizontal and install the cover. Socket bolts 3-M12X40 1-M12X55 : 10mm Torgue : 9.8~12.5kgf·m (71~90 lbf·ft)

1-9) Trochoid pump 1 Insert the key in the shaft. TROCHOID PUMP SIDE

ROUND SIDE

COVER SIDE

Insert the key directing the side to the trochoid pump side. 2 Install side plate (B) on the cover.

3 Fit the ring on the cover.

33-II-1 -18

4 Place the gear in the cover. Install directing the matchmark face to side plate (B) side. MATCH MARK

•

INNER ROTOR OUTER ROTOR

5 Install plate (A) and the plate on the cover.

1-10) Installing gear pump Note: When the gear pump has been disassembled, refer to the section 1-11 “Assembling gear pump”. 1 Fit the coupling to the shaft end on the main pump side.

2 Connect the gear pump to the main pump.

33-II-1 -19

3 Fix the gear pump with 2 socket bolts M10x25. : 8mm Torgue : 5.6~7.0kgf·m (41~51 lbf·ft)

1-11) 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.

•

SUCTION SIDE

DELIVERY SIDE

SUCTION SIDE DELIVERY SIDE ASSEMBLING DIRECTION OF SQUARE RING 2 Install the drive gear and idle gear on the side plate.

3 Place the drive gear , idle gear and the side plate in the housing.

33-II-1 -20

4 Insert O-ring into guide, and install it to plate of 1.8mm thickness, then place it on plate of 1.5mm thickness. GUIDE

LARGE CHAMFERED SIDE

PLATE 1.5mm(0.059 in) PLATE 1.8mm(0.071 in)

5 Place the plate, guide and O-ring in the hous ing. Then pay attention to the suction and delivery direction.

â&#x20AC;¢

SUCTION SIDE

DELIVERY SIDE

6 Fit the square ring.

7 Combine the cover with the housing.

33-II-1 -21

8 Fix the housing and the cover with 4 socket bolts M10 X 20. : 8mm Torgue : 5.6~7.0kgf·m (41~51 lbf·ft)

33-II-1 -22

1.3 MAINTENANCE STANDARD (1) Parts replacement standard

Item

PISTON ASSY

Replacement criterion

CYLINDER BLOCK

Piston assy and cylinder block

Visual inspection To be free from flaw, scuffing and wear. (Especially the sliding section)

Remedy Replace

Check clarance between the piston outer diameter and inner diameter of the cylinder block. _ 0.06mm. (0.0024 in) To be D-d < Piston shoe and piston SHOE

PISTON

Piston shoe and piston

Check the play in the axial direction of the piston and shoe shaft. _ 0.2mm. (0.0079 in) To be <

Shaft OIL SEAL INSTALLING RANGE

Replace

Check the wear of the oil seal. _ 0.025mm.(0.0010 in) To be Wear <

Shaft

Check that the sliding surface is free from flaw.

Replace it when the flaw is severe

Check that it is free from gall and step wear.

Replace it in set if it is impossible to repair.

Check that it is free from slight gall and flaw.

After correction with lapping clean it to remove the lapping compound

Control plate

Guide and

33-II-1 -23

NOTES

2. CONTROL VALVE

Bucket

Boom

Travel straiht

Arm 15

Travel left

Travel right

18 15

Swing

Dozer

Slewing

Service (N&B)

2.1 ASSEMBLY DRAWING (1)-1 Outside view [EU • OCEANIA]

20 19

Manual operte

Pilot operae 1

5 15

9 8

Fig. 2-1

Tale. 2-1

No. 1 2 3 4 5 6 7

SECTION Dozer section Slewing P3inlet Service Swing Arm Travel (right)

Q’TY No. Q’TY No. SECTION NAME 1 8 P1‚P2 inlet&Travel straight 1 15 Over load relief valve 1 1 9 Travel (left) 16 Over load relief valve 1 1 10 Boom 17 Anti cavitation valve 1 1 11 Boom lock 18 Plug assy 1 1 12 Buckt 19 Tie bolt 1 13 P1‚P2 Main relief valve 2 20 Nut 1 1 14 P3 Main relief valve

33 -II -2-1

Q’TY 4 2 1 3 4 4

Bucket

Boom

Travel left

Travel straiht

Arm 15

Travel right

18 15

Swing

Dozer

Slewing

Service (N&B)

[USA]

20 19

Manual operte

Pilot operae 2

5 15

9 8

Fig. 2-2

Tale. 2-2

No. 1 2 3 4 5 6 7

SECTION Dozer section Slewing P3inlet Service Swing Arm Travel (right)

33 -II -2-2

Q’TY 4 2 1 3 4 4

(2) Cross section The control valve is roughly classified into the following 4 sections. • Manual operation section : [EU • OCEANIA] Swing, dozer, service (Nibbler & breaker) [USA] Dozer, service (Nibbler & breaker) • Pilot operation section

: [EU • OCEANIA] Travel straight, travel right and left, boom, arm, bucket, slewing [USA] Travel straight, travel right and left, boom, arm, bucket, slewing, swing

• Accessary section

:P1, P2 inlet (Common with travel straight), P3 inlet ,boom overload

• Accessary section(valve) :P1, P2, P3 main relief, overload relief, anticavitation, boom lock * For respective operation section, only typical example is described.

1) Manual operation : Swing (No.5) [EU] Note) Swing control of [USA] is operated by hyd. pilot line. 14

9 6

13 12

2a 2b 2c 2d 2e 2f 11 2g 10 5

4 3

1 Fig. 2-3

2) Pilot operation : Slewing (No.2)

Table. 2-3

No. 1 2a 2b 2c 2d 2e 2f 2g 3 4 5 6 7 8 9 10 11 12 13 14

NAME Body SPool O-ring 1A P12 Dust wiper Oil seat retainer Spring seat Spring Spool end O-ring 1A P12 Dust wiper Oil sear retainer Load check valve Spring (for check valve) O-ring 1B P11 Plug Socket bolt M5X10 Cover Socket bolt M5X18 Anti cavitation valve O-ring 1BW G4

Q’TY 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 2 1 2 1 1

Table. 2-4

4 6

2d 2e 9 2c 2b

Fig. 2-4

33 -II -2-3

No. 1 2a 2b 2c 2d 2e 3 4 5 6 7 8 9 10 14

NAME Body Spool Spring seat Spring Spring seat Spool end Load chack valve Spring (for chack valve) O-ring 1B P11 Plug O-ring 1BS22 Pirot cover Pirot cover Socket bolt M5X20 O-ribg 1BW G4

Q’TY 1 1 1 1 1 1 1 1 1 1 2 1 1 4 1

3) Main relief valve (P1‚P2‚P3) and Over load relief valve Table. 2-5 15

Fig. 2-5

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

4) Anti cavitation valve 1

Q’TY 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1

Table. 2-6 2

Fig. 2-6

33 -II -2-4

No. 1 2 3 4 5 6 7 8

NAME Anti cavitaion valve Body Plug Spring Back up ring O-ring 1A P10A O-ring 1B P14 O-ring 1B P15

Q’TY 1 1 1 1 1 1 1 1

Precaution (These precautions must be observed for safety.) 2.2 PRECAUTIONS FOR DISASSEMBLY The disassembly and assembly is fundamentally to be carried out at the manufacturer’s plant, but when they are unavoidably necessary, observe the 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. And before disassembly, recheck that every post 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. 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. Table. 2-7

Tools

Remark

QT’Y

Allen wrench

One each

4 , 5 , 6 , 8mm

Spanner

One each

13 , 19 , 21 , 22 , 26mm

Socket wrench

One each

13 , 19 , 21 , 22 , 26mm

Torque wrench

0.2kgf·m~2.0kgf·m (1.4~14lbf·ft)

Torque wrench

2.0kgf·m~10.0kgf·m (14~72lbf·ft)

Magnet

Pliers

Screw driver (-)

Tweezer

Prepare wash oil,hydaulic oil,grease,loctite #242,tag and warker (felt-tip pen) before hand.

33 -II -2-5

2.4 DISASSEMBLING (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. (Refer to Fig. 2-4 and 2-7.) First, loosen and remove 2 washer socket bolts (10) with allen wrench of 4mm. Then, remove pilot cover (9). The spring section of the slewing spool is disposed, so draw out and take out spool assy (2a2e) 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 (7) on the flange bottom installing the pilot cover on the body side is not separated.

2) In case of manual switching type, How to take out this type as an example of the dozer spool is as follows. (Refer to Figures 2-3 and 2-8.) First, loosen and remove 2 socket bolts (12) with allen wrench of 4mm. Then, remove end cover (11). The spring section of the dozer spool is disposed, so draw out and take out spool assy (2a-2g) slightly and horizontally(parallel to the spool hole) from body (1) holding the spring section. Then, pull the spool assy 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.

7 9 6 8

4 6 3 5 10

2d 2e 2c 2b

10 5 4 3

2b 2c 2d 2e 2f

Fig. 2-8 Manual awitching type

Fig. 2-7 Hydraulic pilot switching type

3) Precautions when replacing spool, When replacing the spool, in no case should the spool be disassembled, but replace it by the spool assy.

33 -II -2-6

4) In case of travel straight spool, (Refer to Fig. 2-9.) First, loosen and remove 2 washer socket bolts (16) with allen wrench of 4mm. Then, remove pilot cover (15). Spring (11) and stopper (12) are disposed, so remove them. Draw out and take out spool assy(2a-2c) slightly and horizontally (parallel to the spool hole) from the valve holding the end of the travel straight spool. Then, check that O-ring (13) on the flange bottom installing the pilot cover on the main body side is not separated. And, Loosen 2 socket bolts (16) on the opposite side with allen wrench, and pilot cover (14) can be removed and also filter case assy (7-10).

(3) How to disassemble load check valve First, fix the valve on the work bench, or ask people to hold down the valve in order to keep it from moving. Loosen plug (9) at the center of the valve upper surface with spanner of 19mm (or socket wrench). It may be difficult to loosen the plug because Oring gets caught in the thread. Then,don’t force it to loosen, but tighten the plug once again and loosen it again. Take out spring (7), load check valve(6) through the hole used to remove the plug with tweezers or magnet. The numbers in Fig. 2-10 corresponds to the number of the dozer section in Fig. 2-3. The form of the travel, P3 inlet, and boom ORV sections differ, but they can be disassembled by the same procedure.

9 8 16

43 56

7 14

6 2c 2b 2a 1

15 11

13 8 7 9 10

Fig. 2-9 P1 and P2 inlet and travel straight section

(2) Relief valve (Code:RV) How to remove overload 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 (opposing flat,22) of RV and ORV with spanner of22mm. At that time, don’t remove the valves applying spanner to the opposing flat, 19. 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 don’t disassemble the RV and ORV because it is very difficult to reset the pressure. When there is a failure, replace the assy.

Fig. 2-10 Load check valve Dozer , Slewing , Service , Swing, Arm , Boom , Bucket

PLUG O-RING

SPRING LOAD CHECK VALVE

Fig. 2-11 Load check valbe (Travel LH/RH,P3inlet,Boom ORV)

33 -II -2-7

(4) Disassembling other parts Other parts which are not removed by the procedure from Article (1) to (3) are removed by the following procedure. 1) Service section Plug for actuator part (Refer to Fig. 2-12.) Fix the valve directing the actuator port upward. Loosen and remove plug (13) on both right and left sides of the upper surface of the service change section with spanner of 21mm (or socket wrench).

4) Load check valve and plug for recirculation in arm section (Refer to Fig. 2-13.) Put the valve on work bench directing the actuator port downward. Remove plug (11) at the center of the bottom of the arm switching section with allen wrench of 6mm. And remove O-ring (12) also. Then, loosen and remove one more plug (14) with allen wrench of 6mm. Take out spring (15) and load check valve (13) through the hole the plug was removed from with tweezers or magnet.

14 5

15 13

11 12

Fig. 2-13 Arm section (Load check valve for recirculation and plug)

Fig. 2-12 Service section 2) Pilot cover of hydraulic pilot switching section (Refer to Fig. 2-7.) Loosen and remove 2 washer hexagon socket bolt with allen of 4mm. Draw pilot cover (8) out horizontally. At the same time, check that O-ring (7) on the flange bottom securing the pilot cover on the main frame side is not separated. 3) Spool seal of manual switching section (Refer to Fig. 2-8.) Loosen and remove 2 socket bolts(10) with allen wrench of 4mm. The oil seal retainer (5) is also removed simultaneously. Remove spool seal [(O-ring (3),dust wipe (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 repaired to be used again, check that it is free from flaw, deformation, foreign matter adhered, etc before installation.

5) Disassembling main frame of switching section The figures in ( ) after part name in the description shows the symbol used in the outside view. Loosen and remove 4 nutsM8(20) for the main frame assembly of the switching section on the side of the valve with spanner of 13mm (socket wrench). Draw 4 tie-bolts(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 frame. The main frame of the switching section is equipped with many plugs screwed in. These plugs are for preliminary holes, so donâ&#x20AC;&#x2122;t disassemble when not required. 6) Precautions for disassembly 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.

33 -II -2-8

7) Disassembling anticavitation valve Since the anticavitation valve is essential for the performance, replace the assy if necessary. For reference, how to disassemble for checking the abnormality is shown below. The figures in ( ) after part name in the description shows the symbol in the cross-section (Fig. 2-6). First, hold body (2) with vise at the hexagonal section of the opposing flat, 22. Loosen and remove plug (3) with allen wrench of 8mm. After removing spring (4), push anticavitation valve (1) in from the seat side, taking care not to damage the seat, and draw Oring (6) and back-up ring (5) from the side plug(3) is taken out taking care not to damage the thread around the body (2).

The needle valve is easy to come out, take out it first and store it. Do not disassemble the lock valve, store it as assembly (2~8,11).

8) Relief valve (Code:RV) Disassembling overload relief valve (Code:ORV) Since the overload relief valve is essential for the performance and safety and the resetting of the pressure is very difficult, replace the assy when an abnormality is detected. For reference, how to disassemble for checking the abnormality is shown below. The figure in ( ) after the part name in the description shows the symbol in cross section (Fig. 2-5). First, hold the body (5) with 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), poppet (6) and spring guide (16) with tweezers, etc. Then, loosen and remove plug (4) with spanner of 19mm, and the remaining parts can be taken out at the same time. And take out socket (1), piston (3), spring (10) and (2) in order.

Fix the lock valve cover with a vise, loosen and remove the bush (17) with a 26 mm spanner (or wrench key). Fix the lock valve cover with a vise at the side faces other than the port face. Pull out the pistons B (15) and A1 (14) with a pair of tweezers or a magnet through the bore for bush. Mark on the pistons (B) and (A1) to realize the assembled direction. Do not disassemble the piston guide (13), and store it at assembly with the lock valve cover. Loosen the ball retainer (19) with a 4 mm wrench key. Pull out the Ă¸7steel ball (18) with a magnet through the bore for ball retainer.

Fig. 2-14

9) Disassembling lock valve If the lock valve became abnormal, replace it to new one as assembly. The disassembling procedures described below are for reference only to check the cause for abnormality. At first, loosen two socket bolts (20) with a 5 mm wrench key. Then remove the lock valve cover. Pay attention not to drop off and lose two positioning pins (9) and give any damages to them. Since the lock valve (2) and needle valve (10) are exposed, pull them out with care.

33 -II -2-9

Fig. 2-15

Precautions (Observe the following for safety.) 2.5 PRECAUTIONS WHEN ASSEMBLING 1) The unevenness of tightening torque and the contamination of 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 pay attention 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 degrease the surface sufficiently, and apply it to two threads. (Overapplication may cause a malfunction due to the squeezing out.)

Precautions (Observe the following for safety.) 2.6 PRECAUTIONS WHEN FITTING SEALS 1) Replace seals with new ones when assembling. 2) Pay attention to seals that they 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) Donâ&#x20AC;&#x2122;t stretch the seals until it will be changed permanently. 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 -II -2-10

2.7 ASSEMBLY WORK 1. The assembling method is merely explained, so for figures refer to Section“Disassembly”. 2. Assembling procedure (1) Assembling the main frame of the switching section (Refer to Fig. 2-1.) Put all sections of main frame in order as shown in Table directing the actuator port downward.

MARK SK30SR-2 SK35SR-2 Dozer SA Slewing GE P3 inlet UE Service TE EU FP Swing USA FU Arm DH DD Travel R,H CP P1,P2 inlet AE Travel L,H BM Boom EC Boom lock KE Bucket VF SECTION (Block)

Note: The symbols are marked on the upper surface of the main frame of the switching section (Actuator port face)

Table. 2-8

Then, check that the mating surface of the main frame each switching section is free from dust, etc. and the O-ring is securely fitted in the groove. And, insert 4 tie bolts(19) through the main frame of the switching section from the side, and tighten 4 lock nutsM8(20) to the specified torque with socket wrench of 13mm. T=1.7 ~1.8kgf·m(12~13lbj·ft) Observe the specified torque. When the lock nut is not tightened to the torque other than the specified torque, it may cause a distorsion and oil leakage of the main frame. At this time, don’t tighten the lock nuts at a time, but tighten 4 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 and plug for arm recirculation (Refer to Fig. 2-13.) Put it on work bench directing the actuator port of the valve downward. FitO-ring(12) securely on the counter bore of the hole at the center of arm switching section. Tighten plug (11) to the specified torque with allen wrench of 6mm. T=1kgf.m(7lbf•ft) And, insert load check valve (13) in the hole located at the end of the bottom of the arm switching section in normal direction (Face the flat sec-

tion to the seat side of the main frame of switching section.), and place it in at proper position with tweezers,etc. Apply grease on the spring guide of plug (14), and fit check valve spring (15) on the spring guide. Then, check that O-ring(5) is fitted on the plug. Tighten the plug with allen wrench of 6mm to the specified torque so that the guide of the load check valve fitted on the main frame side 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. T=1kgf·m(7lbf·ft) (3) Assembling load check valve Put the load check valve of the valve on the work bench directing the actuator port upward. 1) Section other than travel, P3 inlet, boom ORV sections (Refer to Fig. 2-10.) Place load check valve (6) 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 (7) 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. Then, check that O-ring (8) is fitted on the plug. Screw in with a certain amount, and tighten it to the specified torque with spanner of 19mm (or socket wrench). T=4kgf·m (29lbf·ft) 2) Travel, P3 supply, boom and ORV sections (Refer to Fig. 2-11.) Place the load check valve in the hole at the center of the valve in normal direction (direct the cap section downward.), and check that it is placed in at the center. Apply grease to the spring and fit the plug in the guide. Then, check that O-ring is fitted on the plug. 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 spanner of 19mm (socket wrench). T=4kgf·m(29lbf·ft) Assemble it paying attention to the position where two types of the load check valve are installed in order not to make a mistake.

33 -II -2-11

(4) Assembling RV and ORV Install the RV and ORV to respective port for installation with the specified torque. T=4kgf·m (29lbf·ft) Observe the specified torque. When the respective valve is not tightened to the torque other than the specified torque, 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 put when disassembling. (5) Assembling spool assy 1) In case of hydraulic pilot switching type, (Refer to Fig. 2-7.) Insert respective spool assy 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 assy and the spool holes of the main frame of the switching section are free from dust, etc. and also O-ring(7) 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. And, don’t force theinsertion 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 byhand, 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 assy and the main frame of the switching section. And, install pilot cover (9) on the flange section of the main frame of the switching section from the spring side of the spool assy securely, and install it on the main frame of the switching section by tightening washer socket bolt (10) with allen wrench of 4mm. T=0.6~0.7kgf·m (4.3~5.1lbf·ft) Fit the flange section on the opposite end of the main frame of the switching section so that pilot cover (8) snaps into the flange section of the main frame of the switchingsection after checking that O-ring (7) is placed in, and then install it on the maintorque of the switching section with washer socket bolt (10) tightening with allenwrench of 4mm to the specified torque. T=0.6~0.7kgf.m (4.3~5.1lbf·ft) 2) In case of manual switching type, (Refer to Fig. 2-8.) 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 assy and the spool holes of the main frame of the switching section are free from dust, etc. 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. And, install end cover (11) on the main frame of the switching section from the spring side of the spool assy with socket bolt (12) tightening with allen wrench of 4mm. T=0.6~0.7kgf·m (4.3~5.1lbf·ft) 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 (10) with allen wrench of 4mm. T=0.6~0.7kgf·m (4.3~5.1lbf·t) At this time, pay attention to the direction of the dust wiper (direct the lip outward.) And, don’t tighten socket bolts at one time, but tighten 2 socket bolts slightly so that oil seal presser is inserted in parallel. 3) In case of travel straight section (Refer to Fig. 2-9.) Install the filter case assy on the flange section of the main frame paying attention to the direction after checking that the travel spool and spool holes of the main frame of the switching section are free from dust, etc. and O-ring(13) is securely fitted on the flange bottom of the main frame of P1 and P2 supply section (2 places before and after the main frame of supply section.) And, insert the travel straight spool assy in the spool hole on the opposite side of the side where the filter case assy was installed paying attention to the direction. Then, apply slight hydraulic oil to the spool before inserting. Check that filter (9) is placed in filter case (7). And, don’t force the insertion of the spool. Install stoppe r(12) and spring (11). And fit pilot cover (15) on the flange section of the main frame securely, tightening washer bolt(16) to the specified torque with allen wrench of 4mm. T=0.6 – 0.7kgf·m(4.3~5.1lbf·ft)

33 -II -2-12

(6) Assembling relief valve and overload 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 assy. For reference, when it is disassembled for checking for the abnormality, assemble it as follows. The figures in ( ) after part name in the description shows the symbol in cross section (Fig. 2-5). 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). T=6kgf·m (43lbf·ft) And adjust the pressure by adjusting screw (7) with allen wrench of 4mm, and tighten lock nut M14 (8) to the specified torque . T=2kgf·m (14lbf·ft) Assemble the relief valves by the procedure reverse of the disassembly paying attention to the direction and order and observing the specified torque. When the tightening of lock nut(M14) does not follow the specified torque, it may cause oil leakage and failure. 1) Assembling anticavitation valve 2) The anticavitation valve is essential for the performance and safety, so in case of abnormality replace it with a assy. For reference, the procedure for disassembly and assembly is shown below. The figure in ( ) after the part name in the description show the symbol in cross section(Fig. 2-6). First, place anticavitation valve(1) in body(2), and place spring(4) in it. Then tighten the plug to the specified torque. T=12kgf·m(43lbf·ft) Assemble the anticavitation valve by the procedure reverse of the disassembly paying attention to the direction and order and observing the specified torque.

When the tightening of the plug does not follow the specified torque, it may cause oil leakage and failure. (7)Assembling lock valve If the lock valve became abnormal, replace it to new one as assembly. The assembling procedures described below are only for reference when it is disassembled to check the cause for abnormality. (Refer to Figures 2-14 and 2-15.) At first, fix the lock valve cover with a vise a the side faces other than the port face. After fixing, insert the piston A1 (14) into the bore on piston guide (13) paying attention to its direction. Then insert the piston B (15) into the bore on lock valve cover paying attention for its direction. After that, tighten the bush (17) with 26 mm spanner (or wrench key) at the specified torque. T=6~7 kgf.m (43~51 lbf.ft) At that time, confirm the fact that the O-ring (16) has been surely installed to the bush. If the pistons (A1 and B) are difficult to insert, do not try to insert them by force. It may connect to malfunction. After the insertion of pistons (A1 and B), 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 (A1 and B) to new ones together with the lock valve cover as assembly. After setting the ø7 steel ball to the place, toghten up the ball retainer (19) at the specified torque. T=0.8~1.0kgf.m (5.8~7. lbf.ft) At that time, confirm the fact that the O-ring (12) has been surely installed to the ball retainer. After confirmation for the fact that the flat O-ring has been surely installer to the inserting side of lock vale of lock valve body, set the lock valve assy (2~8, 11) and needle valve (10), and insert it into the bore for lock valve. Then aligning two positioning pins (9) on the lock valve cover with the bores on the lock valve body, slowly press the lock valve cover up to getting touch with the lock valve body. T=1.0~1.1 kg.m (7.2~8.0 lbf.ft) At that time, confirm that the needle valve (10) is surely placed on the seat inside the lock valve cover. Then tighten the socket bolts (20) with the 5 mm wrench key at the specified torque. At the tightening, make sure to tighten up two socket bolts alternatively so that the lock valve cover is set in parallel.

33 -II -2-13

2.8 Maintenance standard Parts inspection

Parts name

Main frame of switching section

1) Existence of scratch, rust and corrosion

1) Replace it when there is flaw on thefollowing 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 Oring • Seat section of relief valve and overloadrelief valvel Failure it may cause malfunction, etc.

Spool

1) Existence of scratch, rust and corrosion 2) Insert spool in the hole of the main frame of the switching section, stroke it while rotating.

1) Replace it when there is scratch on the peripheral sliding surface 2) In case the spool is not smooth, repair or replace it.

Load check valve 1) Damage of load check valve and spring 2) Insert load check valve in plug and experimentally operate it.

Criterion and corrective action

1) In case there are flaws and scratches on the seat section, repair or replace it. 2) When it moves smoothly, normal, but if it moves unsmoothly, replace it.

Around spring

1) Rust, corrosion, deformation and breakage of spring, spring seat, plug, and cover

1) Replace it when the movement is unsmooth or there is damage causing poor durability.

Around of seal of spool

1) Hardening, deformation and flaw of O-ring 2) Deformation and flaw of dust wiper 3) Rust, corrosion and deformation of oil seal retainer

1) Replace 2) Replace 3) Repair or replace

Relief valve Overload relief valve

1) Rust on outer surface 2) Contact surface of valve seat 3) Spring in abnormal condition 4) O-ring, back-up ring

1) Replace 2) In case there are flaw and gauge, replace it. 3) Replace 4) Replace all parts, as a general rule.

33 -II -2-14

2.9 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. (1) Control valve

Phenomenon

Cause

Corrective action

1.Eachattachment does not function, or the actuation is slow. (Poor power) Or there is no response.

1) Malfunction of relief valve 1) Measure the pressure of relief valve • Dust caught between poppet and seat • Replace the assy. • Dust caught between poppet and seat • Replace the assy. * • Replace the assy. • poppet is stuck. * • Breakage or permanent set in fatigue of • Replace the assy. spring • Readjust it, and tighten the lock nut to the specified torque. • Loose of adjusting screw • Disassemble and clean it. 2) Dust caught between the main frame and In case of severe flaw, replace the main spool, or stuck frame and spool.

1.When spool is placed on the neutral position, the natural drop of the cylinder is large.

1) The space between the main frame of the switching section and the spool is toolarge. 2) The spool is not returned to the neutral position completely. • Dust caught between the main frame and spool, or stuck • Breakage or permanent set in fatigue of spring 3) Malfunction of ORV • Refer to the description marked with *.

3.When the cylinder 1) Malfunction of load check valve is set tothe raise • Dust caught between load check position, the valve and main frame. cylinder moves • Load check valve is stuck. downward • Breakage and permanent set in reversely when fatigue of spring starting the operation.

1) Replace spool. 2) Measure pilot secondary pressure. • Disassemble and clean, or when stuck, replace the main frame and spool together. • Replace spring. 3)Measure the pressure of ORV. Refer to the description marked with *.

1) • Disassembly and cleaning. In case of the severe damage, replacethe main frame and load check valvetogether. • Replace spring.

* In case of abnormality marked with *, dont fail to replace the relief valve assy.

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(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 assy. The handling method is for reference, replace the assy as a rule.

Phenomenon

Cause

Corrective action

1. Pressure does not rise.

The pressure adjusting valve of each relief valve, poppet and piston are stuck, kept open, or got caught dust in the seat section of the valve.

• Check that the engagement valve of respective valve doesn’t get matters caught in it. • Each part slides freely. • Clean all parts completely.

2. Relief pressure is unstable.

The adjusting valve of respective valve is damaged, or the piston is stuck to the poppet.

• Replace the damaged part. • Clean all parts completely. • Remove flaw on the surface.

3. The relief pressure is not within the limit of set values.

1) Wear due to dust 2) Lock nut and adjusting screw are loose. • Breakage and permanent set in fatigue of spring 3) Malfunction of RV and ORV

1) Disassemble and clean 2) Adjusting pressure • Replace spring. 3) Measure the pressure of RV and ORV.

4. Oil leakage

1) Damage on each seat section Wear of O-ring 2) Respective part is stuck due to dust entered.

1) Replace the worn or damaged part. Check that respective part move smoothly before installing. 2) Check that it is free from scratch, score and foreign matter before installing.

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3. PILOT VALVE (Attachment) 3.1 STANDARDS

APPLY LOCTITE#277 (PART OF SLANT LINE) APPLY GREASE ON TOP APPLY GREASE ON TOP

SECONDARY PRESSURE ADJUSTING SHIMS

PORT 2,4

NOT TO BE REUSED

PORT 1,3

Fig. 3-1 Pilot valve (Attachment)

Unit : kgf·m (lbf·ft) No. Thread size 125 M8 301 M14 302,312 M14

No. 101 111 121 122 125 126 131 151 201-1

NAME CASING PORT PLATE SEAL WASHER O-RING SOCKET BOLT SPRING PIN ø 5 X 10 BUSHING PLATE SPOOL

Q’TY 1 1 2 1 2 1 1 1 2

No. 201-2 211 212-1 212-2 213 214 216-1 216-2 217

NAME SPOOL PLUG PUSH ROD PUSH ROD SEAL O-RING ; 1B P20 SPRING SEAT SPRING SEAT WASHER 2

33 -II -3 -1

Q’TY 2 4 2 2 4 4 2 2 4

No. 221-1 221-2 241-1 241-2 301 302 312 501

Tightening Torque Table 2.1 (15.2) 4.8 (34.7) 7 (50.6)

NAME SPRING SPRING SPRING SPRING JOINT ; M14 DISK ADJUSTING NUT ; M14 BELLOWS

Q’TY 2 2 2 2 1 1 1 1

3.2 DISASSEMBLY & ASSEMBLY (1) Tools

No. a b c d

Tool Name

Remark 1.5~10 kgfÂˇm class Torque wrench (10~75 lbfÂˇft) W= 2 ~ 3mm, 4 ~ 5mm Screw driver ( ) (0.08~0.12in, 0.16~0.20in) Screw driver ( ) Spanner and Allen General tools wrench

HANDLE LEVER

BELLOWS (BOOTS)

(2) Caution for disassembly & assembly 1) Exercise sufficient care to prevent entry of dust when disassembling and assembling components. 2) Handle the parts with sufficient care, preventing defect. 3) The spools, spring seats and springs used in ports 1, 3 and ports 2, 4 of this pilot valve differ slightly in dimensions. Before removing those parts, record the locations so they are installed in correct positions.

LEAD WIRE

Fig. 3-2 Disassembling handle lever

(3) Disassembly 1) Remove the handle lever assy, boots and lead wires from valve body (101). (See Fig. 3-2) 2) Fix the pilot valve with a vise, placing copper plates (or lead plates). 3) Place a wrench in the opposing flats of the disk (302) and turn counterclockwise till joint (301)gets loosened. : 22mm 4) Remove the operating part of the handle (301, 302, 312) from the valve body (101). 5) Remove plate (151) 6) Remove plug (211)from valve body (101) so as not to exert uneven load upon it, utilizing the groove in the outer circumference of plug (211) and using a screw driver (b).

PORT 2,4

Take care that the plug (211) may jump out by spring force of the springs (221-1, 221-2, 241-1, 241-2) while the plug is pulling out. 7) Remove push rods (212) and spring seats (2161, 216-2). 8) Record the related location of the holes in the spool assy and valve body (101). Remove the spool assy from valve body (101).

PORT 1,3

Fig. 3-3 Disassembling pilot valve

9) Take off springs (241-1, 241-2). 10) Loosen socket bolt (125), using an allen wrench and remove port plate (111) from valve body (101). : 6mm

33 -II -3 -2

11) Disassemble the spool (201-1, 201-2), spring seat (216-1, 216-2), spring (241-1, 242-2) and washer 2 (217). • These parts to be treated as assy until assembling. 12) Loosen disk (302), adjusting nut (312) and lock nut on the handle operating parts, using spanner, and disassemble joint (301). : 22mm (4) Assembling 1) Before assembling, wash parts with cleaning solvent and dry them with compressed air, Avoid using cloth if possible.

Fig. 3-4 Spool assy

• Before assembling correct all defects made during disassembling, clean parts, coat moving parts with oil and refit parts back in original place. 2) Replace O-rings with new ones. Replace seal washers (121) with new ones, also. 3) Fit O-rings (122) into valve body (101). 4) Install port plate (111) to valve body (101). In that case, beware of the mounting position so that spring pin (126) can be set in the hole of valve body (101) side. 5) Tighten slowly, with specified torque, two socket bolts (125) with seal washers (121). : 6mm T=3 ± 0.3 kgf·m (22 ± 2 lbf·ft)

PORT 2,4

PORT 1,3

Fig. 3-5 Assembling

33 -II -3 -3

6) Install washer (217), spring (241-1, 241-2) and spring seat (216-1, 216-2) into spool (201-1, 2012)in that order. (See Fig. 3-4) 7) Assemble spring (221-1, 221-2) into valve body (101) so it was located before removal. 8) Install the reducing valve assy into valve body (101). 9) Assemble seal (213) in plug (211) so its lip faces as Fig. 3-6. Then insert, push rod (212) with seat spring (216-1, 216-2) into plug (211).Coat the surface of push rod (212) with hydraulic oil. (See Fig. 3-6) 10) Assemble O-ring (214) to plug (211). 11) Assemble the plug assy into valve body (101). (It stops because of the sliding resistance of the O-ring.) 12) Attach plate (151) to valve body (101). 13) Fasten joint (301) to valve body (101) with specified torque. : 22 mm T=4.8 ± 0.3 kgf·m (35 ± 2 lbf·ft) 14) Install disk (302) to joint (301), and fasten adjusing nut (312) in a position where the disk contacts the tip of four push rods (212), to specified torque. : 22 mm T=7 ± 0.5 kgf·m (51 ± 4 lbf·ft) • Fasten the adjusting nut so the gap between disk (302) and push rod (212) gets below 0.2 mm (0.008 in) 15) Pass a lead wire through the hole of the valve body, and through the side hole in the adjusting nut located between 60° and 120°, and pull it out. 16) Assemble grommet (457) into plate (151) and pass lead wire through it. Slacken the lead wire to an extent that is required for moving when operation is performed. 17) Apply heat resistant grease over the contact surface of the joint rotating part, the plate and the push rod. 18) Install the handle lever assy and the boots (bellows) to valve body (101).

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APPLY HYDRAULIC OIL

Fig. 3-6 Inserting push rod

3.3 MAINTENANCE STANDARDS (1) Parts replacement standards 1) Replace O-ring and other seals at each disassembly and assembly. 2) Replace worn parts if leaks affects the operating system. 3) Replace spools having excessive wear on their sliding portion.

Fig. 3-7 Wear of push rod

4) Replace a push rod that is worn to 1mm (0.04in) or over on its top end. (See Fig. 3-7) 5) Replace operating lever and handle pins that have a play of 2mm (0.08in) or over. 6) Replace such parts that arise abnormal sounds, hunting and drops in the primary pressure.

3.4 TROUBLESHOOTING

Trouble Secondary pressure does not rise.

Posible Cause

Remedy

1) Primary pressure is insufficient. 2) Springs (241-1, 241-2) are broken or fatigued. 3) Clearance between spool (201-1, 201-2) and valve body (101) is abnormally large. 4) Play of handle portion is too much.

1) Secure primary pressure. 2) Replace with new ones.

Secondary pressure is unstable.

1) Sliding parts are caught. 2) Tank line pressure varies. 3) Air has contained into pipeline.

1) Correct. 2) Return directly to oil tank. 3) Release air.

Secondary pressure is high.

1) Tank line pressure is high. 2) Sliding parts are caught.

1) Return directly to oil tank. 2) Correct.

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3) Replace assembly. 4) Disassembly and reassembly or replace handle portion.

NOTES

4. PILOT VALVE (TRAVEL) 4.1 CONSTRUCTION 472 APPLY GREASE TO BEARING

501 471

413

APPLY GREASE TO TOP

414

402

214 210 APPLY GREASE 202 TO TOP 271 201 212 224

203

213

336 102

218

225

311 211

252

324 335

217 313 251 261 301 101

Fig. 4-1 Pilot valve (Travel)

Torque kgf·m(lbf·ft) No.

3.0 (22)

101 102 201 202 203 210 211 212 213 214 217 218 224 225 251

NAME CASING CASING(DAMPER) COVER PLUG GREASE CUP PACKING O-RING O-RING O-RING PUSH ROD SHIM SPRING SEAT PISTON STEEL BALL RO PLUG

Q’TY 1 1 2 4 4 4 4 4 2 4 4 4 4 12 3

Torque kgf·m(lbf·ft) No. 0.7 (5.1) 9.0 (65)

0.7 (5.1)

33 -II -4 -1

252 261 271 301 311 313 324 335 336 413 414 420 471 472 501

NAME PLUG O-RING SOCKET BOLT SPOOL SPRING SEAT WASHER SPRING SPRING SPRING CAM SHAFT BUSHING CAM STEEL BALL SET SCREW BELLOWS (BOOTS)

Q’TY 2 3 4 4 4 4 4 4 4 2 4 2 4 2 2

4.2 DISASSEMBLY AND ASSEMBLY

CENTERING HOLE IS ALLOWABLE (SMALLER THANø2mm)

(2) Precautions for disassembly and assembly

30˚

1) Disassemble and assemble the pilot valve paying attention to the rust protection fordust, dirt, etc. in order not to allow them to enter in.

8 -0.2 -0.3 (0.315" -0.008 -0.012 )

10 -0.3 -0.4 (0.394" -0.012 -0.016 )

(1) Special jig for disassembly and assembly Special jig 1(for removal of bushing)

2) Handle parts carefully not to damage

20 (0.79")

3) Write down the installing positions of respective part during disassembly, and assemble respective part to the position as they were before.

2 (0.08")

30 (1.18") Fig. 4-2 Jig 1

(3) Disassembly 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). : 6mm

19) For disassembly of the reduction unit valve assy first push spring seat (311) in and shift the spring seat crosswise making secondary pressure spring (324), remove it from spool (301) passing through the large hole. • Handle the assembled unit as a assy.

5) Contact pry bar (ø7 or less) to one end of cam shaft (413), and strike it slightly with a hammer. 6) Remove cam (420). 7) Remove socket bolt (271). : 6mm 8) Remove cover (201). 9) Remove the casing upper assy, and fix the assy with vise, again. 10) Draw push rod (214) out of plug (202). Fig. 4-3

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) Take out spring seat (218) from casing (102) with pincette. 15) Take out steel ball (225) using magnet. 16) Fix the lower casing assy with vise, and take out O-rings (211,213) from casing (101).

20) Separate spool (301), spring (324) for secondary pressure setting, shim (217) and washer. • Handle the assembled unit as a assy. And there may be unit on which washer is not installed. 21) Remove grease cup (203) from plug (202). 22) Remove O-ring (212) from plug (202).

17) Remove reduction unit valve assy 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 draw the bushing out.

33 -II -4 -2

4.3 ASSEMBLY

6) Place O-rings (211,213) in casing (101).

1) Clean all parts before assembly, and dry them by means of compressed air. Don’t use 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 flex and shifting the spring seat crosswise.

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). 10) Install piston (224). 11) Place O-ring (212) in plug (202). 12) Place packing (210) in plug (202). • Pay attention to the direction when placing the packing in. • Apply grease slightly before placing packing in.

Packing

4) Fix casing (101) with vise, and place spring (335) for return in casing (101). 5) Place the reduction unit subassy described in Articles 2) and 3) in casing (101). • Install them on the positions as they were before. • When placing the reduction unit subassy in, pay attention to the spool lower end so as not to bring into contact with the corner of the casing.

Pay attention to the corner of the casing

Fig. 4-5

13) Place grease cup (203) in plug (202). 14) Install push rod (214) on plug (202). 15) Place the push rod subassy which is sub-assembled by the procedures in Articles 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 assy which is assembled by the procedures in Articles 2) to 6) with vise, and install the upper cover assy which is assembled by the procedures in Articles 7 to 15) on it. 18) Install cover (201) on casing (102). 19) Tighten socket bolt (271) to the specified torque.

Fig. 4-4

20) Install cam (420) on cover (201). 21) Insert cam shaft (413) from the outside pressing cam (420).

33 -II -4 -3

22) Apply Loctite #241 or equivalent to the thread of socket bolt. 23) Tighten socket set 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 (402), fit the lower side in the groove of cover (201).

33 -II -4 -4

4.4 CAUSE OF FAILURES AND CORRECTIVE ACTION

Phenomenon Secondary pressure does not rise.

Causes 1) Insufficient primary pressure 2) Permanent set of spring (324) for setting of secondary pressure. 3) The gap between spool and casing is too large. 4) The control section is loosened.

Corrective action 1) Secure primary pressure. 2) Replace it with new one.

Secondary pressure is unstable.

1) Sliding part is not smooth. 2) Variation of pressure of tank line 3) Air contamination in piping

1) Repair unsmooth section. 2) Return oil to oil tank directly. 3) Bleed air by operating several times.

Secondary pressure is high.

1) Pressure of tank line is high. 2) Sliding part is not smooth.

1) Return oil to oil tank directly. 2) Repair unsmooth section.

Damping does not work.

1) Air is accumulated in piston chamber. 2) Sliding part is not smooth. 3) Permanent set of damping spring (336) 4) Gap between damping piston (224) and casing (damper) (102) is too large. 5) Malfunction of check valve

1) Bleed air by operating several times. 2) Repair unsmooth section. 3) Replace it with new one. 4) Replace it with complete remote control valve. 5) Disassemble and check on check valve section. 6) Replace damping piston.

Damping torque is heavy.

3) Replace it with complete remote control valve. 4) Replace parts of control section.

6) Orifice of damping piston (224) is too large. 1) Sliding part is not smooth. 1) Repair unsmooth section. 2) Orifice of damping piston (224)is clogged. 2) Repair or replace damping piston.

33 -II -4 -5

NOTES

5. SLEWING MOTOR 5.1 CONSTRUCTION 48 49 50 51 52

48-1

44 32 30 22 31 23 21 62 15 19 14 13 12 11 10 17 18

48-5 48-4 48-3

43 42 63 64

48-2 60

26 41 25

27 28

29 37

56 53

38 34 40 46 39 58 59 45 36 35 47 33

16 9

Fig. 5-1

Table. 5-1 No. 1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Q TY 1 1 1 1 1 1 1 2 2 2 2 2 2 1 1 3 3 3 3 1 1 1 1 1 1 1 1 1

No. 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 48-1 48-2 48-3

33 -II -5 -1

Q TY No. 1 48-4 1 48-5 49 1 50 1 51 1 52 3 53 1 54 1 55 9 56 1 57 1 58 1 59 1 60 2 61 1 62 1 63 1 64 1 65 1 66 1 67 2 68 2 69 5 70 1 71 1 72 1 1 1

NAME O-ring 1B P14 Spool Washer Spring O-ring 1B P18 Plug Relief valve assy Check valve Spring Plug O-ring 1B P14 Plug O-ring 1B P8 Plug O-ring 1B P11 Socket bolt M12X30 Name plate Rivet Thrust plate Sun gear Screw Planetary gear Needle bearing Inner race Thrust washer Holder

Q TY 1 1 1 1 1 1 2 2 2 2 2 2 2 1 1 2 1 2 1 1 4 4 4 4 4 1

Relief valve assy (No.53) Table. 5-2

7 9

Fig. 5-2

33 -II -5 -2

No. 53-1 53-2 53-3 53-4 53-5 53-6 53-7 53-8 13 53-9 53-10 53-11 53-12 53-13 53-14 53-15

NAME Body Poppet Seat Spring seat Spring Plug Set screw O-ring 1B P24 O-ring 1B P10 O-ring 1A P15 O-ring 1B P12 Back up ring Back up ring Piston Lock nut

Qâ&#x20AC;&#x2122;TY 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1

5.2 DISASSEMBLING PROCEDURE (1) Precautions before disassembling a) Remove mud, dust, etc. on the outer surface. b) Drain the hydraulic oil in piston motor case and the port circuit. c) Select clean work area, and pay attention to the parts in order not to adhere mud,dust, etc. d) Donâ&#x20AC;&#x2122;t disassemble the motor more than necessary. 5.3 DISASSEMBLY Disassemble the slewing motor by the following procedure.

1. Separate the motor and the reduction unit. Fix the motor assy with vise, and remove socket bolt (62).

2. Disassembling motor 2-1. Fix the motor assy with vise. Loosen socket bolt(46)and remove cover (40).

[Note] : Pay attention not to drop valve plate (43) when removing cover (40).

33 -II -5 -3

2-2. Remove valve plate (43) and pin (42). 43

[Note] : Valve plate (43) may be left on the motor side.

2-3. Take out ball bearing (41). Take out O-ring (45).

2-4. Disassemble check valve 2-4-1. Loosen and remove plug (56).

56 2-4-2. Remove check valve (54) and spring (55).

33 -II -5 -4

2-5 Removing relief valve(53) 2-5-1. Loosen plug (53-6) and remove relief valve assy (53). [Note] : • Don’t turn set bolt (53-7) to maintain the set pressure. •Don’t disassemble relief valve assy because it has effect on the function.

537 536

2-6. Remove valve plate (43), pin (44) and Oring (39). [Note] : Valve plate (43) may be left on the cover side.

2-7. Take out spring (38) and spring seat (37), and remove parking brake piston (34) by use of the parking brake release port of casing (20). [Note] : The piston may pop out due to the air pressure, so be careful not to injure it. So, set the air pressure to low position, and adjust the pressure checking the removing condition of the piston. And, the parking brake timer should be removed after removing the brake piston. (If the parking brake timer is removed before removing the brake piston, it may not be removed.)

33 -II -5 -5

2-8. Remove cylinder block, etc. Cylinder block (24) Collar (25) Spring (26) Washer (27) Snap ring (28) Pin (29) Retainer holder (30) Retainer plate (31) Piston Assy (32) Disk (33)

2-9. Remove retainer plate (31) and piston assy (32).

2-10. Remove pin (29) and retainer holder (30).

33 -II -5 -6

2-11. Remove snap ring (28) keeping washer (27) pressed.

2-12. Remove collar (25),spring (26)and washer (27).

2-13. Remove thrust plate (23).

2-14. Remove the shaft tapping the top end of shaft (22) with a hammer.

33 -II -5 -7

2-15. Remove ball bearing (21) and shaft (22). [Note] : Donâ&#x20AC;&#x2122; t use the removed ball bearing.

52 2-16. Disassembling timer valve (48) 2-16-1. Remove plug (52).

2-16-2. Remove spring (50), washer (49) and spool (48-5).

2-16-3. Remove sleeve (48-1).

481 484 483 485 482

33 -II -5 -8

3. Disassembling reduction unit 3-1. Remove O-ring(19), drive gear (16), thrust plate (15), planetary gear (14), needle bearing (13), inner race (12), thrust washer (11), and holder (10).

3-2. Remove sun gear (66).

3-3. Remove holder (72) and other related parts.

3-4. Fix holder (72) to a vise, and loosen screw (67) to remove thrust plate (65). [Note] : Screw is difficult to remove besause lock-tight was applied to it at assembling. Warming up screw with a drier is effective for easy removal.

3-5. Remove planetary gear (68), needle bearing (69) and inner race (70). [Note] : For taper roller bearings (5,7) and collar (3),replace the body assy (Symbol 1 to 9).

3-6. Remove collar (9) and shim (8).

3-7. Remove pinion shaft (2). [Note] : Be careful not to drop the shaft when removing. When it is difficult to draw it out, remove it tapping by hammer.

33 -II -5 -9

3-8. Separate the inner race from taper roller bearing (7).

3-9. Break oil seal (6) and take it out. [Note] : Donâ&#x20AC;&#x2122;t use the removed oil seal. When removing, pay attention not to damage the outer race of taper roller bearing (5) (7).

17 7

3-10. Remove taper roller bearing (7), outer race and plugâ&#x20AC;&#x2122;(17). The disassembly is now completed.

33 -II -5 -10

5.4 ASSEMBLING PROCEDURE (1) Precautions before assembly a) Clean all parts with cleaning solvent, and blow air. b) Handle the clean parts paying attention not to adhere dust and to be free from dent, flaw, etc. c) Replace seals, bearing and pin with new ones. d) Tighten the respective fastener to the specified torgue. e) Apply grease to the oil seal and O-ring before fitting. (Especially oil seal lip section) f) There are many kinds of small item, so be careful not to miss them. (Especially drop in the hole.)

5.5 ASSEMBLY Assemble the slewing motor by the following procedure. 1. Assembling motor 1-1. Install relief valve assy (53). T = 16 ± 1kgf·m (116 lbf·ft)

1-2. Install check valve (54) and spring (55).

1-3. Install plug (56). T = 4.0 ± 0.2kgf·m (29 lbf·ft)

33 -II -5 -11

1-4. Fit O-rings (48-2,48-3,48-4) on sleeve (48-1).

481

484 483

482

51 1-5. Install sleeve (48-1) on case (20), and place spool (48-5), washer (49) and spring (50) in the hole of the sleeve.

481-6. Install plug (52) with O-ring (51).

T = 8.5kgfÂˇm (61 lbfÂˇft) [Note] :Fit O-ring (51) paying attention not to damage when placing in.

485

33 -II -5 -12

1-7. Install collar (25), spring (26) and washer (27) on cylinder block.

[Note] : Pay attention to the direction of installation.

Taper surface

Cylinder block 27

1-8. Place snap ring(28) in keeping washer (27) pressed.

1-9. Apply grease to pin (29) and install it on cylinder block (24).

1-10. Install retainer holder (30)

33 -II -5 -13

1-11. Set piston assy (32) on retainer plate (31), and install it on cylinder block (24).

[Note] : Apply enough hydraulic oil on the sliding section before installation.

1-12. Press fit ball bearing (21) on shaft (22). [Note] : Install ball bearing (21) directing the snap ring as shown in the figure.

1-13. Press fit shaft (22) and ball bearing (21) on case (20).

1-14. Apply grease on the back side of thrust plate (23) before installation. [Note] : Pay attention to the direction of the thrust plate.

Direct the taper side toward the motor case side.

33 -II -5 -14

1-15. Install cylinder block (24), etc. [Note] : Pay attention not to drop pin (29) when installing. Install disk (33).

34 1-16. Apply grease to O-rings (35) (36) and install it on brake piston (34). 1-17. Place brake piston (34) in case (20) paying attention to the hole position of pin (44).

1-18. Fit spring seat (37) and spring (38) paying attention to the direction.

37 Pay attention to the direction.

1-19. Apply grease to O-ring (39) and place it in casing (20). Check that pin (44) can be placed in the hole of casing (20) and brake piston (34). When impossible to place it in, remove brake piston (34) and match the position before installation.

33 -II -5 -15

1-20. Apply grease to O-ring (45) and pin (44) and install them on cover (40). Press fit ball bearing(41).

1-21. Install pin (42), and then install valve plate (43). Apply grease to the back face to prevent dropping.

1-22. Install cover (40), etc. on casing (20) paying attention to the position of pin (44). [Note] : Be careful not to drop pin (44) and valve plate (43).

1-23. Tighten socket bolt (46) temporarily, and then tighten it to the specified torque with torque wrench. T = 13.1kgfÂˇm (95 lbfÂˇft)

33 -II -5 -16

2. Assembling reduction unit 2-1. Press fit oil seal(6).

4mm(0.16in)

[Note] : Apply grease to the oil seal fitting section of housing (1) and around the oil seal before press fitting.

Dimension after oil seal is press-fitted

17 7

2-2. Press fit taper roller bearing (7) and install plug (17).

2-3. Seal grease in taper roller bearing inner race (5) installed on pinion shaft (2). Brand name of grease: SHELL Alvania EP2 Sealing qâ&#x20AC;&#x2122;ty: 17 to 20cm3 (Approx.14 to 17g)

2-4. Install thrust washer (71), inner race (70), needle bearing (69), planetary gear (68),thrust plate (65) and screw (67) on holder (72). [Note] : Tighten up screw (67) after applying lock-tight. Tightening torque: 0.4 kgf.m (2.9 lbf.ft)

33 -II -5 -17

2-5. Install collar (9) and shim (8). [Note] : Reuse shim (8) removed when disassembling.

2-6. Install holder (72), etc.

2-7. Install sun gear (66). Install holder (10).

2-8. Install thrust washer (11), inner race (12), needle bearing (13), planetary gear (14),thrust plate (15) and drive gear (16) on holder (10).

2-9. Apply grease to O-ring (19), and place it in housing (1).

33 -II -5 -18

[Note] : Selection for thrust plate (15). When any consisting parts of reduction unit were changed, select and install thrust plate corresponding to the measured valve “E” referring to the below table.

E dimension (measured value)

less than 6.6

6.6 - 7.2

more than 7.2

Part No. of Thrust plate (15) Plate thickness : mm

80841-12020 3.2

80841-23019 2.8

80841-23018 2.3

3. Assembling motor assy 3-1. Install the reduction unit on the motor assy, tighten socket bolt (62) temporarily, and tighten it to the specified torque. T = 13.1kgf.m (95 lbf·ft)

The assembly is now completed.

Match the protruded section with port.

33 -II -5 -19

5.6 MAINTENANCE STANDARD Replace all parts referring to the list shown below. (1) Motor

Maintenance standard

Part name Piston assy (32)

1. Severe flaw and roughness of each sliding surface 2. Too large gap from the assy to cylinder block bore Upper limit of diameter clearance : 0.04mm (0.0016") 3. Large looseness of shoe ball Max. looseness(moving range) : 0.4mm (0.016")

Thrust plate (23) Retainer holder (30) Retainer plate (31) Valve plate (43) Brake piston (32)

1. Sever flaw and roughness of each sliding surface

Cylinder block (24)

1. Severe flaw and roughness of each sliding surface 2. Severe wear or breakage of the mating surface

Disk (33)

1. Severe flaw or peeling of each sliding surface (Friction plate) 2. Severe wear and peeling of mating surface

Ball bearing (21,41)

1. Flaking and peeling of rolling contact surface 2. Indentation of rolling contact surface 3. Abnormality of bearing rotation(Noise, unsmooth rotation)

Spring (26)

1. Sever breakage and deformation

O-ring (35,36,39,45,57,59,61)

1. Flaw causing oil leakage, flaw causing insufficient sealing, and permanent set

(2) Reduction unit

Maintenance standard

Part name Pinion shaft (2)

1. Severe flaw, wear and flaking of gear tooth surface

Plate (4)

1. Severe flaw and wear

Taper roller bearing (5,7)

1. Severe flaw, indentation and flaking of roller and race section 2. Unsmooth rotation with noise * Replace the body assy when required to replace the taper roller bearing.

Oil seal (6)

1. Severe flaw, deformation and wear of lip section 2. Hardening of lip section

Housing (1) Holder (10) Drive gear (16) Planetary gear (14)

1. Severe flaw, wear and flaking of gear tooth surface * Replace the body assy when it is necessary to replace the housing.

Inner race (12)

1. Severe flaw, wear and flaking of needle bearing rolling surface

Needle bearing (13)

1. Severe flaw, wear and flaking of needle bearing surface

Planetary gear (14)

1. Severe flaw, wear and flaking of gear tooth surface 2. Severe flaw, wear and flaking of rolling surface in contact with needle bearing

Thrust plate (15,23)

1. Severe flaw, wear and seizure of sliding surface

33 -II -5 -20

(3) Valve

Part name

Maintenance standard

Piston(53-14) Casing(20)

1. Severe flaw of sliding section and roughness of sliding surface 2. Too large gap between piston and case hole Upper limit of diameter clearance: 0.04mm (0.0016")

Spring(50) Spring(55)

1. Severe breakage and deformation

Plug(56, 53-6) 1. Flaw causing oil leakage, flaw causing insufficient sealing and permanent Check valve(54) deformation. O-ring(53-8 to 53-11)(57) Back up ring(53-12, 53-13) O-ring(48-2 to 48-4)(51)

(4) Others

Part name Other plug and O-ring

Maintenance standard 1. Flaw causing oil leakage, flaw causing insufficient sealing and permanent deformation.

33 -II -5 -21

NOTES

6. SWIVEL JOINT 6.1 CONSTRUCTION

Tale. 6-1 Construction

No. 1 2 3 4 5 6 7 8

NAME SHAFT BODY FLANGE THRUST RING PIN SLIPPER SEAL O-RING O-RING

Q’TY 1 1 1 1 1 1 1 1

No. 9 10 11 12 13 14 15

33 -II -6-1

NAME DUST SEAL DUST SEAL SNAP RING BOLT PLUG SPRING WASHER BACK-UP RING

Q’TY 1 1 1 2 1 4 4

6.2 DISASSEMBLY AND ASSEMBLY 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 matter, dust, etc.

6.2.2 Disassembly (1) Loosen bolt and remove flange (3). Fix the hud with vise. : 17mm or : 17mm

(2) Take out O-ring (8), snap ring (11) and thrust ring (4).

8 11 (3) Remove shaft (1) from the body (2). • Apply the knock pin to the end face of the shaft, and strike it with hammer. • Choose the knock pin in copper, plastic, etc.

Knock pin

33 -II -6-2

(4) Remove dust seal (10) from the shaft.

(5) Remove seal, etc. from the inside of the body. â&#x20AC;˘ Be sure of the position of seal, etc. referring to the construction drawing. â&#x20AC;˘ Take out O-ring with the pointed thing like gimlet.

33 -II -6-3

6.2.3 Assembling (1) Place seals in the inside of the body. • Check the seal position referring to the construction drawing. • Pay attension to O-ing that they are free from twisting. • Don’t deform or bend the slipper seal localy.

(2) Install dust seal (10) on shaft (1). • Apply enough grease to the lip secton of the dust seal.

(3) Install shaft (1) on body (2). • Apply hydraulic oil or grease around the shaft lightly. • Strike the shaft with plastic hammer paying attention not to damage seal.

1 2

33 -II -6-4

(4) Fit thrust ring (4) and snap ring (11). • Fit the snap ring in the groove accurately.

4 11

(5) Fit O-ring (8) and install flange (3).

(6) Install spring washer (14) and bolt (12). : 17mm or : 17mm • Tightening torque : 5.3~5.8kgf.m (38~42 lbf.ft) • Put pipe through the locking pin of the shaft, and check that the shaft rotates smoothly at torque approx.8 to 11kgf.m (58~80 lbf.ft)

33 -II -6-5

6.3 MAINTENANCE STANDARDS 6.3.1 Check Procedures and Remedy

Check Interval 2000hr

Place Checked

Check Procedure

Seals which prevent external leakage of hydraulic oil.

Check if oil is leaking out.

Remedy Replace the O-rings if there is leakage.

4000hrs ---------All seal parts. Replace all the seal parts. Disassemble and All sliding portion. Check for abnormal wear, defects, Recondition in accordance with check whether corrosion, etc. due to seizing, the service limit. there is leakage foreign material being caught, etc. or not When disassembling All parts. due to trouble

Check for abnormal wear, defects, Recondition in accordance with corrosion, etc. due to seizing, the service limit. foreign material being caught, etc. Regarding the seal kit, replace

6.3.2 Parts Service Limit (1) Body, Shaft

Portion

Judgment Criteria

Remedy

Seal Parts and Sliding Portion

Wearing of surface treated with ultrasonic tempering, Replace and coming off of surface due to seizing, foreign material getting caught, etc.

Body and shaft sliding portion other than seals.

Abnormal wear or defects by 0.1mm (0.004 in) deep or deeper due to seizing or foreign material getting caught, etc.

Replace

Defects less than 0.1mm (0.004 in) deep.

Repair with an oil stone.

Portions which slide against the thrust ring.

Wearing by 0.5mm (0.020 in )or more, or abnormal wear. Replace. Wear less than 0.5mm (0.020 in).

Repair so that is smooth.

Defects due to seizing or foreign material getting caught, etc. which are within the wear limit of 0.5mm (0.020 in) and within repairable level.

Repair so that is smooth.

(2) Flange and Thrust Ring

Portion Portions of flange which slide against the shaft end. Thrust Ring

Judgment Criteria

Remedy

Wearing by 0.5mm (0.020 in) or more, or abnormal wear. Replace Wear less than 0.5mm (0.020in).

Repair so that is smooth.

Defects due to seizing or foreign material catching, etc, which are within the wear limit of 0.5mm (0.020 in) and to within repairable level.

Repair so that is smooth.

33 -II -6-6

(3) Slipper Seal

Judgment Criteria LOOSEN SEAL

1.5mm or more

0.5mm or more

Remedy

Loosen seal from grooves is excessive

Replace

Slipper seal width is 1.5mm (0.059 in) or more smaller than the width of the seal groove.

Replace

Unequal wear of 0.5mm (0.020 in) or more.

Replace

(4) O-ring

Judgment Criteria LOOSEN O-RING

Remedy

Loosen O-ring from seal grooves is excessive.

Replace

Unequal wear of 0.5mm (0.020 in) or more.

Replace

0.5mm or more

(5) Backup Ring

Remedy

Judgment Criteria Width 4mm or less

Thickness of 1.5mm (0.059 in) or less Width of 4mm (0.16 in) or less.

Thickness 1.5mm or more

33 -II -6-7

Replace

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 (2) and the shaft (1) side port. (2) Connect a pressure gauge to the body (4) side. (3) Increase the pressure gradually to 230 kgf/cm2 (3270 psi) adjusting the relief valve (6), then perform 1 minute leak test. â&#x20AC;˘ Open the neighboring ports on both sides and check visually for leakage from the ports. â&#x20AC;˘ Check for external leakage, etc. by a color check.

33 -II -6-8

6.4 TROUBLESHOOTING

Troubles

Possible Causes

Remedy

External Oil Leakage

O-ring is defective.

Replace all the seal parts.

Internal Oil Leakage

Thrust ring is defective. Excessive wear on sliding surfaces.

Replace all the seal parts. Replace the assembly.

Shaft Sticks

Shaft and body are stuck together.

Carry out grinding and honing. If excessive looseness cause oil leakage, replace the assembly.

Flange Looseness

Capscrew tightening isinsufficient.

Retighten with the specified torque.

33 -II -6-9

NOTES

Book Code No.

PW34 02E ➁

NEW HOLLAND EH35 Model Cross-reference: SK35SR-2 is NEW HOLLAND Model EH35

TRAVEL SYSTEM TABLE OF CONTENTS PART I - REMOVING AND INSTALLING ASSY 1. NAME OF TRAVEL SYSTEM PARTS .................. I-1-1

2. CRAWLER

7.1 Removal and installation procedures .......... I-1-23

2.1 Removal and installation procedures (Rubber) ......I-1-1 2.2 Removal and installation procedures (Steel) ........ I-1-3

7.2 Maintenance standards ............................... I-1-23 8. TRAVEL MOTOR

2.3 Construction .................................................. I-1-6

8.1 Removal and installation procedures .......... I-1-24

2.4 Maintenance standards ................................. I-1-6

8.2 Maintenance standards ............................... I-1-25

UPPER ROLLER

SLEWING BEARING

3.1 Removal and installation procedures ............ I-1-8

9.1 Removal and installation procedures .......... I-1-26

3.2 Construction .................................................. I-1-9

9.2 Construction ................................................ I-1-27

3.3 Disassembly and Assembly........................... I-1-9

9.3 Disassembly and Assembly......................... I-1-27

3.4 Maintenance standards ............................... I-1-10

9.4 Maintenance standards ............................... I-1-28

LOWER ROLLER

PART II - DISASSEMBLING / ASSEMBLING COMPONENTS

4.1 Removal and installation procedures .......... I-1-11 4.2 Construction ................................................ I-1-12 4.3 Disassembly and Assembly......................... I-1-12 4.4 Maintenance standards ............................... I-1-14 5.

SPROCKET

FRONT IDLER

1. TRAVEL MOTOR 1.1 Summary ...................................................... II-1-1 1.2 Tools and Jigs ............................................... II-1-4 1.3 Disassembly ................................................. II-1-8 1.4 Assembly .................................................... II-1-29

5.1 Removal and installation procedures .......... I-1-15

1.5 Maintenance standards .............................. II-1-44

5.2 Construction ................................................ I-1-16 5.3 Disassembly and Assembly......................... I-1-16 5.4 Maintenance standards ............................... I-1-18 6.

IDLER ADJUSTER 6.1 Removal and installation procedures .......... I-1-19 6.2 Construction ................................................ I-1-19 6.3 Disassembly and Assembly......................... I-1-20 6.4 Maintenance standards ............................... I-1-22

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PW34

PREFACE 1.

This manual covers all the procedures required for the dis/re-assembling of the machine in compilation by items.

This manual consists of Part I ; REMOVING AND INSTALLING ASSY, and Part II ; DISASSEMBLING AND ASSEMBLING COMPONENTS.

Revision First edition First revision Second revision

Date of Issue January, 2001 November, 2002 December, 2002

Remarks S5PW3402E A S5PW3402E ➀ A S5PW3402E ➁ A

Any use of editorial or pictorial content is strictly prohibited without express written permission from New Holland Construction, LLC. Carol Stream, IL 60188 U.S.A. Copyright © 2003 New Holland Construction, LLC. All Rights Reserved.

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Part I : REMOVING AND INSTALLING ASSY 1. NAME OF TRAVEL SYSTEM PARTS

5. FRONT IDLER

9. SLEWING BEARING

6. IDLER ADJUSTER

7. SPROCKET

4. LOWER ROLLER 3. UPPER ROLLER

2. CRAWLER 8. TRAVEL MOTOR

Fig. 1-1 Name and location of parts

2. CRAWLER 2.1 REMOVAL AND INSTALLATION PROCEDURES 2.1.1 Removing Rubber Crawler (1) Lift the one side of machine with attachment, as shown in Fig. 2-1, and place support under lower frame to support machine. (2) Loosen grease nipple for crawler adjuster, discharging grease in cylinder, and release tension of crawler. : 19mm

90°~110° SUPPORT

Fig. 2-1 Crawler removing posture

• When loosening the grease nipple of the adjuster, do not loosen it more than one turn. • 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.

GREASE NIPPLE

Fig. 2-2 Loosening crawler tension

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(3) Put steel pipes in the rubber crawler, turn the sprocket backward sloly and when the rubber crawler has floated off the idler stop the rotating.

ROTATING DIRECTION

(4) Slide the rubber crawler sideways, and remove it.

2.1.2 Installing rubber crawler Installation work is performed in the reverse order of removal. (1) Engage the rubber crawler with the sprocket and mount it on the idler.

STEEL PIPE

Fig. 2-3 Removing rubber crawler

ROTATING DIRECTION

(2) Put steel pipes in the rubber crawler, turn the sprocket slowly and then 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. STEEL PIPE

(4) Confirm that the rubber crawler is engaged securely with the sprocket, idler and lower roller.

Fig. 2-4 Installing rubber crawler

(5) Tighten the grease nipple for the crawler adjuster, and adjust tension by feeding grease. : 19mm

T= 6 ± 1 kgf·m (43 ± 7 lbf·ft)

Rubber shoe Appropriate tension A = SK30SR-2 : 60 ~ 70 mm (2.4 ~ 2.8 in)

GREASE GUN

SK35SR-2 : 60 ~ 70 mm (2.4 ~ 2.8 in)

Fig. 2-5 Feeding grease Steel shoe Appropriate tension A =

LOWER ROLLER

SK30SR-2 : 118 ~ 128 mm (4.6 ~ 5.0 in) SK35SR-2 : 118 ~ 128 mm (4.6 ~ 5.0 in)

CRAWLER FRAME

Fig. 2-6 Rubber crawler tension

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2.2 REMOVAL AND INSTALLATION PROCEDURES (STEEL : OPT) (1) Removal 1) The crawler track link includes a set of master pin(6), which should be placed at the position front of the front idler.

Lock pin

6 Fig. 2-7 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 to the master pin.

Fig. 2-8 Removing of master pin 3) Loosen grease nipple for track spring adjustment, discharge grease in the cylinder and slack the tension of the shoe. :19mm • When loosening grease nipple for adjustment, don’t turn it more than one turn to loosen. • When grease is remained, move the machine forward and rearward slightly. • Be careful that the grease nipple may be

Grease nipple

Fig. 2-9 Loosening grease nipple for adiustment

popped out.

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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. 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.

6 8 Fig. 2-10 Removing lock pin

Be careful not to be injured by scattering materials .when large hammer is used.

Donâ&#x20AC;&#x2122;t be close to the machine because the end of the crawler may drop just before extending the track link assy to the ground while rotating the sprocket. Put square timber 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. 2-11 Removing master pin SK30SR-2

177 kg (390

SK35SR-2

380 kg (840

lb) lb) (2) Installation 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.

Square timber

Fig. 2-12 Removing crawler

To front idler

Fig. 2-13 Direction of crawler

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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 bar.

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. 2-14 Installing crawler

Fig. 2-15 Alignment of pin holes 4) Align master link holes on the both ends of the crawler link with the link holes inserting bar, apply master pin drawing out jig (a) used when removed and press fit master pin by hammer.

6 a

When large hammer is used, be careful not to be injured by scattering materials. â&#x20AC;˘ Apply molybdenum grease to the master pin before press fitting. 5) After press fitting master pin (6), insert lock pin (8) and bend the top end in advance.

Fig. 2-16 Press fitting master pin

6) After completion of installation, adjust the tension of crawler by the same procedure of the rubber crawler. :19mm

GREES NIPPLE Fig. 2-17 Extension of track link (Example for rubber crawler)

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2.3 CONSTRUCTION (1) Construction of rubber crawler

No.

NAME

Q’TY per machine

RUBBER CRAWLER ASSY

• This standard machine provides rubber crawler. (2) Construction of Steel crawler No.

Fig. 2-18 Rubber crawler assy

(Q’TY for one side) SK30SR-2 SK35SR-2

NAME

2 4

Shoe assy • Track rink assy

• Track rink (LH)

• Track rink (RH)

• • Master rink (LH)

• • Master rink (RH)

• • Track pin

• • Master pin

• • Bushing

• • Pin

• • Shoe

5 7 6

1 3 8

9 Fig. 2-19 Construction of steel crawler

2.4 MAINTENANCE STANDARDS (1) Rubber crawler

(Example of pad shoe) CORE

Place M mark or at machine center B

RUBBER COVER

mark

L : Distance between the bottom of frame and top of rubber crawler

CENTER LINE OF STEEL CORD SECTION B-B

Fig. 2-20 Rubber crawler shoe Table. 2-1 ITEM Slack of rubber crawler L Cracks and notch on rubber crawler Breakage of steel cords Contact surface of rubber crawler and lower roller

STANDARD VALUE 60 ~ 70 (2.4 ~ 2.8) None None None

REPAIRABLE LEVEL --------

Unit : mm (in) SERVICEABILITY LIMIT REMEDY --------

Where the depth of them does Where the depth of them not reach to the steel cords. None

reachs to the steel cords. Exist

Where 10 percent of cores Where half of cores are are visible from outside.

visible from outside.

Adjustment Replace Replace Replace

Height (H)

77 (3.0)

--------

63(2.5)

Replace

Lug projection (h)

15 (0.6)

--------

0(0)

Replace

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(2) Steel crawler (Track link) Master pin

Track pin

Master link E

F G

D B

Bushing

4 or more 40 TYP74 5 or more 60

Fig. 2-21

Table. 2-2 Item Symbol A Link pitch B Bushing O.D. C Link height

Interference of bushing and link

Reference value 101.6 (4.0) 0 ø32.2 -0.04 (ø1.27) 61 (2.4) Basic dimension 0 Shaft ø32.2 -0.04

Repairable level Service limit 105 (4.13) 107(4.21) ø30(ø1.18) ø28 (ø1.10) 57(2.24) 56 (2.20) Fit Fit Interference Interference (ø1.27) 0.11 ~ 0.20 0 (0.0043~0.0079)

Interference Interference +0.06 0 Shaft ø19.2 0 (ø1.27) 0.15 ~ 0.26 (0.0059 ~ 0.010)

Interference of track pin and link

Clearance Fitting of master pin and (ø1.27) 0.02 ~ 0.12 Shaft ø18.93 +0.05 0 link (0.0008~0.0047)

Clearance gap of link

Welding of link and shoe

To be free from weld crack, blow hole, etc.

Slack of iron crawler

118 ~128 mm (4.6 ~ 5.0)

0.9 (one side) (0.035)

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4(both side) 6(both side) (0.157) (0.236)

Unit: mm (in) Remedy Parts over the critical value in use should be replaced with link assy.

Replace

Replace link.

Replace Repair weld.˚ Adjust the tension.

3. UPPER ROLLER 3.1 REMOVAL AND INSTALLATION PROCEDURES 3.1.1 Removal (1) Loosen the grease nipple for crawler adjusting within one turn to discharge grease and release tension on the crawler. : 19mm GREES NIPPLE • Turn the grease nipple slowly paying attention Fig. 3-1 Releasing crawler tension

not to turn more than one turn, and be careful for the spouting out grease. (2) Push up the crawler with a hydraulic jack, and place suitable square lumber 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.

SQUARE LUMBER

: 17 mm Weight of upper roller assy : 3 kg (6.6 lb)

Fig. 3-2 Supporting with wooden bloks 3.1.2 Installation • Beforeinstalling the upper roller, 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. Gaar oil SEA #90 Oil: APIGL ----- 4 grade Volume : 45 cc (2.7 cu•in)

Fasten the nut on to the idler side.

UPPER ROLLER Fig. 3-3 Removing / Installing upper roller

1) Insert the shaft of the upper roller assy into the lower frame. 2) Coat mounting capscrews with Locktite #262 and tighten it to the torque. : 17 mm Tightening torque : 6.7 kgf•m (48 lbf•ft) • Install it so the nut is located on the idler side. • At installation, support the crawler with square wooden blocks the same way as it was dismantled so it does not disturb the work.

3) After installing upper roller, tighten grease nipple for crawler adjuster, grease it, and adjust crawler tension.

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: 19 mm Tightening torque : 6 kgf•m (43 lbf•ft)

3.2 CONSTRUCTION No.

NAME

Q’TY No.

NAME

Q’TY

ROLLER

BEARING

SHAFT

O-RING

SEAL COVER

SNAP RING

COVER

PLUG

SEAL

3.3 DISASSEMBLY AND ASSEMBLY The seal cover (3) and cover (4) of both sides of upper roller are press-fitted into the roller (1). Therefore, this portion is usually not disassembled and assembled. If it is necessary, do as follows :

Fig. 3-4 Construction of upper roller

3.3.1 Disassembling 1) Remove plug (9), and drain out oil. : 5mm 2) 3) 4) 5)

Remove seal cover (3) by means of drilling holes on or cutting it, then remove seal (5). Remove snap ring (8). Remove cover (4) utilizing threaded hole (PT 1/8) on it or other means. Place roller (1) with its end face on to the support base, and set the press-in jig. Pull out shaft (2) together with bearings (6) by means of a press machine or hammering. If removing bearings (6) from shaft (2) is required, remove them by means of using a gear puller or other means.

3.3.2 Assembling 1) Apply molybdenum grease to shaft (2), then install two bearings (6) on it. 2) Place roller (1) on to a plane base, applying a pad to shaft (2) end, press it together with bearings (6) into roller (1) with a press machine or hammering. 3) Attach snap ring(8). 4) Applying grease to new O-ring (7), attach it to cover (4), then press it in roller (1). 5) Install new seal (5). 6) Install new seal cover (3). 7) Fill 45 cc (2.7 cu•in) of gear oil SAE #90, API GL4 in the roller (1) through plug bore on cover (4). 8) Tighten plug (9).

Press-in jig

Support base

Fig. 3-5 Pressing out shaft

Pad

Fig. 3-6 Installing shaft

: 5mm

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3.4 MAINTENANCE STANDARDS

Fig. 3-7 Upper roller

Unit : mm (in) STANDARD VALUE REPAIRABLE LEVEL

ITEM

Code A

Tread dia.

Tread width

ø75 (2.95)

ø71 (2.80)

SERVICE LIMIT

REMEDY

ø69 (2.72) Replace

Bearing

Oil Roller rotation

Inspection item

98 (3.86) •Clean the bearing throughly and check that it turns smoothly. •Inspect the inner race, outer race and balls to see that they do not show peeling, galling, dent, rust and discoloration. •Check that tha mating surface of the bore and the outside of the bearing shows rotated mark. Gear oil SAE #90 API GL ----- 4Grade, about 45cc (2.7 cu·in) Roller rotates smoothly by hand

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Replace Those that show any irregularity.

Replenish Reassembly

4. LOWER ROLLER LOWER ROLLER ASSY (1)

4.1 REMOVAL AND INSTALLATION PROCEDURES Q’ty on one side SK30SR-2 : 4 pcs. SK35SR-2 : 4 pcs.

CAPSCREW (2)

4.1.1 Removing (1) Slightly loosen capscrews (2) fastening lower roller assy (1) to the lower frame. : 22mm (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. : 19mm

Fig. 4-1 Lower roller assy

(3) Lift the lower frame good enough to remove the lower roller, using the attachment. (4) After lifting the lower frame to a proper height, place square lumber under the lower frame to stabilize the machine. SUPPORT

(5) Remove the capscrews (2) fastening the lower roller, and remove the lower roller assy. : 22mm Weight of lower roller assy : 8 kgf (18 lb)

Fig. 4-2 Crawler removing posture

4.1.2 Installing (1) Installing position of lower crawler distance from collar end and center of attaching capscrew is as follows. Rubber : 23.5 mm (0.93 in) Steel : 31.5 mm (1.24 in)

23.5 (0.93")

FRAME

COLLAR

(2) Coat the mounting capscrews (2) with Loctite #262 in advance.

Rubber crawler

(3) Place the roller assy between the crawler and lower frame. Fasten the capscrews (2) temporarily. : 22mm

31.5

(4) Lower the machine in full contact with the ground and tighten the capscrews (2) as specified. : 22mm T = 18.5 kgf·m (134 lbf·ft) (5) Tighten the grease nipple of the crawler adjuster. Lift the machine, and adjust the crawler tension by feeding grease. : 19mm T = 6 kgf·m (43 lbf·ft)

(1.24")

FRAME

COLLAR

Steel crawler Fig. 4-3 Installing position of lower roller (collar)

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4.2 CONSTRUCTION No. 1 2 3 4 5 6 7 8 9 10

NAME Roller Collar Shaft Bearing Seal Seal Snap ring Snap ring Pin Plug : PT 1/8

Q'TY 1 2 1 2 1 1 1 2 1 1

(Note) Seals (5) and (6) are indentical.

2 8

Fig. 4-4 Lower roller construction

4.3 DISASSEMBLY AND ASSEMBLY 4.3.1 Disassembling 1) Loosen the plug (10) to drain oil. 2) 3) 4) 5)

2 8

: 5 mm Remove the snap ring (8). Remove collar (2) and pin(9). Remove the seals (5) and (6). Remove the snap ring (7).

Fig. 4-5 Removing collar and seal

6) Put the lower roller on the supporting stand, and push out the shaft (3) together with the bearings (4). â&#x20AC;˘ Except the case that replacement of the bearing (4) is necessary, do not remove the bearings from the shaft (3).

METAL BLOCK

STAND

Fig. 4-6 Removing shaft / bearing

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4.3.2 Assembling (1) Apply molybdenum grease to the shaft (3), and install the bearings (4).

METAL BLOCK

3 1

• In case of re-use of the bearing, confirm its smooth rotation, and no defect and rust on them.

(2) Apply molybdenum grease to the lower roller (1), and press the shaft (3) together with the bearings into the place.

STAND

(3)Install the snap ring (7).

Fig. 4-7 Installing shaft / bearing

(4)For the seal (5), first apply grease into groove on the lip portion of the seal body (5a). Then push the seal body (5a) and sleeve (5b) into the place evenly with the specialized pushing jig paying attention not to give any distortion on the lip.

SEAL PUSHING JIG 7

• Replace the seal to new one at reassembly. • When the seal is not installed properly due to one-sided pressing etc, replace it to new one.

5b 5 5a

(5) With the same procedure of the above, install the seal (6) of the opposite side. Fig. 4-8 Installing seal (6) Install pin (9) and collar (2) (7) Iustall the snap ring (8) (8) Fill in 70 cc (4.3 cu·in) of the gear oil SAE #90 through the bore of plug (10) on the roller (1).

(9) Tighten up the plug (10). : 5 mm • After assembling the lower roller, confirm its smooth rotation with hands and no leakages on it. 10

Fig. 4-9 Assembling lower roller

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2 8

4.4 MAINTENANCE STANDARDS

Fig. 4-10 Lower Roller Unit : mm (in) Code

ITEM

Flange O.D.

ø142 (5.59)

Tread O.D.

ø93 (3.66)

Flange width

29.5 (1.16) Basic dimension

Fitting roller / bearing

— —

Oil Roller rotation

ø30 (1.18)

ø72 (2.83)

Bore Shaft Bore Shaft

Fitting shaft / bearing

Tolerance

Fitting

ø87 (3.43)

ø85 (3.35)

Fitting

+0.018 (0.00070) Interference 0.002 Interference +0.002 (0.00008) (0.00008) 0.002 0(0) 0.028 (0.00008) -0.010 (0.00039) (0.0011) Clearance 0 (0) Clearance 0.004 -0.013 (0.00051) (0.00016) 0.004 -0.009 (0.00035) Interference (0.00016) 0.039 -0.039 (0.0015) (0.0015)

REMEDY

Welding repair or replacement

Replace of shaft or bearing

REPAIRABLE SERVICE LEVEL LIMIT

STANDARD VALUE

Gear oil SAE #90, 70cc (0.43 cu·in) Rollers rotate smoothly by hand

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Replace of roller or bearing Replenish Reassembly

5. FRONT IDLER 5.1 REMOVAL AND INSTALLATION PROCEDURES 5.1.1 Removing (1) Remove the crawler assy. (2) Remove idler together with idler adjuster assy, rolling it, using a pry-bar or equivalent. (3) Loosen capscrews (c), and separate idler assy (a) from idler adjuster assy (b). : 17mm

Fig. 5-1 Removing idler

Weight of idler assy : Approx. 27 kgf (60 lb) Weight of idler adjuster assy : 16 kgf (35 lb) • The separated idler assy (a) is easy to fall down. Lay it down so it does not fall down on your

feet, utilizing square lumber. 5.1.2 Installing (1) Install idler assy (a) to the idler adjuster assy (b) by means of capscrews (c) in the reverse order of removing the idler assy. Coat the threaded part of capscrews (c) with Loctite #262 beforehand.

Fig. 5-2 Disassembling idler assy

: 17mm T : 6.7 kgf·m (48 lbf·ft)

(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 assy, and adjust the crawler tension. • On that occasion, confirm the lubrication through the grease nipple is proper and that grease is not leaking from the grease cylinder.

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Fig. 5-3 Installing idler

5.2 CONSTRUCTION

2 7

5 7 2

3 9 1

No.

NAME

Q’TY

Idler

Collar

Shaft

Bearing

Oil seal

Snap ring

Spring pin

Plug : PT 1/8

Shim

DIRECT PIN'S SPLIT OUTSIDE VIEW A

5.3 DISASSEMBLY AND ASSEMBLY 5.3.1 Disassembly (1) Remove the plug (8) and drain the oil [Approx. 80 cc (4.9 cu·in) ] : 5mm (2)Push out the spring pin (7) applying the pin extruding jig to it and lightly tapping the jig with a hammer, then remove the collar (2). (3)Remove the shim (9), seals (5) and snapring (6). (4)Supporting the idler (1) with the supporting stand, apply the shaft extruding jig to the shaft (3), and push it out together with the bearing (4) using a pressing machine.

Fig. 5-4 Idler assy construction 7 PIN EXTRUDING JIG 1

Fig. 5-5 Extruding pin

PRESSING SHAFT EXTRUDING JIG

• Except the case that replacement of the bearing (4) is necessary, do not remove the bearing from the shaft (3).

STAND

Fig. 5-6 Extruding shaft

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5.3.2 Assembly (1) Apply molybdenum grease to the shaft (3), and install the bearings (4).

PRESS WITH SHAFT PRESSING JIG

4 1

• In case of re-use of the bearing, confirm its smooth rotation, and no defect and rust on them. (2) Applying molybdenum grease to the idler (1), press the shaft (3) together with the bearings into the idler. (3) Install the snap ring (6) and oil seal (5).

STAND

(4) For the oil seal (5), first apply grease into the groove on lip portion of the seal body (5a). Then push the seal body (5a) and sleeve (5b) into the place evenly with the special pushing jig paying attention not to give any distortion on the lip.

Fig. 5-7 Shaft / Bearing installation

SEAL PUSHING JIG 5b 5 5a

• Replace the seal to new one at reassembly. • When the seal is not installed properly due to one-sided pressing etc, replace it to new one. (5) Install the opposite seal (5) with the same procedure. (6) After installing shims (9), install the collar (2) to the shaft (3), and fix it with tapping the spring pin (7) in. Install the collar (7) of the opposite side with the same procedure.

Fig. 5-8 Installing seal

2 7 PIN EXTRUDING JIG

• Install the spring pin (7) so that the gap on it faces to outside. [See Fig. 5-10]

(7) Fill in 80 cc (4.9 cu·in) of the gear oil SAE #90 through the bore for plug on the idler (1). Fig. 5-9 Tapping pin

(8) Tighten up the plug (8). : 5mm

DIRECT PIN'S SPLIT OUTSIDE

Fig. 5-10 Pin's Split direction

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5.4 MAINTENANCE STANDARDS D C

E F

Fig. 5-11 Idler assy

Unit : mm (in) Code

ITEM

STANDARD VALUE

A B C D

Dia. of idler projection Tread dia. Flange width Tread width

+0.04 ø347 +1 -2 (13.66 -0.08 ) ø305 – 0.5 (12.01 – 0.02) 40 (1.57) 84 (3.31)

Basic dimension

Fitting idler / bearing

— Oil — Idler rotation G Tightening Torque (Capscrew M10)

Fitting

+0.018 (0.00070) Interference Interference +0.002 (0.00008) 0.002 ø35 (0.00008) 0.002 (1.38) 0(0) 0.030 (0.00008) -0.012 (-0.00047) (0.00118) Clearance 0 (0) 0.004 Clearance -0.013 (-0.00051) (0.00016) ø80 0.004 (3.15) -0.009 (-0.00035) Interference (0.00016) 0.039 -0.039 (-0.00154) (0.00154) Gear oil SAE #90, 80cc (4.9 cu·in) Idler rotates smoothly by hand T = 6.7 kgf·m (48 lbf·ft) : 17mm Apply Loctite #262

Bore Shaft Bore Shaft

Fitting

Fitting shaft / bearing

ø341(13.43) ø339(13.35) ø229 (9.02) ø227 (8.94) 34 (1.34) 32 (1.26)

REMEDY

Replace

Fitting

Replace of shaft or bearing

Tolerance

REPAIRABLE SERVICE LIMIT LEVEL

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Replacement of idler or bearing Replenish Reassembly Retightening

6. IDLER ADJUSTER 6.1 REMOVAL AND INSTALLA LATION LA TION PROCEDURES PR OCEDURES 6.1.1 Removing (1) Idler adjuster assy assembled with idler assy (a) is removed from the lower frame . Do this work by referring to "5.1.1" Removing front idler.

(2) Loosen capscrews (c) and separate idler assy (a) from idler adjuster assy (b). : 17mm

Fig. 6-1 Disassembling idler assy

Weight of idler assy : 27 kg (60 lb) Weight of idler adjuster assy : 16 kg (35 lb) • The separated idler assy is easy to fall down. Lay it down so it does not fall down on your feet, utilizing square lumber. 6.1.2 Installing (1) Installation is done in the reverse order of removal : First of all, assemble idler assy (a) to idler adjuster assy (b), and tighten them together with capscrews (c). In that case, coat the threaded part of capscrews (c) with Loctite #262 beforehand.

NAME

No.

: 17mm T : 6.7 kgf·m (48 lbf·ft) (2) Before installing the idler adjuster to the crawler frame, assemble it with the idler assy. For the procedure, refer to "5.1.2" Installing front idler. 6.2 CONSTRUCTION

Q’TY

Piston

Grease cylinder

Spring

Bracket

Nut

Oil seal

O-ring

Spring pin

10 Grease nipple

4 1 8 7

9 10 Fig. 6-2 Idler adjuster assy

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Holding-down nut

6.3 DISASSEMBLY AND ASSEMBLY (1) Disassembly 1) Before disassembling snd assmbling the idler adjuster assy, prepare spring setting jig (V).

Retainer plate

Capacity of hydraulic jack : more than 5 tons (11000 lbs)

Hydraulic jack â&#x20AC;˘ Large power is needed to set the spring.Prepare a special jig before disassmbly and assembly.

2) Place a hydraulic jack between the jig base and the stand.

Base Fig. 6-3 Spring set special jig (V) 4

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 assy.

5) Taken out oil seal (7) and O-ring (8) from grease cylinder (2). 6) Set the idler adjuster assy on the stand of the jig, with its bracket side facing up. 7) Fit retainer plate to bracket (4) tighten holdingdown nuts alternately, and secure idler adjuster assy.

Fig. 6-4 Slinging work of idler adjuster

Holding-down nut

8) Remove spring pin (9), press spring (3) lifting it with jack so that nut (5) can be turned freely, and remove nut (5) 5

Retainer plate

Fig. 6-5 Fixing Holding-down nut

Fig. 6-6 Compression of spring

34 -I-1-20

9) Allow the hydraulic jack to retract slowly till the spring is extended to its free length. Remove the retainer plate and take off bracket (4). The free length of the spring: Approx. 337 mm (13.3 in) 10)Hook lifting eye nut (W) to screw M24XP3 on grease cylinder (2) top end and hoist it.

Retainer plate

11)Remove the set of grease cylinder (2) and spring (3) using crane frome the jig.

(2) Assembly Assembly is done in the reverse order of disassenbly. 1) Insert grease cylinder (2) into spring (3) and attach lifting eye nut (W) to screw M24XP3 at the tip of the grease cylinder. Lift the grease cylinder by crane and erect it in the center of the jig stand upright.

Fig. 6-7 Removing retainer plate, bracket (4)

W 2) Install bracket (4) on top of spring (3). Center the rod of grease cylinder (2) and the holes in bracket (4). Attach the retainer plate and four holding-down nuts. Fasten the nuts evenly all round fix the idler adjudter assy to the jig body. 3) Extend the hydraulic jack, compress spring (3) to a set length and screw in nut (5) to the screwed part at the tip of grease cylinder (1). Set length of the spring : 277 mm (10.9 in)

Fig. 6-8 Removing and Installing of idler adjuster

4) Tighten nut (5) till the holes for locking spring pins (9) are aligned, then fit spring pin (9). : 36mm

5 Holding-down nut Retainer plate 4 3 2

Fig. 6-9 Attach idler adjuster assy to the jig.

34 -I -1-21

5) Remove idler adjuster assy from jig. 6) Fit oil seal (7) and O-ring (8) to grease cylinder (2). • Apply grease on oil seal (7) and O-ring (8). 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. 8) Tighten grease nipple to piston (1). : 19mm Tightening torque : 6 kgf·m (43 lbf·ft)

6.4 MAINTENENCE STANDARDS Table. 6-1

Code A B — D E F

Rubber crawler ITEM Installed length of spring 277 (10.9) Free length of spring 337 (13.3) Stroke 20 (0.79) Set length 445 (17.5) Outside view of piston No scoring and rusting Tightening torque of grease nipple 6 kgf·m (43 lbf·ft)

Unit : mm (in) Steel shoe

449 (17.7)

D (Steel shoe) D (Rubber crawler) A,B E

F Fig. 6-10 Idler adjuster assy.

34 -I-1-22

7. SPROCKET LOWER FRAME

7.1 REMOVAL AND INSTALLATION PROCEDURES 7.1.1 Removing (1) Remove the crawler assy. (2) Place square lumber under the lower frame so the sprocket is off the ground. (3) Loosen socket bolts (M12) for the mounting of the sprocket by means of an allen wrench key and remove the sprocket. : 10mm Single weight of sprocket : 14 kg (31 lb) 7.1.2 Installing (1) Check the fixing parts of the travel motor and the sprocket, eliminate burrs and dirt thoroughly, and install the sprocket.

SQUARE LUMBER

SPROCKET

Fig. 7-1 Free sprocket from load

SOCKET BOLT

(2) Apply Loctite #262 to the threaded portion of socket bolts to mount the sprocket and fasten the bolts temporarily.

SPROCKET Fig. 7-2 Removing sprocket

(3) Remove the square lumber under the lower frame and tighten socket bolts with specified torque to fix sprocket and travel motor. : 10mm T : 10.4 kgf·m (75 lbf·ft)

TRAVEL MOTOR

(4) Install crawler. Fig. 7-3 Tightening socket bolts 7.2 MAINTENANCE STANDARDS

P. C. D3 76.6 (14.83")

Fig. 7-4 Sprocket

Unit : mm REMEDY STANDARD VALUE REPAIRABLE LEVEL SERVICE LIMIT ITEM Code Replace 36 (1.42) 28 (1.10) A Width of sprocket teeth 30 (1.18) Welded repair, or replace ø385.6 (15.18) ø378 (14.88) O.D. of sprocket ø380 (14.96) B

34 -I -1-23

8. TRAVEL MOTOR 8.1 REMOVAL AND INSTALLATION PROCEDURES 8.1.1 Removing (1) Remove the crawler assy.

LOWER FRAME

(2) Place square lumber under the lower frame so the sprocket is off the ground. (3) Remove the capscrews (A5) located inside the lower frame and remove the covers (A2) (A3).

SQUARE LUMBER

SPROCKET

Fig. 8-1 Making sprocket free from load

: 17 mm

A2,A3 (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.

: 19 mm, 22 mm (6) Loosen the socket bolts (B3) that fasten the travel motor to the lower frame. On that occasion, put a matching mark between the lower frame and the travel motor. : 10 mm

Fig. 8-2 Removing cover / travel motor

(7) Place a wire sling in a part near the sprocket of the travel motor for balancing, and remove the unit out of the lower frame. Weight of travel motor (with sprocket) : 56 kgf (123 lb) SQUARE LUMBER

8.1.2 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 socket bolts (B3) with Loctite #262 and tighten them. : 10 mm T : 10.4 kgfÂˇm (75 lbfÂˇft)

34 -I-1-24

Fig. 8-3 Removing / Installing travel motor

(3) Reconnect the hydraulic pipings as before, and tighten the joints with specified torque. Unit : kgf·m (lbf·ft) Thread Spanner size ( mm) PF 1/4 19 PF 3/8 22

Tightening torque of joint 30¡ Flare O-Ring Type Metal Joint 3.0 – (22) 3.7 – (27) 5.0 – (36) 7.5 – (54)

(4) Install the covers (A2) (A3) located inside the lower frame, and tighten capscrews (A5). (See Fig. 8-2)

Fig. 8-4 Installing hydraulic pipings (RH-travel motor)

: 17 mm (5) Remove the square lumber supported the lower frame and install the crawler. (6) Check the oil level in the reduction unit of travel motor [See Item (7) mentioned below] and replace or replenish oil as required. Spec. of oil : GEAR OIL SAE #90 Volume of oil : 750cc (46 cu·in) : 8 mm (7) Checking oil level in reduction unit a) Stop the machine so the drain plug on reduction unit comes right under the machine. b) Remove the level plug and check the oil level and contamination. The oil level is proper if it is close to the plug bore. Replenish oil when deficient.

FILL PLUG

LEVEL PLUG

DRAIN PLUG

Fig. 8-5 Checking oil level

Socket bolt for sprocket Loctite #262 TRAVEL MOTOR 10.4 kgf·m (75 lbf·ft)

OIL

TIGHTENING TORQUE

8.2 MAINTENANCE STANDARDS ITEM Sprocket fixing Socket bolt M12 Travel motor fixing Socket bolt M12 Spec. and grade Volume

SPEC.

Apply Loctite #262 10.4 kgf·m (75 lbf·ft) Gear oil SAE #90 750 cc (46 cu·in)

34 -I -1-25

Socket bolt for travel motor Loctite #262 10.4 kgf·m (75 lbf·ft)

Fig. 8-6 Installing travel motor

9. SLEWING BEARING A

9.1 REMOVAL AND INSTALLATION PROCEDURES 9.1.1 Removing (1) Remove the upper slewing structure. (See detail of "Upper Slewing Structure") (2) Remove capscrews (B) that fix the inner race of slewing bearing (A) : 19mm

Fig. 9-1 Slewing bearing (3) Remove the grease in the inner race of slewing bearing. (4) Fix lifting-bolts to slewing bearing (A), and lift it by crane. Weight of slewing bearing assy : 43 kgf (95 lbs) 9.1.2 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.

Fig. 9-2 Lifting slewing bearing

(2) Lift up the bearing and place it on the lower frame, aligning the "S" mark stamped on the inner race as shown in Fig. 9-3. (3) Coat the threads of the capscrews (B) with Loctite #262 and tighten all capscrews temporarily.

B LOCKTITE #262 11.7 kgf·m (85 lbf·ft)

LOWER FRAME

(4) Tighten the capscrews at 180½ intervals alternately, and tighten them up to a specified torque. : 19mm T : 11.7 kgf·m (85 lbf·ft)

Section A-A

(5) After installing the slewing bearing on the lower frame, install upper slewing structure.

INNER "S" ZONE (S-MARK) Fig. 9-3 Location of "S" mark to install slewing bearing

34 -I-1-26

9.2 CONSTRUCTION No. 1 2 3 4 5

NAME NAME Q’TY No. 1 INNER RACE 6 PULG OUTER RACE 1 7 TAPER PIN 70 9 SEAL B BALL 65 10 GREASE NIPPLE SPACER SPACER (ADJUSTING) 5

Q’TY 1 1 1 1

3,4,5

2 6 10

9.3 DISASSEMBLY AND ASSEMBLY 9.3.1 Disassembling (1) Take off seal B (9) fitted in the groove on lower circumference of inner race (1), and place the bearing in level on a square lumber.

7 9

Fig. 9-4 Cross-section of slewing bearing

(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 center 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.

2 SQUARE LUMBER

6 9

9.3.2 Assembling (1) Degrease thoroughly the groove for seal B (9) located in the outer circumference of inner race (1). Coat the grooves with adhesive Cyano Bond PO-1, fit seal B (9), and place inner race (1) on a surface table.

Fig. 9-5 Disassembling slewing bearing 2

(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. (3) Insert balls (3) and spacers (4) (5) coating with grease (NLGI No.2 Lithium bace with MOS2) alternately through the bole for plug (6) on outer race (2).

4,5

Fig. 9-6 Removing balls / spacers

• 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 or a hooked rod.

2 8

PUSH ROD

1 SQUARE LUMBER

Fig. 9-7 Installing balls

34 -I -1-27

(4) Install plug (6) to outer race (2), confirming the direction and the position of the bore for taper pin (7).

LIFTING BOLT

(5) Push taper pin (7) into bore, and caulk the head of the taper pin with a punch.

HOOK ROD

(6) Confirm that grease nipple (10) is useful. Apply grease (NLGI-2 EP type) and confirm that the outer race rotates smoothly and that the lip of the seal is not scored. grease amount : Approx. 90g (3.2oz) 9.4 MAINTENANCE STANDARDS Regarding the maintenance standards for the wear of the slewing bearing, refer to the Article Measuring Slewing Performances in PW13 Maintenance Standards and Test Procedures.

34 -I-1-28

4,5

SQUARE LUMBER Fig. 9-8 Installing spacer

Part II : DISASSEMBLING AND ASSEMBLING COMPONENTS 1. TRAVEL MOTOR 1.1 SUMMARY

OIL LEVEL CHECK PORT

OIL FILLING PORT

(1) General View

(PF 3/8)

DRAIN PORT (PF 3/8) Rotating direction

Oil inlet

Oil outlet

(View from X side)

Port

Clockwise

Counterclockwise

Fig. 1-1

VIEW X

(2) Hydraulic circuit diagram High speed

Low speed

No.

NAME

SIZE

Oil inlet port â&#x20AC;¢ Oil outlet port

PF1/2

Drain port

PF1/4

A B D1 D2 P P2

PF1/8 Pressure detecting port PT1/8

Fig. 1-2

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(3) EXPLODED VIEW OF TRAVEL MOTOR AND REDUCTION UNIT

Fig. 1-3

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Table 1 NAME

NAME

Q'TY

No.

HUB

109

TIMING PLATE

110

WASHER

SPINDLE KIT

112

PISTON

• SPINDLE ASSY

113

SPRING

8 1

No.

Q'TY

• • SPINDLE

114

SPRING

• • HOLD FLANGE

115

FRICTION PLATE

• REAMER BOLT

116

MATING PLATE

• BOLT

132

OIL SEAL

135

O-RING

4 9

RV GEAR ASSY

139

O-RING

• RV GEAR

145

SNAP RING

• CRANK SHAFT

149

BEARING

• SPACER

150

BEARING

• TAPERED ROLLER BEARING

151

ROLLER

• NEEDLE ROLLER BEARING

167

PIVOT

169

MATING PLATE

177

PARALLEL PIN

190

SPRING

REAR FLANGE ASSY

7 8

INPUT GEAR

SPUR GEAR KIT

• SPUR GEAR

COVER

• REAR FLANGE KIT

201

• • REAR FLANGE

223

• • SPOOL

RING

SNAP RING

BALL BEARING

SNAP RING

25 26

• SPOOL KIT

263

• • SPOOL

264

• • OIL STOPPER

218

• VALVE SEAT

SNAP RING

219

• VALVE

O-RING

220

• SPRING

O-RING

221

• PLUG

O-RING

222

• RING

224

• PLUG

FLOATING SEAL KIT

225

• STOPPER

• FLOATING SEAL

226

• PLUG

227

• VALVE

PLUG

228

• SPRING

SOKET PLUG

230

• SPRING

O-RING

233

• O-RING

PARALLEL PIN

236

• O-RING

237

• O-RING

2 2

PISTON KIT

241

• PARALLEL PIN

• PISTON ASSY

243

• SOCKET BOLT

105

• • PISTON

1252

• SOCKET PLUG

106

• • SHOE

254

• SOCKET PLUG

266

• SPRING

PISTON ASSY

268

• STEEL BALL

161

• PISTON

273

• O-RING

162

• SHOE

275

• ORIFICE

276

• ORIFICE

280

• PLUG

299

• NAME PLATE

102

DRIVE SHAFT

103

SWASH PLATE

104

CYLINDER BLOCK

107

RETAINER PLATE

108

THRUST BALL

34-II-1-3

1.2 TOOLS AND JIGS (1) Standard tools No. 1 2

NAME

SIZE

Hex. wrench key

6 (M8 and PF1/4), 5 (PF1/8) and 8 (PF3/8)

Q'TY 1 each

Socket wrench

Barrel type

Dial type, about 18 kgf • m (130 lbf • ft)

Dial type, about 56 kgf • m (405 lbf • ft)

Nominal socket size 24 and 30

1 each

Nominal rod size 5, 6, and 8

1 each

(Ratchet handle) 3 4

Torque wrench Torque wrench adaptor

Extension bar

150 mm (6")

Hammer

Nominal size 12

Plastic hammer

L= about 300 mm (12")

Flat screwdriver

About 150 mm (6")

Snap ring pliers

For shaft

For bore

Lifting capacity: 300 kg (660 lb) or over

1 set

Lifting eye (for M12)

(2)

Lifting eye (for PF 3/8)

(2)

Wire with hooks

(1)

Vat for general use: W450XD300XH120

Lifting tool

Container

Leather gloves

1 pair

34-II-1-4

(2) Tools

APPLICATION ITEM (No. in cross-sectional or exploded view) Disassembly and assembly Parts cleaning 104 and 149 149

1 Disassembly 161, 162, 163, and 112 Drying after cleaning 3

NAME

SIZE

REMARKS Q’TY 1 set 1 set

General workbench Cleaning bath

For rough and finish cleaning 1 set Workbench for press Pressing capacity : 150 kg (330 lb) or over 1 set Heating bath Heating capacity : 100ºC (212ºF) or over Volume 500X500X500 mm (20"X20"X20") JIS C 9605 1 Electric drill Portable electric drill [Max. drill diameter : ø10 (0.394")] 1 Drill ø2 (0.0787") 2 Compressed air Pressure 3 ~ 5 kgf/cm (43 ~ 71 psi) 1 set Lathe

(3) Measuring instrument

APPLICATION ITEM (No. in cross-sectional or exploded view) For snap ring (20) thickness adjustment For snap ring (20) thickness adjustment

NAME Thickness gauge Outside micrometer

For ball bearing (21) pre-load Single depth miadjustment crometer

34-II-1-5

SIZE Measurement 0.04 ~ 0.3 mm (0.00016 ~ 0.0118 in) Measured value:0 ~ 25 mm (0 ~ 1 in) Minimum graduation: 0.01 (0.00039 in) Measured value:0 ~ 25 mm (0 ~ 1 in) Minimum graduation: 0.01 (0.00039 in)

REMARKS Q’TY 2 1

(4) Jigs No.

No.

NAME Working bench for travel motor

NAME Retainer metal (III)

This is used to carry out the work for assembly and disassembly of travel motor easy and safe.

This is used to press fit the oil seal (132) into the oil seal fitting hole of the spindle (2).

Fixing metal

Retainer metal (IV)

This is used to connect the spindle (2) and hub (1).

Apply it on outer race of bearing (22) fitted on the crank shaft (9) of RV gear assembly, and then strike it to insert RV gear assembly securely.

Retainer metal (I)

Jig for adjusting the preload to the bearing

3 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).

This is used to press fit ball bearing (21) in the hub (1), and also used to measure axial clearance of ball bearing (21) .

Retainer metal (II)

Steel rod (1)

This is used to pull out bearing (149) from drive shaft (102).

34-II-1-6

This is used to remove ring (18) from the hub (1).

No.

NAME Lifting eye for PT

NAME Point punch

This lifting eye is used to remove the cover (8) from the hub (1) with wire and crane.

This is used to remove the ring (222) in pilot valve.

Long lifting eye

Jig for cover removal

Application "A" Hub M12 Spindle M12 Travel motor M12

This is used to remove the cover (8) from the hub.

This lifting eye is used to sling up travel motor, the spindle (2) and the hub (1). Spatula

This is used to remove the timing plate (109) from rear flange (201). Pin punch ø10 (0.39 ”)

12 150 (5.9 ”) ø4 (0.16 ”)

This is used to remove the outer race of bearing (21).

34-II-1-7

1.3 DISASSEMBLY 1.3.1 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 1-2. 1.3.2 GENERAL PRECAUTIONS FOR WORKING

CAUTION • 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.

CAUTION • 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-II-1-8

1.3.3 DISASSEMBLING (1) Cleaning travel motor 1) Tighten the lifting eyes into the tapped holes of the spindle (2).

Lifting eye

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. 1-4 Mounting lifting eye

3) Clean the travel motor with a car brush. 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. 1-5 Cleaning travel motor (2) Installing travel motor 1) Place travel motor on a workbench. While aligning the threaded holes of the hub (1) and the workbench, place the travel motor in fixing holes of the workbench slowly.

Fig. 1-6 Placing travel motor on workbench 2)

Fix the travel motor with two socket bolts on the workbench.

Socket bolt

Fig. 1-7 Fixing travel motor on workbench

34-II-1-9

(3) Draining lubricating oil 1) Turn over the travel motor. 2) Loosen a plug (33) and two socket plugs (34). â&#x20AC;˘ If the plug (33) and the socket plugs (34) are removed and the travel motor is reversed, oil spills. Loosen them to such an extent that they can be turned by hand.

Fig. 1-8 Removing plug (33) 3) Turn over the travel motor. 4) Remove the plug (33) and two socket plugs (34) from the cover (8) and drain out the lubricating oil. â&#x20AC;˘ When draining out the lubricating oil, place a container under the workbench. 5) Remove the O-rings (37) from the plug (33) and two socket plugs (34).

Fig. 1-9 Draining oil

(4) Removing cover 1) Turn over the travel motor. 2) Mark on the mating surface between the hub (1) and cover (8), using a paint marker.

Fig. 1-10 Matching marks on the hub (1) and cover (8) 3) Find the matching part of the ring (18), and punch at a point of the outside of the hub, approximately 20 mm (0.8 in) inward from the tip of ring (18) for drilling purpose.

Fig. 1-11 Punching a hole for pushing ring (18) out

34-II-1-10

4) Drill a 2 mm (0.08 in) hole from the outside of the hub (1) toward the ring (18) using an electric drill. • Put a drill against the punched hole and drill it till the ring comes off from the cover as it is pushed by the drill. • Wipe off the metal chips produced by drilling to prevent them from damaging the part to be removed.

Fig. 1-12 Drilling push rod for ring (18)

5) Put a steel rod into the hole and push the ring (18). • In this case, the tip of the ring (18) stands out above the cover (8) as pressed by the steel rod.

Fig. 1-13 Pushing ring (18)

6) Hold the tip of the ring (18) coming off from the cover (8) and remove the ring (18) out of the ring groove of the hub (1).

Fig. 1-14 Removing ring (18)

7) Screw two bolts at the center of a cover removal jig in the tapped holes of the plugs (33) and (34). • If the cover (8) is hard to remove due to the resistance of the O-ring (29), lift it up while lightly and uniformly tapping the outer rim of the cover by a plastic hammer.

Fig. 1-15 Removing cover (8)

34-II-1-11

8) Place a block against two bolts outside the cover removal jig and tighten the bolts to allow the cover (8) to come off little by little. 9) Remove the O-ring (29) from the cover (8). • Do not reuse the removed O-ring (29).

Fig. 1-16 Removing O-ring (29)

(5) Removing input gear 1) Remove the snap ring (24) from the drive shaft (102).

102

• Perform the work with care because, if the tip of the pliers comes off from the snap ring hole, the snap ring may fly out.

Fig. 1-17 Removing snap ring (24) 2) Remove the input gear (6) from the drive shaft (102).

Fig. 1-18 Removing input gear (6) (6) Removing spur gear 1) Remove two snap rings (25) from the crank shaft (9). • Perform the work with care because, if the tip of the pliers comes off from the snap ring hole, the snap ring may fly out.

Fig. 1-19 Removing snap ring (25)

34-II-1-12

2) Remove two spur gears (7) from the crank shaft (9).

Fig. 1-20 Removing spur gear (7) 3) Remove two snap rings (25) from the crank shaft (9). • Perform the work with care because, if the tip of the pliers comes off from the snap ring hole, the snap ring may fly out.

Fig. 1-21 Removing snap ring (25) (7) Removing rear flange 1) Turn over the travel motor. • This work is intended to remove the plug easily when the internals of the rear flange (201) are disassembled. • Loosen the plug only when disassembling the internals of the rear flange (201). 2) Loosen two plugs (224). Fig. 1-22 Loosening plug (224)

3) Loosen two plugs (226).

Fig. 1-23 Loosening plug (226)

34-II-1-13

4) Loosen six socket bolts (243) and remove them from the rear flange (201).

Fig. 1-24 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. 1-25 Removing rear flange (201)

6) Remove the parallel pins (42) from the spindle (2).

Fig. 1-26 Removing parallel pin (42) 7) Remove the O-rings (26) and (28) from the spindle (2). â&#x20AC;˘ Do not reuse the removed O-rings (26) and (28).

Fig. 1-27 Removing O-rings (26) and (28)

34-II-1-14

(8) 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 (1). â&#x20AC;˘ It may be hard to remove the rear flange as the mating surface of it is stuck with oil. Insert a spatula 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. 1-28 Removing timing plate (109)

3) Remove the parallel pins (241) from the rear flange (201).

Fig. 1-29 Removing parallel pin (241)

4) Remove bearing (150) from the rear flange (201).

Fig. 1-30 Removing bearing (150) (9) Removing brake valve parts from rear flange 1) Remove two plugs (224) from the rear flange (201).

Fig. 1-31 Removing plug (224)

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2) Remove two stoppers (225) and two springs (228) from the rear flange (201). 225

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.

221 224

Fig. 1-32 Removing stopper (225), spring (228) and spool (223)

4) Remove two plugs (226) from the rear flange (201).

Fig. 1-33 Remove the plug (226)

5) Remove two springs (230) and two valves (227) from the rear flange (201).

Fig. 1-34 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. 1-35 Removing O-ring (236)

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7) Remove the O-ring (237) from the plug (226). • Do not reuse the removed O-ring (237).

Fig. 1-36 Removing O-ring (237) (10) Removing two-speed switching spool 1) Remove the plug (221) from the rear flange (201). 2) Remove the O-ring (273) from the plug (221). • Do not reuse the removed O-ring (273).

Fig. 1-37 Removing plug (221)

3) Remove the spool (263) and spring (266) from the rear flange (201).

Fig. 1-38 Removing spool (263)

(11) Removing parking brake valve (219) • Remove the ring (222) only when replacing the valve (219). 1) Place the rear flange (201) inside up on the workbench. 2) While pressing the valve seat (218) with a steel rod, remove the ring (222) from the rear flange (201) by using a sharp-pointed steel rod.

Fig. 1-39 Removing ring (222)

• Smoothly repair the hole portion damaged during the removal of the ring (222).

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CAUTION â&#x20AC;˘ Be careful not to blow compressed air suddenly. Otherwise the parts may fly out to cause injury.

3) Block the hole of the valve seat (218) and blow compressed air through the oil passage to remove the valve seat (218) from the rear flange (201).

Fig. 1-40 Removing valve seat (218)

4) Hold the rear flange (201) with the hole portion facing down and lightly shake up and down to remove the valve (219) and the spring (220). â&#x20AC;˘ Do not reuse the removed ring (222), valve seat (218) and O-ring (233).

Fig. 1-41 Removing valve (219) and spring (220)

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(12) Removing the parking brake section Protection cover

CAUTION • Install a protection cover on the piston

Air hose

(112). Otherwise the piston may fly out suddenly from the spindle (2) due to compressed air to cause injury.

Fig. 1-42 Removing piston (112) 1) Blow compressed air into the passage hole for the parking brake of the 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. 1-43 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 mating plates (116), two friction plates (115), and a mating plate (169). 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. 1-44 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. 1-45 Removing cylinder block (104)

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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 shoe by a set (hereafter referred to as the piston assembly).

Fig. 1-46 Removing retainer plate (107)

7) Remove the retainer plate (107) from piston assembly (105) and (106) [seven sets].

Fig. 1-47 Removing piston assembly (105) and (106)

8) Remove the thrust ball (108) from the cylinder block (104).

Fig. 1-48 Removing thrust ball (105) 9) Remove three rollers (151) from the cylinder block (104).

Fig. 1-49 Removing roller (104)

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(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 center of the retainer metal ( I ) with the washer center in order to prevent the cylinder block from being damaged by contact. • Put a vinyl sheet over the cylinder block so as not to damage the surface of the cylinder block.

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 pair of snap ring pliers.

Retainer metal

Vinyl sheet

Fig. 1-50 Removing spring (114)

Press

Retainer metal ( I )

Washer (110) Snap ring (145) Spring (114)

CAUTION

Cylinder block (104)

• Release pressing force slowly. Otherwise the spring may fly out to cause injury.

Fig. 1-51 Removing spring (114)

3) Remove the snap ring (145), washer (110), spring (114), and washer (110) out of the cylinder block.

Fig. 1-52 Removing internals of cylinder block (104)

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(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. 1-53 Removing swash plate (103)

2) Pull the drive shaft (102) out of the spindle (2). Then the 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.

Fig. 1-54 Removing drive shaft (102)

3) Remove two pivots (167) and two the parallel pins (177) from the spindle (2). 4) Remove the two-speed switching piston assy (piston and shoe) and spring (190) from the spindle (2). • Piston (161)

Åm• Shoe (162)

Piston assembly

Compressed air (Air gun)

Fig. 1-55 Removing pivot (167) and the parallel pin (177)

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(16) Removing ball bearing • Remove the ball bearing, only when its replacement is necessary.

Press

1) Place the retainer metal ( II ) on the press bench and put the drive shaft (102) into it. Retainer metal ( II )

Hold down the tip of the drive shaft (102) by a press and remove the bearing (149) from the shaft. Fig. 1-56 Removing ball bearing (149) • Do not reuse the ball bearing. (17) Removing hold flange 1) Incline the travel motor by 90 degrees. 2) Fix the hub (1) and the spindle (2) by tightening two fixing plates. The fixing plates should be tightened in diagonal position with each other.

Fixing plate

Be sure to attach the fixing plates to remove the hold flange (3). Otherwise the hub (1) separates from the spindle (2) which will fall from the workbench. Fig. 1-57 Fixing hub (1) and piston (2) 3) Turn over the travel motor.

CAUTION • Perform the work with care because, if the tip of the pliers comes off from the snap ring hole, the snap ring may fly out. Fig. 1-58 Removing snap ring (20) 4) Remove two snap rings (20) from the hold flange (3). 5) Put matching marks on the snap rings (20) and the hold flange (3) with an oil paint marker. • This is intended to place them in the same positions as at installation.

Fig. 1-59 Putting match marks on snap rings (20) and hold flange (3)

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6) Incline the travel motor by 90 degrees. 7) Loosen two reamer bolts (19). • An adhesive is applied to the tapped hole for the reamer bolt (19). The adhesive on the reamer portion may cause the seizure when the reamer is loosened, leading to the difficulty of disassembling. Therefore loosen the reamer bolts (19) as slowly as possible. If it becomes tight on the way, screw it and then unscrew it again. • The tightening torque is 25.7 ± 4.0 kgf•m (186 ± 29 lbf•ft). More torque is needed to loosen the bolt because of the applied adhesive.

Fig. 1-60 Loosening reamer bolt (19)

8) Loosen two bolts (35). • An adhesive is applied to the tapped hole for the bolt (35). The adhesive on the threaded portion may cause the seizure when the bolt is loosened, leading to the difficulty of disassembling. Therefore loosen the bolts (35) as slowly as possible. If it comes tight on the way, screw it and then unscrew it again. • The tightening torque is 25.7 ± 4.0 kgf•m (186 ± 29 lbf•ft). More torque is needed to loosen the bolt because of the applied adhesive. Fig. 1-61 Loosening bolt (35) 9) Return the travel motor to the original position by turning it by 90 degrees. 10) Put match marks on the hold flange (3) and the spindle (2) with an oil paint marker. • This is intended to reinstall the hold flange (3) in the same position as the spindle (2). • The two mounting holes for the reamer bolts (19) and the two mounting holes for bolt (35), provided on the spindle (2), have been machined simultaneously. The spindle (2) and the hold flange (3) shall be replaced together as a set (hereafter referred to as the spindle assy).

Fig. 1-62 Putting match mark on hold flange (3) and spindle (2)

11) Remove the hold flange (3) from the Spindle (2).

Fig. 1-63 Removing hold flange (3)

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(18) Removing fixing plate 1) Turn over the travel motor. 2) Remove two fixing plates.

Fixing plate

Fig. 1-64 Removing fixing plate (19) Removing spindle 1) Place a clean container under the travel motor.

Lifting eye

2) Attach two lifting eyes to the tapped holes in the spindle (2) in diagonal position with each other and tighten them. 3) Attach a wire with hooks to lifting eyes, lift the spindle (2) up and remove it from the hub (1). Then the floating seal (31), the outer race of the tapered roller bearing (22), and the oil seal (132) are also removed together.

(20) Removing the bearing, RV gear assembly and pin 1) Remove the floating seal (31) from the hub (1). â&#x20AC;˘ Remove the ball bearing (21) little by little, tapping evenly the end face of pin (17) at 3 or 4 points of the peripheral corner of the bearing so that the bearing is not stuck. â&#x20AC;˘ When the fit section of the outer race of the ball bearing (21) comes out of the hub (1), the ball bearing (21), RV gear assembly (4, 9, 12, 22, and 23), and pin (17) drop from the hub (1). Therefore spread a rubber mat under the working bench so as not to damage the parts. 2) Tapping the end face of pin (17) with pin punch and hammer, remove the ball bearing (21) from the hub (1). Then RV gear assembly [two RV gears (4), crank shaft (9), tapered roller bearing (22), needle roller bearing (23), spacer (12)] and the pin (17) are also removed together. (see Fig. 1-67)

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Fig. 1-65 Removing spindle (2)

Hammer Aluminum rod

Pin Ball bearing

Fig. 1-66 Removing ball bearing (21)

3) Remove the fallen ball bearing (21), RV gear assy and pin (17). • Do not remove the tapered roller bearing (22), needle roller bearing (23), and spacer (12) from the crank shaft (9) except for replacement.

Hammer Pin punch

4) Turn over the motor. 5) Remove the ball bearing (21). • Remove the ball bearing (21) little by little, tapping evenly the end face of pin (17) at 3 or 4 points of the peripheral corner of the bearing so that the bearing is not stuck. .

Fig. 1-67 Removing ball bearing (21) and pin (17) Oil seal (21) Removing spindle fittings

Spindle

1) Remove the oil seal (132) from the spindle (2) • Never reuse the removed oil seal (132).

Fig. 1-68 Removing oil seal (132) 2) Remove the floating seal (31) from the spindle (2).

Fig. 1-69 Removing floating seal (31)

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Remove the outer races (2 pcs) of the tapered roller bearing (22) from the spindle (2). • It may be hard to remove the outer race of the tapered roller bearing (22) as the outer race is closely stuck on the mounting surface of the spindle by lubricant film. In this case, tap the center of the mounting hole of the spindle (2) with an aluminum rod. Then the outer race is removed easily as the lubricant is broken. Fig. 1-70 Removing outer race of bearing (22)

(22) Disassembling hold flange 1) Remove the outer race of the tapered roller bearing (22) from the hold flange (3).

(23) Rough washing of parts 1) Separate the four parts, namely the hub (1), spindle (2), cover (8), and rear flange (201), from the other parts (hereafter referred to as built-in parts).

Fig. 1-71 Removing outer race of bearing (22)

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.

CAUTION • Kerosene is combustible. Be careful not to cause fire, burns, and injury.

Fig. 1-72 Rough washing of parts

• 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.

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(24) 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. • Dry the inner surfaces of the hub (1), the spindle (2), and the hold flange (3) in the dust-free and dry conditions by blowing compressed air on them. After drying, apply hydraulic oil to every part.

Fig. 1-73 Finish cleaning

• Dry the inner surface of the rear flange (201), the hydraulic motor components, and RV gear assy in the dust-free and dry conditions by blowing compressed air on them. After drying, apply hydraulic oil to every part. • Be careful not to damage the surface of twentyeight pins (17) and not to lose them while handling.

Fig. 1-74 Finish cleaning

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1.4 ASSEMBLY Perform assembly basically in reverse order of disassembly.

1.4.1 PREPARATION Prepare a workbench, tools and jigs as in the case of Section 1.3 DISASSEMBLY.

1.4.2 GENERAL PRECAUTIONS FOR ASSEMBLY (1) For assembly also, take the general precautions described in Section 1.3. (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) In principle, replace the reamer bolts with new ones. If reuse is unavoidable, remove completely the adhesive on the reamer bolt with a brush, and grind off flaws on the bolt seating face with an oilstone. (5) Degrease the tapped holes for the reamer bolts and hexagonal bolts in the spindle (2) and threaded portions of the reamer bolt (19) and hexagonal bolt (35) in order to apply an adhesive to them when assembling. (6) Be careful not to damage the O-rings, oil seals, and floating seals at installation (Lightly apply grease to them for smooth installation). (7) Prior to assembly, apply clean hydraulic oil (NAS standards class 9 or higher) to movable and sliding portions of hydraulic motor components and valves. (8) Use no cloth gloves during assembly to prevent malfunctions due to textile lint. (9) On completion of assembly, plug every opening to prevent the entry of dirt. (10) Photos and figures of typical models are shown. Any partial difference between them and the product in use does not affect the assembling procedure.

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), hold flange (3), and ball bearing (21) 2. Parts requiring thickness adjustment of snap ring after their replacement ................................ spindle (2), hold flange (3), crank shaft (9), spacer (12), and the tapered roller bearing (22)

Note : When replacing any of the above parts, use the parts previously adjusted. Otherwise, the travel motor may malfunction resulting in early breakage.

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(1) Reassembling hub section 1) Attach two lifting eyes to the tapped holes of the hub (1) in diagonal position.

Lifting eye

2) 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 in the workbench, carefully insert the hub (1) into the fixing hole in the workbench. Fig. 1-75 Lifting hub (1) 3) Attach the hub (1) to the workbench by tightening the socket bolts in diagonal position.

CAUTION

Fixing bolt

• Fully tighten the socket bolts. Otherwise, the travel motor may fall down to cause injury when it is turned over.

Workbench Fig. 1-76 Installing hub (1) to the workbench

4) Insert the ball bearing (21) into the hub (1). • Place a pin punch against the peripheral rim of the ball bearing (21), hammer it lightly all around and press the bearing into the hub little by little. 5) Apply grease to the O-ring of the floating seal (31), and fit the floating seal in the groove of the hub (1). • Remove the O-ring from the floating seal to apply grease to its surface lightly. • Align the floating seal with the groove of the hub and press it into the groove. Make sure that the top of the floating seal is in parallel with the hub groove within 1 mm (0.04 in).

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Fig. 1-77 Inserting ball bearing (21)

(2) Assembling spindle section 1) Apply grease to the O-ring of the floating seal (31), and fit the floating seal in the groove of the spindle (2). â&#x20AC;˘ Remove the O-ring from the floating seal to apply grease to its surface lightly. â&#x20AC;˘ Align the floating seal with the groove of the spindle and press it into the groove. Make sure that the top of the floating seal is in parallel with the spindle groove within 1 mm (0.04 in). Fig. 1-78 Installing floating seal (31)

2) Fit two outer races of the tapered roller bearing (22) into the respective engaging bores of the spindle (2).

Fig. 1-79 Inserting outer race of tapered roller bearing (22)

3) Attach two lifting eyes to the spindle (2) in diagonal position.

Lifting eye

4) 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.

Fig. 1-80 Inserting spindle (2)

5) Fix the hub (1) and the spindle (2) with fixing plate in diagonal position.

Fixing plate

6) Turn over the travel motor.

Fig. 1-81 Fixing hub (1) and spindle (2)

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(3) Installing RV gear assembly 1) Place the RV gear assembly (4, 9, 12, 22, and 23) into the spindle (2) slowly. • Align the inner race of the tapered roller bearing (22) set on the crank shaft (9) with the bore for the outer race of the tapered roller bearing (22) set in the spindle (2), and then install the RV gear assembly onto the spindle (2).

Fig. 1-82 Inserting RV gear assy

2) Insert twenty-eight pins (17) into the clearance between the pin grooves of the hub (1) and the tooth groove of the gear. • Prior to inserting, apply lube oil to the pins (17).

Fig. 1-83 Inserting pin (17) Hammer 3) Insert the ball bearing into the hub (1). Pin punch • Place a pin punch against the outer race corner of the ball bearing (21) and tap it with a hammer to press the ball bearing into the hub little by little.

(4) Installing hold flange 1) Make sure that the hub (1), spindle (2), hold flange (3) and ball bearing (21) have not been replaced.

Fig. 1-84 Inserting ball bearing (21)

• Go to the next step 2) if nothing has been replaced. • Even if one of them has been replaced, adjust preload of bearing according to “(19) preload adjustment to bearing” and then go to the next step 2). 2) Fit the hold flange (3) to the inner race of the ball bearing (21).

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Fig. 1-85 Inserting hold flange (3)

(5) Tightening reamer bolt and hexagonal bolt 1) Coat the reamer part of the reamer bolt (19) with a seizure preventive lubricant and coat the thread part of the reamer bolt with an adhesive. 2) Tighten two reamer bolts (19) until the hold flange (3) is completely press-fitted into the ball bearing (21). Tightening torque: 25.7 ± 4.0 kgf•m (186 ± 29 lbf•ft) 3) Apply adhesive to the thread part of the hexagonal bolt (35). Fig. 1-86 Installing reamer bolt (19) 4) Tighten two bolts (35) at the specified torque. Tightening torque: 25.7 ± 4.0 kgf•m (186 ± 29 lbf•ft) 5) Turn over the travel motor. 6) Remove two fixing plates. 7) Turn over the travel motor. 8) Fit the outer race of the tapered roller bearing (22) to the hold flange (3).

(6) Installing snap ring 1) Make sure that the spindle (2), hold flange (3), crank shaft (9), tapered roller bearings (22) and spacer (12) have not been replaced.

Fig. 1-86A Inserting outer race of tapered roller bearing (22)

• Go to the next step 2) if nothing has been replaced. • Even if one of them has been replaced, perform “(20) Procedure for adjusting the axial clearance of the tapered roller bearing” and then proceed to the next step 2). 2) Install the snap ring (20) to the snap ring groove in the hold flange (3). 3) Install two snap rings (25) to the crank shaft (9). Fig. 1-87 Installing snap ring (20)

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(7) Reinstalling spur gear 1) Install two spur gears (7) onto the crank shaft (9).

Match mark (punched)

• Align the match marks (punched) of two spur gears (7) as shown at right and install them to the crank shaft (9). 2) Install two snap rings (25) into the snap ring grooves of the crank shaft (9).

(8) Installing oil seal 1) Turn over the travel motor. 2) Coat the lip of the oil seal with lithium grease and then press the oil seal (132) into the oil seal bore of the spindle (2) using the retainer metal ( III ) and a hammer.

Fig. 1-88 Installing spur gear (7)

Retainer metal ( III ) Oil seal Spindle

Fig. 1-89 Installing Oil seal (132)

(9) Installing shaft

CAUTION • Carefully carry out the insertion work using leather gloves to prevent possible burns. •Insert bearing (149) until it closely contacts the flange of the drive shaft (102). 1) Put the ball bearing (149) in a heating bath to heat it at 100 ± 10ºC (212 ± 18ºF) for 10 minutes and then insert it onto the drive shaft (102). 2) Fix two the parallel pins (177) into the pin holes of the spindle (2). 3) Coat two pivots (167) with lithium grease to prevent them from dropping and then fit them to the parallel pins (177) of the spindle (2). 4) Install the spring (190), piston assembly [piston (161) and shoe (162)] into the spindle (2). 5) Incline the travel motor by 90 degrees. 6) Fit the drive shaft (102) into the spindle (2). 7) Install the swash plate (103) into the spindle (2).

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Leather gloves

Fig. 1-90 Inserting bearing (149)

Fig. 1-91 Installing shaft

(10) Installing cylinder block 1) Place the washer (110), spring (114), washer (110), and snap ring (145) in this order, into the cylinder block (104). 2) Place the cylinder block (104) on the press bench. 3) Place the retainer metal ( I ) against the washer (110). While holding down the retainer metal ( I ) by press, fit the snap ring (145) into the snap ring groove of the cylinder block (104) with a pair of snap ring pliers.

Fig. 1-92 Installing cylinder block

Retainer metal ( I ) (11) Reassembling hydraulic motor section 1) Put three rollers (151) into the holes of the cylinder block (104).

Vinyl sheet

Fig. 1-93 Installing snap ring (145)

2) Place the thrust ball (108) on the cylinder block (104). 3) Fit seven piston assemblies to the retainer plate (107). • After assembling, immerse the whole unit in hydraulic oil. 4) Fit the seven piston assemblies to the cylinder block (104).

Fig. 1-94 Installing piston assy and retainer plate (107)

• 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). • After installing the cylinder block, turn it by hand to make sure that it fits properly. If not, inspect it. Fig. 1-95 Inserting cylinder block (104)

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(12) Insatlling parking brake • Prior to installing, immerse the friction plate (115) in hydraulic oil. 1) Incline the workbench by 90 degrees. 2) Insert the mating plate (169) into the groove outside of the cylinder block (104), and then install two friction plates (115) and two mating plates (116) 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) Incline the travel motor by 90 degrees. 5) Install the piston (112) into the spindle (2).

Fig. 1-96 Installing friction plate (115)

• 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. • Take care not to damage the O-rings when installing the piston (112).

(13) Reassembling brake valve parts inside rear flange 1) Fit two O-rings (237) to two plugs (226). • Coat the O-rings (237) with grease.

Fig. 1-97 Installing mating plate (116)

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). • 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 center of tapped hole with the plug center. 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 a hexagonal wrench key.

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Fig. 1-98 Inserting plug (226)

Fig. 1-99 Temporarily tightening plug (226)

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 center 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. 1-100 Inserting spool (223)

6) Install the O-ring (236) to the plug (224). 7) Install the spring retainer (225) and spring (228) into the plug (224). 8) Screw two plugs (224) into the rear flange (201). 9) Temporarily tighten two plugs (224) to the rear flange (201) with a wrench.

(14) Reassembling rear flange fittings Installing two-speed switching spool inside rear flange 1) Insert the spring (266) and the spool (263) into the rear flange (201).

Fig. 1-101 Temporarily tightening plug (224)

2) Fix the O-ring (273) to the plug (221). 3) Screw the plug (221) into the rear flange (201). 4) Tighten the plug (221) in the rear flange (201) at the specified torque with a hexagonal wrench key. Tightening torque : 3 ± 0.5 kgf•m (22 ± 4 lbf•ft)

Fig. 1-102 Installing bearing (150)

5) Coat the ball bearing (150) with hydraulic oil and fit it to the rear flange (201). 6) Put two the parallel pins (241) into the pin holes in the rear flange (201).

Fig. 1-103 Installing parallel pin (241)

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7) Apply grease to the interface of the timing plate (109) in contact with the rear flange (201). 8) Install the timing plate (109) into the rear flange (201), using the parallel pin (241) as a guide. â&#x20AC;˘ 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 (201) is installed into the spindle (2). 9) Install eight springs (113) into the rear flange (201).

Fig. 1-104 Instaling timing plate (109)

â&#x20AC;˘ Sufficiently coat the springs (113) with grease and fix them so as not to allow them to drop from the rear flange (201).

(15) Connecting rear flange with the spindle 1) Insert the O-rings (26) and (28) into the O-ring groove of the spindle (2).

Fig. 1-105 Installing O-rings (26) and (28)

â&#x20AC;˘ Fit the O-rings (26) without applying grease. Otherwise grease may seep out of the contact face between the rear flange (201) and the spindle (2) as if oil leakage occurred. 2) Fix two the parallel pins (42) to the spindle (2). 3) Fill 0.3

(0.08 gal) of hydraulic oil into the spindle

(2). 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. 1-106 Installing parallel pin (42)

Fig. 1-107 Installing rear flange (201)

34-II-1-38

5) Screw six hexagonal bolts (243) into the spindle (2) and tighten them at the specified torque. Tightening torque: 3 ± 0.5 kgf•m (22 ± 4 lbf•ft) 6) Tighten the plug (224) at the specified torque. Tightening torque: 20 ± 1.5 kgf•m (145 ± 11 lbf•ft) 7) Tighten the plug (226) at the specified torque. Tightening torque: 8 ± 1.0 kgf•m (58 ± 7 lbf•ft)

Fig. 1-108 Tightening plug (224)

(16) Installing input gear 1) Turn over the travel motor. 2) Install the input gear (6) to the drive shaft (102). • Install the input gear (6) to the drive shaft (102) by matching the teeth of two spur gears (7). When gear is not engaged, check it for possible errors. 3) Install the snap ring (24) into the snap ring groove of the drive shaft (102).

Fig. 1-109 Installing input gear (16) (17) Reassembling cover 1) Fill 0.75 (0.20 gal) of lubricating oil into the hub (1). 2) Insert the O-ring (29) into the O-ring groove of cover (8). 3) Install the cover (8) onto the hub (1). • Align the match marks on the cover (8) and the hub (1) for installing them in place as previously. • Install the cover (8) onto the hub (1), tapping the outer circumference of the cover (8) with a plastic hammer. Be careful not to install the cover forcibly by striking. Otherwise the O-ring is damaged resulting in oil leakage.

Fig. 1-110 Installing ring (18)

4) Fit the ring (18) to the ring groove of the hub (1). 5) Install the O-ring (37) to the plug (33). 6) Screw the plug (33) into the cover (8) and tighten it to the specified torque. Tightening torque: 6 ± 1.0 kgf•m (43 ± 7 lbf•ft) Fig. 1-111 Installing plug (33)

34-II-1-39

(18) Removing travel motor 1) Remove the fixing bolts for the travel motor from the workbench. 2) Securely screw two lifting eyes into the tapped holes of the spindle (2). 3) Attach a wire with hooks to the lifting eyes, lift the travel motor up by a crane and remove it from the workbench. Fig. 1-112 Removing travel motor Torque wrench (19) Preload adjustment of ball bearing • To ensure proper service life of the ball bearing (21), apply the specified preload to the ball bearing. Therefore, when any the part affecting the preload is replaced, make sure to temporarily assemble according to the following procedure and check the preload. Otherwise, the hydraulic motor may malfunction to reduce its service life. • Parts affecting the preload Hub (1), spindle (2), hold flange (3), and ball bearing (21) • When nothing is replaced, omit this procedure and go to the step 2) of Section (4) shown in Page 34-II-1-32. • The procedure for preload check and adjustment is as follows:

Procedure for preload adjustment of ball bearing 1) Attach the preload adjusting jig for main bearing to the spindle (2), tighten the special nut and press the ball bearing (21) into the hub (1). Specified tightening torque for special nut: 3 kgf•m (22 lbf•ft)

Clearance measuring jig

Fig. 1-113 Installing bearing preload adjusting jig

Fig. 1-114 Measuring depth A Depth micrometer

2) Determine the depth “A” through the measuring hole of the preload adjusting jig for main bearing using a depth micrometer. 3) Since the dimension “B” of the preload adjusting jig is known, determine the clearance “C” by the following formula: A: Actual value “C”=”A” - ”B” B: Jig body dimension C: Specified dimension

Hub

Preload adjusting jig for main bearing

Spindle

Fig. 1-115 Adjusting preload to main bearing

34-II-1-40

4) Then determine the dimension “D” of the hold flange (3). 5) After measurement steps 2) through 4), adjust the hold flange (3) as follows:

Hold flange

I. When the actual dimension “D” of the hold flange (3) is smaller than the specified dimension by 0.02 mm (0.08 ”) or more: Cut away the face “E” of the hold flange (3) to the specified dimension by lathe etc. II. When the actual dimension “D” of the hold flange (3) falls within the tolerance of the specified dimension “C” [ ± 0.02 mm ( ± 0.008”)]. Use the hold flange as it is. III. When the actual dimension “D” of the hold flange (3) is larger than the specified dimension by 0.02 mm (0.08”) or more; Replace the hold flange with a new spindle assembly. The new hold flange has an adjusting allowance without exception. • Since the hold flange and the spindle are drilled simultaneously, they shall be treated as a unit. Therefore they cannot be replaced separately. Replace the hold flange as a unit together with the spindle. This unit is referred to as the spindle assembly. 6) Remove the preload adjusting jig for main bearing from the spindle (2). 7) On completion of adjusting the hold flange according to Sections I, II, or III, go to the step 2) of Section (4) shown in page 34-II-1-32.

34-II-1-41

Fig. 1-116 Adjusting hold flange (3)

(20) Procedure for adjusting the axial clearance of the tapered roller bearing • When any of the following parts has been replaced, it is necessary to adjust the axial clearance of the tapered roller bearing (22) to the specified value by adjusting the thickness of the snap ring (20). Otherwise, the hydraulic motor may malfunction to reduce its service life.

[

Parts affecting the clearance : Spindle (2), hold flange (3), crank shaft (9), spacer (12) and tapered roller bearing (22)

]

• When any of the above parts are not replaced, it is not necessary to adjust the snap ring thickness. Directly proceed to the regular assembly step according to Section (6) shown in page II1-33. • The procedure for adjusting axial clearance is as follows: (1) Adjustment procedure 1) Lightly tap the outer race of the tapered roller bearing (22) installed to the crank shaft (9) using a hammer and the retainer metal (IV). • This is intended to put the RV gear assy into the spindle (2) securely. Fig. 1-117 Checking RV gear installation 2) Insert the thinnest snap ring (20) into the snap ring groove of the hold flange (3).

Retainer metal (IV)

3) Lightly tap the outer periphery of the snap ring (20) using a hammer and the retainer metal (IV). • Ensure that the gear assembly has been securely installed in the spindle (2). RV gear assy 4) Insert a thickness gauge between the snap ring (20) and the tapered roller bearing (22) to measure the clearance. 5) Measuring thickness of snap rings • Set thickness of the snap ring (max.) MAX=

Thicness of thickness gauge

Fig. 1-118 Checking RV gear parts installation

Thicness of snap ring presently installed

Set thickness of the snap ring (min.) MIN=

Thicness of thickness gauge

Thicness of snap ring presently installed

0.05 mm (0.002”)

6) When the snap ring thickness has been determined, select a snap ring from twelve kinds of ones (refer to Item (2) in page 34-II-1-43) to install it in the hold flange. 7) Install the snap ring satisfying the set thickness and then proceed to the step 2) of Section (6) shown in page 34-II-1-33.

Thickness gauge

Fig. 1-119 Measuring clearance between snap ring (20) and bearing (22)

34-II-1-42

(2) Table for clearance adjusting parts

Dimensions

Part name Snap ring (20)

Ă¸54.2 (2.13â&#x20AC;?)

Class

Marking stamp (Classification symbol)

Dimension

t mm(in)

Over 1.90 to 1.95 (0.075 to 0.077) incl.

Over 1.95 to 2.00 (0.077 to 0.079) incl.

Over 2.00 to 2.05 (0.079 to 0.081) incl.

Over 2.05 to 2.10 (0.081 to 0.083) incl.

Over 2.10 to 2.15 (0.083 to 0.085) incl.

Over 2.15 to 2.20 (0.085 to 0.087) incl.

Over 2.20 to 2.25 (0.087 to 0.089) incl.

Over 2.25 to 2.30 (0.089 to 0.091) incl.

Over 2.30 to 2.35 (0.091 to 0.093) incl.

Over 2.35 to 2.40 (0.093 to 0.094) incl.

Over 2.40 to 2.45 (0.094 to 0.096) incl.

Over 2.45 to 2.50 (0.096 to 0.098) incl.

34-II-1-43

1.5 MAINTENANCE STANDARDS 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.

Parts name

Trouble

(2) (3) (19) (35)

Spindle kit Spindle Hold flange Reamer bolt Bolt

(4)

RV gear assy RV gear

(9)

Crank shaft

(12) (22) (23)

Spacer Tapered roller bearing Needle roller bearing

(20)

Snap ring

• The end face of the circumference is abnormally worn.

(21)

Ball bearing

• Dent is found. • Flaking is found. • Uneven wear is found.

(201)

Rear flange kit Rear flange

(223)

Spool

Standard value Allowable value (Standard (Criteria) dimension)

• Severely damaged visually • Abnormal wear such as galling

• RV gear tooth surface shows uneven wear. • Crank shaft-related parts do not move smoothly when crank shaft (9) is turned.

• Portion in contact with the spool (223) is scratched. • Clearance with the spool is large. • Surface contacting with valve (227) is scratched. • Depth to the contact surface with valve (227) is large. • Outer circumference is damaged. • Outer circumference is worn unevenly.

34-II-1-44

Diametric Diametric clearance 7 ~ clearance 33 13 µ (0.0003 µ (0.0013”) ~ 0.0005”)

Parts name

Item No.

Trouble

(102)

Drive shaft

• Contact shaft with oil seal (132) is worn. • Spline is worn.

(104)

Cylinder block

• Spline is worn. • Bore surface is heavily worn. • Sliding surface with timing plate (109) is damaged or worn unevenly.

(105)

Piston assembly Piston

(106)

Shoe

(107)

Retainer plate

• The end face of the circumference is worn unevenly.

(108)

Thrust ball

• Spherical slideng portion with retainer plate (107) is worn unevenly.

(109)

Timing plate

• Sliding surface is seized or worn unevenly.

(115) (116)

Friction plate Mating plate

• Both end faces are worn unevenly. • Specified torque cannot be achieved. • Seizure is seen.

• Clearance is found in the axial direction between piston (105) and shoe (106). • Shoe is worn abnormally. • Shoe is worn unevenly.

(227)

Valve

• Seat surface is damaged.

(149) (150)

Bearing Bearing

• Dent is present. • Flaking is seen. • Uneven wear is present.

(263)

Spool

• Outer circumference is damaged.

34-II-1-45

Standard value Allowable value (Standard (Criteria) dimension)

Clearance 0.05 mm (0.002 ”)

Braking torque 6.6 kgf•m (48 lbf•ft)

Clearance 0.15 mm (0.006 ”)

Braking torque 6.6 kgf•m (48 lbf•ft)

NOTES

Book Code No.

PW42 02E ➀

NEW HOLLAND EH35 Model Cross-reference: SK35SR-2 is NEW HOLLAND Model EH35

TROUBLESHOOTING (HYDRAULIC SYSTEM) TABLE OF CONTENTS 1. GENERAL PRECAUTIONS .................................................................. 1-1 2. TROUBLE DIAGNOSIS: HYDRAULIC .................................................. 1-2 3. TROUBLESHOOTING 1-(1) Attachment operational failure ................................................ 1-3 1-(2) Attachment speed is slow ....................................................... 1-3 1-(3) Attachment operating power is low ......................................... 1-3 1-(4) Malfunction of attachment ....................................................... 1-4 2-(1) Travel operation error ............................................................. 1-5 2-(2) Travel speed is slow ............................................................... 1-5 2-(3) Travel operating power is low ................................................. 1-6 2-(4) It deviates in travel independent operation ............................. 1-6 3-(1) Slewing error .......................................................................... 1-7 3-(2) Slewing speed is slow ............................................................. 1-7 3-(3) Slewing operating power is low .............................................. 1-7 3-(4) Slewing operational failure ...................................................... 1-8 4-(1) The engine speed lowers ........................................................ 1-8 4-(2) Malfunction of pump ............................................................... 1-8

PW42

42 -0-1 ➀

Revision First edition -----Second revision

Date of Issue January, 2001 December, 2002

Remarks S5PW4202E A S5PW4202E ➀ A

Any use of editorial or pictorial content is strictly prohibited without express written permission from New Holland Construction, LLC. Carol Stream, IL 60188 U.S.A. Copyright © 2003 New Holland Construction, LLC. All Rights Reserved.

42-0-2 ➀

1. GENERAL PRECAUTIONS Troubleshooting provides the process to investigate the cause of trouble in order when a trouble occurred. This manual describes the way how to solve the specific phenomenon systematically as quick as possible. For the troubleshooting concerning the inside of equipment, refer to the troubleshooting for each manual of the equipment. 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. (2) 1) 2)

3) 4) 5)

(3) 1) 2) 3) 4) 5)

(4) 1)

Verify background of trouble occurred. Model name and serial number. Kind of attachment. Check that the combination of attachments was proper and that the operating manner was not unreasonable. Operating time on the hour-meter. Record of troubles. First trouble or repeated trouble. History of the trouble and additional modifications. Reoccurrence of the same trouble in the past or trouble due to additional modification. How to diagnose trouble Verify defective part. Reproduce the troubled conditions. Where the defective part can not be verified, surmise the possible causes systematically. Verify the surmised cause. Report estimated repairing method, procedures and term to the user. Explanation of the cause of trouble 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 reoccurrence of the same kind of trouble. 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 -1-1

Make field investigation.

Verifying background of trouble occurred.

Diagnosing trouble by means troubleshooting.

2. TROUBLE DIAGNOSIS: HYDRAULIC

Attachment

Attachment operational failure (excluding swing and dozer operation)

(2) Travel speed is slow. 1 (3)

Attachment operating power is low.

Pump

Swing operation

Travel operation

(4) Malfunction of attachment (1) Travel operational failure (2) Travel speed is slow. 2 (3) Travel operating power is low. (4) It deviates in travel independent operation. (1) Slewing operational failure (2) Slewing speed is slow. 3

(3) Slewing operating power is low. (4) Malfunction of slewing operation (1) Engine speed is reduced due to pump load. 4 (2) Malfunction of pump

Abbreviation E/G SOL SW ATT C/V R/V V

: : : : : : :

Engine Solenoid Switch Attachment Control valve Relief valve Valve

42 -1-2

Hydraulic cylinder

Travel motor unit

Slewing motor unit

Shuttle valve

Check valve

Actuator

Attachiment spool

Travel spool

Travel straight valve

Each over load R/V

Main gear pump R/V

Travel & ATT main R/V

Valve

Gear pump

Trochoid pump

Reference No.

Classification

Phenomenon (1)

Pump

Main pump

Causes

3. TROUBLESHOOTING

Attachment operational failure (excluding swing and dozer operations)

1— (1) Boom, arm and bucket can be operated.

YES

Any of them can not YES be operated. Lever lock SOL or lever lock S/W is failed.

Spool stick of C/V exists.

Check C/V spool for possible failure. Check lever lock SOL or lever lock S/W for possible failure. (To Troubleshooting for Electric system)

Attachment operating speed is slow.

1— (2) Is each operating speed of boom, arm and bucket within the respective reference?

Is the number of travel sprocket rotations within the reference value?

YES

Failure of cylinder

YES

Failure of pump

Does C/V spool which NO is not within the reference value function?

Failure of C/V spool

YES

Set cylinder to stroke end,disconnect hose on the return side,apply pressure,and check that leaking inside of piston is within the reference value.

Failure of cylinder

Attachment operating power is low.

1— (3) Is main relief pressure NO within reference value ?

Failure of main relief V

YES

Is over load relief pressure NO within reference value?

Failure of over load relief V

YES

Set cylinder to stroke end,disconnect hose on NO the return side, apply pressure,and check that leaking inside of piston is within reference value.

Failure of cylinder or failure of cylinder side V

42 -1-3

Attachment operational failure

1â&#x20AC;&#x201D; (4) Natural drop of YES attachment is large.

Is oil tightness of YES Is leaking inside of each cylinder is within cylinder within reference value? reference value?

YES

Failure of C/V spool Failure of lock valve

Boom, arm and bucket operating YES power is low, therefore travel deviate occurs at the time when the speed becomes slow. Any of attachments can not be operated in combination, or travel is possible, but boom, arm and bucket don t move.

Failure of cylinder or failure of cylinder side V

Travel straight valve does not return.

YES

Travel straight valve does not switch.

Failure of swing cylinder

Operational failure

YES

Does swing spool in C/V move?

Adjust wire.

YES

Disconnect hose between C/V and swing cylinder on the C/V side, and check the delivery pressure. YES

Impossible to maintain

Failure of C/V swing spool. Failure of swing cylinder Check the check valve in C/V for dust, etc.

YES

42 -1-4

Travel operational error

2 â&#x20AC;&#x201D; (1) Is travel pilot pressure normal?

Is pilot pressure pump delivery pressure is Approx. 3.5kgf/cm2(50psi) or over.

YES

Does travel spool move?

Failure of pilot pump

Failure of travel pilot V

Failure of C/V travel spool

YES

Is much wear dust accumulated YES on hydraulic oil return filter?

Failure of travel motor

Is much wear dust contami- YES nated in lubricating oil for travel reduction unit?

Failure of travel reduction unit

Travel speed is slow.

2 â&#x20AC;&#x201D; (2) Is travel sprocket speed YES within reference value?

Travel sprocket speed YES Is much wear dust accumulated on hydchanges in 1&2 speed. raulic oil return filter? NO

Failure of travel motor

YES

Failure of travel reduction unit

Does 2-speed cahnge spool of travel motor move? NO

YES

Is much wear dust contaminated in hydraulic oil for travel reduction unit?

YES

Failure of travel motor spool

Is travel motor drain within reference value?

Failure of travel motor

Check on travel 2 speed SOL.V. (To troubleshooting for Electric System)

Is ATT operating speed YES Is travel pilot other than travel speed pressure normal? within reference value?

YES

Does C/V spool move?

Failure of C/V travel spool

Is E/G speed within reference value?

YES

Failure of pump

E/G speed error

YES

Adjust accel wire.

42 -1-5

Adjust E/G speed.

Travel power is low.

2â&#x20AC;&#x201D; (3) Is the power of boom, arm and bucket normal?

Is main relief pressure normal?

Failure of main relief V

YES

Does travel sprocket speed change in 1 & 2 speed?

Is much wear dust accumulated YES Failure of travel motor on hydraulic oil return filter?

YES

Does 2-speed cahnge spool of travel motor move?

YES NO

Failure of travel motor spool Does monitor indicate 2-speed by switching travel 2-speed SW on?

Is much wear dust contami- YES Failure of travel nated in hydraulic oil for reduction unit travel reduction unit? Failure of 2-speed S/W or failure of cluster

YES

To Troubleshooting for Electric System

Deviated in travel independent operation.

2â&#x20AC;&#x201D; (4) There is a big difference between right and left sprocket speeds at travel idling.

Is tension of shoe within reference value?

YES

Adjust shoe tension. It may be caused by deflection of construction like lower frame, etc.

YES

Is it free from bent of hose of YES travel line and oil leakage?

Replace hose.

Is travel spool full stroked?

Is travel pilot normal?

YES

Check on travel pilot V or replace it. Check on C/V travel spool or replace it.

YES

Does the flow change in YES reverse by changing the connection of pump delivery hose?

Check on pump or replace it.

Does the deviation change in YES reverse by changing the connection of right and left hoses between C/V and travel motor?

There is flaw on the outer surface of the travel spool. NO

Is much wear dust accumulated on hydraulic oil return filter?

YES

Replace travel spool assy. Replace C/V. Check on travel motor or travel reduction unit, or replace it.

YES

Is travel motor drain within reference value?

YES

Replace travel spool assy. Check on travel motor or travel reduction unit, or replace it.

42 -1-6

Malfunction of slewing operation

3— (1) Can arm operation be operated?

Adjust lever lock SOL or lever lock SW. (To Troubleshooting for Electric System)

YES

Does slewing spool for C/V move?

Failure of C/V slewing spool

YES

Is much wear dust accumulated on hydraulic oil return filter?

YES

Failure of slewing motor when it is gun metal Failure of slewing reduction unit when it is iron powder

Slewing speed is slow.

3— (2) Is slewing speed within reference value at no load?

YES

Is slewing relief pressure within reference value?

Failure of slewing relief V

YES

Is slewing motor drain within reference value?

Is dozer operating speed within reference value?

YES

Failure of slewing motor

Failure of C/V slewing spool

Is engine speed within reference value?

YES

Failure of gear pump

Improper E/G speed

Slewing power is low.

3— (3) It is difficult to operate 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.

Is gear pump main relief pressure within reference value?

Improper gear pump main relief pressure

YES

Is slewing relief pressure within reference value?

Failure of slewing relief V

YES

Is much wear dust accumulated on hydraulic oil return filter?

YES

Failure of slewing motor when it is gun metal Failure of slewing reduction unit when it is iron powder

42 -1-7

Slewing operational failure

3 — (4) It is impossible to stop slewing operation at slope.

YES

Is slewing parking brake power within reference value?

Slewing drift after slewing inertia exerted on it is large.

YES

Is slewing brake power within reference value?

Parking brake spring force in slewing motor, or friction plate failure for parking brake

NO NO

Is swing relief pressure within reference value?

Failure of slewing relief V

Engine speed lowers.

4 — (1) E/G speed lowers by operating slewing, boom and arm operations simultaneously, or dozer, travel and boom operations simultaneously.

YES

Is E/G speed lowered and finally is it stopped?

YES

Malfunction of control unit of pump

Pump operational failure

4 — (2) Oil leaks between E/G and pump installing flange.

YES

Is coupling worn severely?

Replace coupling and seal for pump shaft

YES

Is pump internal pressure within reference value?

Is return filter allowable?

Replace return filter

YES

Does hydraulic oil in tank satisfy NAS 9 class?

Replace seal for pump shaft. Noise from pump

YES

Flush hydraulic oil, or replace return filter.

Has the hydraulic oil YES YES Shortage of hydraulic oil Make up hydraulic oil. in hydraulic tank become cloudy white? NO NO

Is much wear dust on return filter in hydraulic tank?

YES

Check air intake through piping on the suction side. Replace parts inside of pump. Check coupling for severe wear. (Refer to Article before mentioned.)

42 -1-8

Book Code No.

PW43 02E ➀

NEW HOLLAND EH35 Model Cross-reference: SK35SR-2 is NEW HOLLAND Model EH35

TROUBLESHOOTING (ELECTRICAL SYSTEM) TABLE OF CONTENTS 1. TROUBLE DIAGNOSIS ................. ...................... ................................ . 1-1 2. TROUBLESHOOTING 1-(1) Engine does not start ............................................................... 1-2 1-(2) Horn does not sound ............................................................... 1-4 1-(3) Working light does not light up ................................................. 1-4 1-(4) Hourmeter does not actuate .................................................... 1-5 1-(5) Fuel gauge does not actuate ................................................... 1-5 1-(6) Water temperature does not actuate ....................................... 1-5 2-(1) All control can not be carried out ............................................. 1-6 3-(1) Travel 1, 2 speed change can not be carried out ..................... 1-7 4-(1) Deceleration switching (OPT) can not be carried out .............. 1-8

PW43

43 -0-1 ➀

Revision First edition -----Second revision

Date of Issue January, 2001 December, 2002

Remarks S5PW4302E A S5PW4302E ➀ A

Any use of editorial or pictorial content is strictly prohibited without express written permission from New Holland Construction, LLC. Carol Stream, IL 60188 U.S.A. Copyright © 2003 New Holland Construction, LLC. All Rights Reserved.

43-0-2 ➀

Classification

Reference No.

Causes

Phenomenon

Gauge cluster Generator Working light Deceleration motor Horn Coolant temp.sensor Fuell level sensor Ttavel 1,2 speed SOL Lever lock SOL Engine stop SOL Horn switch Working light switch Travel 1,2 speed switch Lever lock limit switch Deceleration switch Engine stop SOL relay Charging indicator relay Safety relay Timer unit Holding ciruit unit Fuse,Disconnection,Short circuit,Looseness Others

1. TROUBLE DIAGNOSIS : ELECTRIC SYSTEM Electrical equipment

Sensor Solenoid

(1) Engine does not start. (2) Horn does not sound.

General

Working light does not (3) 1

light up. Hourmeter does not

(4)

actuate. Fuel gauge does not

(5)

actuate. Water temperature

Deceleration

Travel Attachment operation operation

(6)

does not actuate. All controls does not

(1) function. (Excluding swing

and dozer operations) 3

(1)

Travel 1 & 2 speed can not be changed. Deceleration switching can not be carried out.

Abbreviation Decel : Deceleration SOL : Solenoid

43 -1-1

Switch

Relay

2. TROUBLESHOOTING

Engine does not start.

1â&#x20AC;&#x201D; (1) Starter does not rotate. Check voltage of battery.

Check battery fluid and specific gravity.

Charge battery, or replace it.

Check on starter motor IN side.

Voltage of B terminal of NO starter motor(M-1) is 12V.

Replace starter cable.

Voltage of B terminal of key switch is 12V.

Replace fusible link 45A.

Voltage of C terminal of key switch is 12V. OK

Replace key switch.

(Hereafter when key is in start position.)

Check on safety relay IN side. OK

Check on safety relay OUT side. OK

Check on starter motor IN side.

Voltage of black-white NO harness(C terminal) at connector(CN-7F) of safety relay(R-2) is 12V.

Check on harness.

Voltage of white-red NO Malfunction of safety OK Replace safety relay. harness(S terminal) at relay connector(CN-7F) of NO safety relay(R-2) is 12 V. Check on generator. Voltage of S terminal NO Disconnection of harness between of starter motor(M-1) safety relay(R-2) is 12V. and starter motor

Check on harness.

Replace starter motor.

43 -1-2

Starter functions, but engine does not start. (When key is ON position) Voltage between green-red YES Failure of engine stop and black harness of connecsolenoid valve (SV-3) tor (CN-303) of engine stop solenoid valve (SV-3) is 12V when key is ON position. Voltage between yellowYES Disconnection of harness NO green and red-white harbetween engine stop ness of connector (CN-9F) relays and engine stop of engine stop relay (R-7) solenoid valve (SV-3). is 12V for 1 second after keying on. NO Failure of timer unit(R-6) Voltage of white-black line of connector (CN22F) of timer unit (R-6) is 12V.

YES

Voltage between white and black harness of connector YES (CN-303) of engine stop solenoid valve (SV-3) is 12V. NO

Voltage of white harness YES of fuse box is 12V.

Replace engine stop solenoid valve.

Check on harness.

Replace timer unit.

Disconnection of harness between engine stop relay (R-7) and timer unit (R-6)

Check on harness.

Disconnection of harness between timer unit (R-6) and fuse box

Check on harness.

Engine stop solenoid (SV-3) error

Replace engine stop solenoid valve.

Disconnection of harness between engine stop solenoid valve (SV-3) and fuse box

Check on harness.

No.2 fuse box is blown.

YES

Harness is shortcircuited to frame.

Check that harness in fuse box are free from disconnection.

Voltage of key switch ACC is 12V.

Check harness placed on the short-circuited section.

YES

Harness is disconnected between key switch and fuse box.

Check on harness.

Check on switch.

43 -1-3

Horn does not sound.

1â&#x20AC;&#x201D; (2) When horn switch is pressed, Voltage between pink-black and black harness is 12V.

YES

Failure of horn

Replace horn.

Voltage of red-green harness of horn switch (SW-7) is 12V.

YES

Voltage between red-green harness of fuse box is 12V.

Disconnection of harness between horn (E-3) and horn switch (SW-7) Failure of horn switch (SW-7)

YES

Disconnection of harness between horn switch (SW-7) and fuse box

YES

Harness is short-circuited to frame.

Check on harness.

Replace horn switch. Check on harness.

No.4 fuse is blown.

Check harness on shortcircuited section. Check that line in fuse box is free from disconnection. Check diode (D-1) for short circuiting.

Working light does not light up.

1â&#x20AC;&#x201D; (3) When key is switched ON, Voltage between light green -red and black harness of working light (L-2) is 12V.

YES

Working light error

Replace working light.

Disconnection of harness between working light switch (SW-2) and working light (L-2)

Check on harness.

Voltage between yellow and green harness of working light switch (SW-2) is 12V.

YES

Failure of working light switch (SW-2)

Voltage of yellow-green harness of fuse box is 12V.

Replace working light switch.

YES

Disconnection of harness between working light switch (SW-2) and fuse box

Check on harness.

YES

Harness is short-circuited to frame.

Check harness on the shortcircuited section.

No.3 fuse is blown.

Check that line in the fuse box is free from disconnection.

43 -1-4

Hourmeter does not actuate.

1— (4) While engine is starting, Voltage between whiteVoltage of pink line of green and black harness YES connector (CN-27F) YES Failure of gauge cluster of connectors (CN-27F) of gauge cluster (E-6) of gauge cluster (E-6) is is 0V. NO Disconnection of har12V. ness between gauge cluster (E-6) and charge NO indicator relay (R-8) Disconnection of harYES Voltage of white-green ness between cluster harness of fuse box is 12V. gauge (E-6) and fuse box

Replace gauge cluster.

Check on harness.

No.6 fuse is blown.

YES Harness is short-

circuited to frame.

Check that harness in fuse box is free from disconnection.

1— (5) Fuel gauge does not actuate.

Check harness on the short-circuited section.

When key is switched ON, Disconnection of harVoltage between whitegreen and black harness YES ness between gauge of connector (CN-27F) cluster (E-6) and level of gauge cluster (E-6) gauge (SE-1) is 12V.

Check on harness.

Disconnection of harVoltage of white-green YES ness between gauge line of fuse box is 12V. cluster (E-6) and fuse box NO

No.6 fuse is blown.

YES Harness is short-

circuited to frame.

Check that harness in fuse box is free from disconnection.

1— (6) Water temperature meter does not actuate.

Check harness placed on shortcircuited section.

When key is switched ON, Voltage between white- YES Disconnection of harness between gauge green and black harness cluster (E-6) and water of connector (CN-27F) temperature sensor of gauge cluster (E-6) (SE-2) is 12V.

Check on harness.

Disconnection of harVoltage of white-green YES ness between gauge harness of fuse box is 12V. cluster (E-6) and fuse box NO

No.6 fuse is blown.

YES Harness is short-

circuited to frame.

43 -1-5

Check harness placed on the short -circuited section. Check that harness in fuse box is free from disconnection.

All controls do not function,

2â&#x20AC;&#x201D; (1) When key is switched ON, When lever stand was lowered, Voltage between green-white YES and black harness of connector (CN-108F) of lock lever solenoid valve(SV-1) is 12V.

Check on lock lever solenoid. (To Troubleshooting for Hydraulic System)

Voltage of pink-blue harness of plug (F-2) of the left lock lever switch (SW-9) is 12V.

YES

Disconnection of harness between lock lever switch (SW-8) and lock lever solenoid valve(SV-1)

Check on harness.

Failure of lock lever switch (SW-9)

Replace lock lever switch(SW-9).

Failure of lock lever switch (SW-8)

Replace lock lever switch(SW-8).

Disconnection of harness between fuse box and lock lever switch (SW-8)

Check on harness.

Harness is short-circuited to frame.

Check harness on the shortcircuited section.

NO YES

Voltage of yellow-black harness of plug (F-1) of the right lock lever switch (SW-8) is 12V. NO

Voltage of yellow harness of fuse box is 12V.

YES

No.2 fuse is blown.

YES

Check that line in fuse box is free from disconnection.

43 -1-6

Travel 1 & 2 speed change can not be carried out.

3â&#x20AC;&#x201D; (1) (regardless of 1,2 speed mode)

When key is switched ON, Voltage of yellow-black harness of connector (CN-109F) of travel 2-speed solenoid valve (SV-2) is 12V.

Disconnection of harness between fuse box and travel 1&2speed solenoid valve (SV-2)

Check on harness.

Disconnection of harness between fuse box and holding circuit unit(E-14)

Check on harness.

Harness is short-circuited to frame.

Check harness on the shortcircuited section.

YES

Voltage of white-green harness of connector (CN-1F) of holding circuit unit (E-14) is 12V. YES

No.6 fuse is blown.

Check that line in fuse box is free from disconnection.

After selector switch was switched ON, Voltage of light green harness YES of connector (CN-109F) of travel 1&2-speed solenoid valve (SV-2) is 0V.

Check on travel 1&2-speed solenoid valve. (To Troubleshooting for Hydraulic System)

Voltage of light green line of YES Disconnection of harness betconnector (CN-1F) of holding ween travel 1&2-speed solenoid circuit unit (E-14) is 0V. valve and holding circuit unit

Check on harness.

Voltage of white-black harness of connector (CN-1F) of holding circuit unit (E-14) when travel 1&2-speed selector switch is pressed.

Check on harness of travel 1&2-speed switch, and between travel 1&2-speed switch and holding circuit unit.

YES

Check on holding circuit unit

43 -1-7

Decel change operation in option can not be carried out.

4â&#x20AC;&#x201D; (1) When key is switched ON, Voltage of yellow-green harness of connector (CN-113F) of decel motor (M-4) is 12V.

Disconnection of harness between fuse box (E-1) and decel motor (M-4) No.3 fuse is blown.

Check on harness.

Check on harness on the short-circuited section.

YES

Check that harness in fuse box is free from disconnection Voltage of yellow-black line of connector (CN-6F) of decel relay (R-3) is 12V.

YES

Disconnection of harness between fuse box (E-1) and decel relay (R-3)

Check on harness on the short-circuited section. Check that line in fuse box is free from disconnection.

YES

When decel operation is off, Voltage between blue-white and green-yellow harness of connector (CN-113F) of decel motor (M-4) is 0V. YES When decel operation is on, Voltage between black-yellow and green yellow harness of connector (CN-113F) of decel motor (M-4) is 0V.

Failure of decel motor (M-4)

Adjust decel motor.

Disconnection of harness between decel motor (M-4) and decel relay (R-3)

Adjust harness.

Failure of decel relay (R-3)

Replace decel relay.

Failure of holding circuit unit

Replace holding circuit unit.

Failure of decel switch (SW-11)

Check on decel switch.

Disconnection of harness between decel switch (SW-11) and holding circuit unit (E-14)

Check on harness.

When decel operation is on, Voltage of blue-black harness of connector (CN-6F) of decel relay (R-3) is 0V.

YES

When decel switch (SW-11) is pressed, Voltage of black-white harness YES of connector (CN-1F) of holding circuit unit (E-14) is 0V.

43 -1-8

Book Code No.

PW44 02E ➀

NEW HOLLAND EH35 Model Cross-reference: SK35SR-2 is NEW HOLLAND Model EH35

TROUBLESHOOTING (ENGINE) TABLE OF CONTENTS 1. TROUBLE DIAGNOSIS: ENGINE ........................................................... I-1 2. TROUBLESHOOTING 1-(1) Starter not rotate ....................................................................... I-3 1-(2) Starter rotates but hard to start ................................................. I-4 2-(1) Idling trouble ............................................................................. I-5 2-(2) Medium speed trouble .............................................................. I-5 2-(3) High speed trouble ................................................................... I-5 3-(1) Engine output not enough ......................................................... I-6 3-(2) Knocking at high temperature ................................................... I-6 4-(1) Exhaust trouble ......................................................................... I-7 4-(2) Excessive oil consumption ........................................................ I-7 4-(3) Excessive fuel consumption ..................................................... I-7 4-(4) Engine not stop when key turned OFF ..................................... I-8

PW44

44 -0-1 ➀

Revision First edition -----Second revision

Date of Issue January, 2001 December, 2002

Remarks S5PW4402E A S5PW4402E ➀ A

Any use of editorial or pictorial content is strictly prohibited without express written permission from New Holland Construction, LLC. Carol Stream, IL 60188 U.S.A. Copyright © 2003 New Holland Construction, LLC. All Rights Reserved.

44-0-2 ➀

Starting

trouble

Rotation

trouble

drops

Other

trouble Trouble

Output

down

4 (1) Starter not rotate

(2) Starter rotates but hard to start

(1) Idling not smooth

(2) Medium speed hunting

(3)

(1)

(2)

(1)

(2) Excessive oil consumption

(3) Excessive fuel consumption

(4) Engine not stop when key turned OFF

(5) High speed not smooth

Not reach max. speed

Engine output not enough

Overheat

Knocking at high temperature

Large amount of black exhaust gas

White exhaust gas

When key tuned OFF, power supply

disconnected but engine not stop

44-1-1

Flywheel gear damaged

Defective head gasket

Check fuel feed

Internal part seizure

Valve spring fatigue

Piston ring worn

Engine dealer Suction/ Lubrication exhaust Cooling system system

Piston liner worn

Crank shaft oil seal defective

Governor spring fatigue

Control rack movement not smooth

Compression pressure low

Oil cooler element damaged

Check thermostat

Fuel mixed

Check relief valve

Oil gets into comb. chamber through piston / valve guide

Air cleaner and muffler

Electric

Fuel system

Valve spring fatigue

Serviceman

Valve clearance

Electric

Injection pump

Gas/fluid

Check nozzle

Engine

Check injection timing

Mechanism

Feed pump function

Visual check

Generator current limiter

Starter motor

Stop solenoid valve

Glow Plug

Glow relay

Connector and wiring

Safety relay

Starter key

Fuse

Improper battery electrolyte level

Excessive amount of engine oil

Fluid

Gas leakage through valve gasket

Inspection

Large amount of blowby gas

Poor quality fuel or heavy oil used

Improper viscosity or level of engine oil, or leakage

Filters Improper specific gravity of battery electrolyte

Probable Cause/Component

Poor quality fuel or leakage

Coolant level

Breather hose clogged or depressed

Fan belt slip

Fuel filter clogged

Primary fuel filter clogged

Air cleaner clogged

Oil filter clogged

Air or water entered fuel system

No fuel or leakage

Group No.

Classification

1. TROUBLE DIAGNOSIS: ENGINE

Mechanical

This page is blank because of editing convenience.

44-1-2

2. TROUBLESHOOTING

Engine does not start.

1 â&#x20AC;&#x201D; (1) Starter does not rotate. Check voltage of battery.

Check battery fluid and specific gravity.

Charge battery, or replace it.

Check on starter motor IN side.

Voltage of B terminal of NO starter motor(M-1) is 12V.

Replace starter cable.

Voltage of B terminal of key switch is 12V.

Replace fusible link 45A.

Voltage of C terminal of key switch is 12V. OK

Replace key switch.

(Hereafter when key is in start position.)

Check on safety relay IN side. OK

Check on safety relay OUT side. OK

Check on starter motor IN side.

Voltage of black-white NO harness(C terminal) at connector(CN-7F) of safety relay(R-2) is 12V.

Check on harness.

Replace starter motor.

44-1-3

Starter rotates but hard to start

1-(2)

Check starter power OK

Less

Check battery electrolyte level and specific gravity

Charge or replace battely Check compression pressure Valve clearance Valve spring fatigue Piston liner worn Piston ring worn Defective head gasket Flywheel gear damaged Check radiator and thermostat

Check engine itself

Check air suction system OK

Air cleaner clogged Check indicator

Check fuel feed system

Check fuel meter Check water separator Check fuel filter Check fuel quality

Check electrical system

12 V detected for glow plug

YES

Feed pump performance Check injection pump Check injection nozzle Check injection timing

Defective glow plug

Improper ground connection Check engine oil viscosity

Check if engine oil viscosity suitable for ambient temperature

Note: Check with the engine start key being in ON position.

44-1-4

Defective harness between key switch and glow Change engine oil

Idling not smooth

Idling speed too high

Adjust engine speed

Medium speed hunting

Check control rack Check governor spring

2-(2)

Rotation trouble

Medium speed

Idling

2-(1)

Check injection pipe Check injection nozzle Cylinder compression pressure not even Check injection pump Check thermostat

2-(3)

YES

High speed

Check if air mixed in fuel

Release air

Check air suction system

Check if air cleaner clogged

Check fuel feed system OK

Check fuel meter Check water separator Check fuel filter Check fuel quality

Check injection nozzle Check injection pump Check injection timing

Not reach max. speed

Adjust engine speed

Note: Check the above items in the condition of coolant temperature at 50 — 5…C. (122— 9…F)

44-1-5

Engine output not enough

3-(1)

Overheat

Engine coolant temperature lamp lighted NO

Check engine coolant temperature switch Check gauge cluster Check wiring and connector

Check electrical system OK

Check coolant level Check fan belt slip Check radiator clogging Check thermostat

Check cooling system OK

Check fuel quality Check injection timing Check fuel injection valve

Check fuel system OK

Check engine oil system Check air suction system OK Check fuel feed system OK

Check engine oil OK

Check engine mechanical

Air filter clogging Check indicator

Check if air mixed in fuel

Check work condition

Check engine oil filter OK

Check air cleaner filter

Release air

Check water separator Check fuel filter Check fuel quality

Check feed pump performance Check injection pump Check injection nozzle Check injection timing

Check if engine oil viscosity suitable for ambient temperature

Change engine oil

Large amount of blowby gas Gas leakage through gasket Check if engine oil gets into comb. chamber through piston / valve guide

Note: Check in the condition of operating at high speed.

Check compression pressure Check valve clearance Valve spring fatigue Control rack not smooth Piston ring worn Defective head gasket

Knocking at high temperature

3-(2)

Check fuel system

Check fuel quality

Change fuel

Check engine mechanical

Check if engine oil gets into comb. chamber OK

Check oil adhering condition at exhaust port

Large amount of blowby gas Gas leakage through gasket

Check compression pressure Check injection timing Check injection nozzle

Note: Check in the condition at engine coolant temperature of 50 — 5…C. (122— 9…F)

44-1-6

4-(1)

Large amount of black exhaust gas

Check air cleaner

Replace air element

Exhaust trouble

Check engine oil viscosity Check if engine oil too much

Check gas leakage through head gasket

Check injection nozzle Check injection timing Check injection pump Check valve clearance Valve spring fatigue Check piston ring defect

Check if water mixed in fuel

Check water separator

Large amount of white exhaust gas

OK Check if engine oil gets into comb. chamber through piston / valve guide Check compression pressure Large amount of blowby gas Check injection timing Gas leakage through gasket Note: Check in the condition at engine coolant temperature of 50 — 5…C. (122— 9…F)

Excessive oil consumption

4-(2)

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

Check if breather hose depressed or clogged

Replace breather hose

Check fuel quality

Instruct to feed proper fuel

Check engine oil viscosity OK Check if engine oil gets into comb. chamber through piston / valve guide

Instruct to feed proper engine oil Defective crank shaft oil seal Piston liner worn Piston ring worn

Note: Check in the condition of no engine oil leakage.

Excessive fuel consumption

4-(3)

Check fuel leakage

Check fuel quality

Instruct to feed proper fuel

Large amount of blowby gas Check gas leakage through gasket

Check nozzle function OK

Check injection timing

Note: Check in the condition the proper fuel is used.

44-1-7

Check compression pressure

Engine not stop when key turned OFF

4-(4)

Engine stop Engine stop solenoid NO solenoid valve valve (SV-3) normally incorrectly installed energized YES Check resistance of starter key terminal (between terminals B and ACC)

Note: Check with the engine start key being in OFF position.

44-1-8

Correct engine stop solenoid valve installation Resistance 0 detected between terminals B and ACC

YES

Replace key switch

Check harness

Book Code No.

PW51 02E ➀

NEW HOLLAND EH35 Model Cross-reference: SK35SR-2 is NEW HOLLAND Model EH35

ENGINE TABLE OF CONTENTS See the included YANMAR SERVICE MANUAL. This Service Manual explains the engine proper and a faithful reproduction of YANMAR DIESEL ENGINE'S Service Manual for 3TNE82A and others.

ENGINE MODEL

APPLICABLE MACHINES SK30SR-2

3TNE82A-YBD SK35SR-2

PW51

51 -0-1 ➀

Revision First edition -----Second revision

Date of Issue January, 2001 December, 2002

Remarks S5PW5102E A S5PW5102E ➀ A

Any use of editorial or pictorial content is strictly prohibited without express written permission from New Holland Construction, LLC. Carol Stream, IL 60188 U.S.A. Copyright © 2003 New Holland Construction, LLC. All Rights Reserved.

51-0-2 ➀

NOTES

NEW HOLLAND CONSTRUCTION, LLC Part Number 245 E NORTH AVENUE CAROL STREAM, IL 60188 U.S.A

North American English Printed in U.S.A.

6-75740NA Jan 04 Bur