New Holland EH45 Compact Excavator Service Repair Manual (6-75750NA) – New Holland EH45

SERVICE MANUAL EH45 Compact Excavator

CONSTRUCTION 6-75750NA

SERVICE MANUAL

Section 1 SPECIFICATIONS

EH45 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 - 6-75750

Source Code No. S5PJ0002E-01

00 –0–1 ➀

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 © 2003 New Holland Construction, LLC. All Rights Reserved.

00 –0–2 ➀

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

S5PJ0102E-00 Oct 2001

S5PJ0102E-01 Jan 2003

S5PJ0202E-00 Oct 2001

S5PJ0202E-01 Jan 2003

S5PJ0302E-00 Oct 2001

Section

Chapter Title

Chapter Number

Preliminary Remarks

S5PJ0102E

Specifications

S5PJ0202E

S5PJ0302E-01 Jan 2003

Attachment Dimensions

S5PJ0302E

S5PJ1102E-00 Oct 2001

S5PJ1102E-01 Dec 2002

Tools

S5PJ1002E

S5PJ1202E-00 Oct 2001

S5PJ1202E-01 Jan 2003

Standard Maintenance Time Table

S5PJ1202E

S5PJ1302E-00 Oct 2001

S5PJ1302E-01 Jan 2003

Maintenance Standard and Test Procedures

S5PJ1302E

S5PJ2202E-00 Oct 2001

S5PJ2202E-01 Jan 2003

Hydraulic Systems

S5PJ2202E

S5PJ2302E-00 Jan 2001

S5PJ2302E-01 Jan 2003

Electric System

S5PJ2302E

S5PJ2402E-00 Oct 2001

S5PJ2402E-01 Jan 2003

Components System

S5PJ2402E

S5PJ3102E-00 Oct 2001

S5PJ3102E-01 Jan 2003

Disassembling and Assembling

S5PJ3102E

S5PJ3202E-00 Jan 2001

S5PJ3202E-01 Jan 2003

Attachments

S5PJ3202E

S5PJ3302E-00 Oct 2001

S5PJ3302E-01 Jan 2003

Upper Structure

S5PJ3302E

S5PJ3402E-00 Oct 2001

S5PJ3402E-01 Jan 2003

Travel System

S5PJ3402E

S5PJ4202E-00 Oct 2001

S5PJ4202E-01 Jan 2003

Troubleshooting (Hydraulic)

S5PJ4202E

S5PJ4302E-00 Oct 2001

S5PJ4302E-01 Jan 2003

Troubleshooting (Electrical)

S5PJ4302E

S5PJ4402E-00 Oct 2001

S5PJ4402E-01 Jan 2003

Troubleshooting (Engine)

S5PJ4402E

S5PJ5102E-00 Oct 2001

S5PJ5102E-01 Jan 2003

Engine

S5PJ5102E

Section 1 SPECIFICATIONS

Section 2 MAINTENANCE

Section 3 SYSTEM

Section 4 DISASSEMBLY and ASSEMBLY

Section 5 TROUBLESHOOTING

Section 6 ENGINE Section 7 MISCELLANEOUS

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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.

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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 â&#x20AC;&#x201C;1â&#x20AC;&#x201C;4

Book Code No.

PJ01

NEW HOLLAND EH45 Model Cross-reference: SK45SR-2 is NEW HOLLAND Model EH45

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 ➀

02E

➁ PJ01

REVISION

DATE OF ISSUE

REMARKS

First Edition

October, 2001

S5PJ0102E

Second Revision

January, 2003

S5PJ0102E ➀ K·E

K·E

01 –0–2 ➀

1. GENERAL PRECAUTIONS FOR REPAIRS 1.1 PREPARATION BEFORE DISASSEMBLING Understanding operating procedure Read OPERATION & MAINTENANCE MANUAL carefully to understand the operating procedure.

Read Operator's Manual before disassembling

(1)

(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)

1) 2) 3) 4) 5) 6)

(5) 1) 2) 3)

Recording Record the following items for communication and prevention of recurring malfunction. Inspection date and place Model name, applicable machine number, and hour meter read Trouble condition, location and cause. Visible Oil leakage, water leakage and damage Clogging of filters, oil level, oil quality, oil contamination and loosening of connections Result of consideration if any problem exists based on the operation rate per month calculated from hour meter indication after the last inspection date. 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 Wear appropriate clothes with long sleeves, safety shoes, safety helmet and protective glasses. Suspend warning tag "DO NOT OPERATE" from the doorknob or the operating lever, and have a preliminary meeting before starting work. Stop the engine before starting inspection and maintenance to prevent the operator being caught

WARNING

5) 6) 7) 8)

(1) 1)

2) 3) 4)

in machine. Identify the location of a first-aid kit and a fire extinguisher, and also where to make contact in a state of emergency. Choose a hard, level and safe place, and place the attachment on the ground securely. Use a lifter such as a crane to remove heavy parts (20 kg [45 lbs] or more) from the machine. Use proper tools, and replace or repair defective tools. 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 Removing hydraulic equipment Before disconnecting pipes, release the hydraulic pressure of the system, or open the return side cover and take out the filter. Carefully drain oil of the removed pipes into a containers without spilling on the floor. Apply plugs or caps on the pipe ends to avoid oil spillage and dust intrusion. 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. 6) If it is hard to remove a part according to the procedure, do not try it by force but investigate the cause.

01â&#x20AC;&#x201C;1â&#x20AC;&#x201C;1

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 releasing 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 releasing will result in damage to the equipment.

idle condition. Complete the air releasing when seeping of hydraulic oil is recognized, and tightly plug. 4) Perform air releasing 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) Perform air releasing of pilot line by performing a series of digging, slewing and travel. 6) 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)

1.4 ELECTRICAL EQUIPMENT 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. Do not splash water on the electrical equipment and connectors during machine washing.

(8)

(9)

3) Perform air releasing after loosening the upper drain plug, starting the engine and keep it in low

01–1–2

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. • 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) 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. 2) 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.

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

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

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)

FIG. 2-1 LIFE HAMMER AND "EMERGENCY EXIT" LABEL

In addition, the life hammer is equipped with a cutter on the lever side to cut the seat belt, etc.

2.2 WHEN MACHINE CAN NOT GO OUT FROM THE SOFT GROUND BY ITSELF ; 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 towing eyes. 2. Attach other end to the vehicle used to pull the machine. Operate the Machine’s Travel Lever in the proper direction while pulling with the other vehicle. PV-1-5

FIG. 2-2 TOW MACHINE PROPERLY

• While towing, do not enter between the machine and towing vehicle. • Do not apply a shock load onto the towing rope. • Make sure to always use towing eyes (shackles) or the towing. • 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.

01–1–4

3. INTERNATIONAL UNIT CONVERSION SYSTEM (Based on MARKS' STANDARD HANDBOOK FOR MECHANICAL ENGINEERS) Introduction Although this manual uses the JIS unit system, if you need SI unit, refer to the following international system of units. Given hereinafter is an excerpt of the units that are related to this manual : 1. Etymology of SI Units French:Le Systéme International d' Unités English:International System of Units 2. Construction of SI Unit System Base units Table 3-1

SI unit system

SI units

Supplementary units Table 3-2

Derived units of base units Table 3-3 Derived units bearing peculiar designations Table 3-4

Derived units

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

(4)Derived Units bearing Peculiar Designations [ Table 3-4 ] QUANTITY UNIT SYMBOL FORMULA Frequency Hertz Hz 1/s Force Newton N kg•m/s 2 Pressure and Stress Pascal Pa N/m2 Energy, Work Joule J N• m and Quantity of heat Power Watt W J/s Quantity of Coulomb C A •s electricity Electric Volt V W/A potential difference, Voltage, and Electromotive force Quantity of Farad F C/V static electricity and Electric capacitance Ω V/A Electric Ohm resistance Celcius Celcius degree ˚C (t+273.15)K temperature or degree Illuminance Lux lx lm/m 2

(1)Base Units [ Table 3-1 ] QUANTITY Length Mass Time Electric current Thermodynamic temperature

UNIT metre kilogram second ampere kelvin

Amount of substance mol Luminous intensity candela

SYMBOL m kg s A

(5)Prefixes of SI [ Table 3-5 ] PREFIX Giga Mega Kilo Hecto Deca Deci Centi Milli Micro Nano Pico

K mol cd

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

UNIT radian steradian

SYMBOL rad sr

SYMBOL

MULTIPLICATION FACTORS

G M k h da d c m µ n p

109 6 10 3 10 2 10 10 -1 10 -2 10 -3 10 -6 10 -9 10 -12 10

(6)Unit Conversion [ Table 3-6 ] (3)Derived Units [ Table 3-3 ] QUANTITY Area Volume Velocity Acceleration Density

UNIT

SYMBOL m2 square metre m3 cubic metre m/s metre per second m/s2 metre per second squared kg/m3 kilogram per cubic metre

QUANTITY JIS SI CONVERSION FACTOR – kgf Weight – kg Mass kgf N 1 kgf=9.807 N Force kgf•m N•m 1 kgf•m=9.807 N•m Torque kgf/cm2 MPa 1 kgf/cm2=0.09807 MPa Pressure kW 1 PS=0.7355 kW Motive power PS rpm min-1 r/min 1 Revolution 1 Units that are allowed to use

01–1–5

(7)Unit conversion logarithmic chart

FORCE

1 N=0.10197 kgf

100

500

1,000

100

5,000 10,000

20,000 N

500

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/cm2

0.1

100

1,000

1 kgf/cm2=0.09807 MPa

01–1–6

MPa kgf/cm2

Book Code No.

PJ02

02E ➀

NEW HOLLAND EH45 Model Cross-reference: SK45SR-2 is NEW HOLLAND Model EH45

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 ...................................................................................1-9 6. TYPE OF CRAWLER SHOES ..................................................................1-11 7. TYPE OF BUCKET ...................................................................................1-11 8. MACHINE LIFTING PROCEDURE ..........................................................1-12 9. WORKING RANGES ................................................................................1-14 10. LIFTING CAPACITIES ..............................................................................1-16 11. ENGINE SPECIFICATIONS .....................................................................1-18

02 –0–1 ➀

PJ02

REVISION

DATE OF ISSUE

REMARKS

First Edition

October, 2001

S5PJ0202E

Second Revision

January, 2003

S5PJ0202E ➀ K·E

K·E

02 –0–2 ➀

1. COMPONENTS NAME

ARM CYLINDER BOOM

ARM

CANOPY

BUCKET CYLINDER

RIGHT OPERATING LEVER

SWING CYLINDER DOZER OPERATING LEVER

TRAVEL LEVER

IDLER LINK

MONITOR PANEL FUEL TANK HYDRAULIC TANK

BUCKET LINK BOOM CYLINDER

THROTTLE LEVER RESERVOIR TANK

BUCKET LEFT OPERATING LEVER

RADIATOR

SAFETY LOCK LEVER

AIR CLEANER

DOZER CYLINDER MUFFLER

DOZER BLADE RUBBER CRAWLER SHOE IDLER CONTROL VALVE

ENGINE

IDLER ADJUSTER

SLEWING MOTOR

UPPER ROLLER LOWER ROLLER SLEWING RING

BATTERY HYDRAULIC PUMP SWIVEL JOINT TRAVEL MOTOR

02 – 1 – 1

2. MACHINE DIMENSIONS SK40SR-2 A. CANOPY

57 .5 °

1,960 (6´-5˝) 700 (2´-4˝) 725 (2´-5˝) 70 (2.8˝)

115 (4.5˝)

Unit : mm (ft-in)

885 (2´-11˝)

340 (13.4˝)

620 (24.4˝)

1,530 (5´-0˝) 1,820 (6´-0˝) 2,340 (7´-8˝) 4,985 (16´-4˝)

400 (15.7˝) 1,560 (5´-1˝) 1,960 (6´-5˝)

95 (3.7˝)

.5 °

1,960 (6´-5˝) 700 (2´-4˝) 705 (2´-4˝) 70 (2.8˝)

R980 ˝) (38.6

2,600 (8´-6˝)

885 (2´-11˝) 620 (24.4˝)

350 (13.8˝)

1,630 (5´-4˝)

50 (2.0˝)

1,840 (6´-0˝)

1,530 (5´-0˝) 1,820 (6´-0˝) 2,340 (7´-8˝) 4,985 (16´-4˝)

02 –1–2

340 (13.4˝)

B. CAB

2,600 (8´-6˝)

1,840 (6´-0˝)

350 (13.8˝)

1,630 (5´-4˝)

50 (2.0˝)

R980 ˝) (38.6

400 (15.7˝) 1,560 (5´-1˝) 1,960 (6´-5˝)

Model Unit : mm (ft-in)

R980 ˝) (38.6

58 °

1,960 (6´-5˝) 700 (2´-4˝) 725 (2´-5˝) 70 (2.8˝)

340 (13.4˝)

1,610 (5´-3˝) 1,970 (6´-6˝) 2,480 (8´-2˝)

400 (15.7˝) 1,560 (5´-1˝) 1,960 (6´-5˝)

R980 ˝) (38.6

58 °

1,960 (6´-5˝) 700 (2´-4˝) 710 (2´-4˝) 70 (2.8˝)

120 (4´-7˝)

4,080 (13´-5˝) 5,300 (17´-5˝)

885 (2´-11˝) 620 (24.4˝)

350 (13.8˝)

1,750 (5´-9˝)

25 (1.0˝)

1,840 (6´-0˝)

2,600 (8´-6˝)

B. CAB

2,600 (8´-6˝)

885 (2´-11˝) 620 (24.4˝)

350 (13.8˝)

1,750 (5´-9˝)

25 (1.0˝)

1,840 (6´-0˝)

1,610 (5´-3˝) 1,970 (6´-6˝) 2,480 (8´-2˝) 4,080 (13´-5˝) 5,300 (17´-5˝)

02 –1–3

340 (13.4˝)

A. CANOPY

140 (5.5˝)

SK45SR-2

400 (15.7˝) 1,560 (5´-1˝) 1,960 (6´-5˝)

Model Unit : mm (ft-in)

.5 °

1,960 (6´-5˝) 700 (2´-4˝) 725 (2´-6˝) 70 (2.8˝)

R980

˝)

(38.6

400 (15.7˝)

58 °

1,960 (6´-5˝) 700 (2´-4˝) 710 (2´-4˝) 70 (2.8˝)

R980 ˝) (38.6

620 (24.4˝)

350 (13.8˝)

885 (2´-11˝)

2,600 (8´-6˝)

1,840 (6´-0˝)

25 (1.0˝) 1,750 (5´-9˝)

1,560 (5´-1˝) 1,960 (6´-5˝)

120 (4´-7˝)

4,080 (13´-5˝) 5,300 (17´-5˝)

340 (13.4˝)

1,610 (5´-3˝) 1,970 (6´-6˝) 2,480 (8´-2˝)

B. CAB

2,600 (8´-6˝)

885 (2´-11˝) 620 (24.4˝)

350 (13.8˝)

1,750 (5´-9˝)

25 (1.0˝)

1,840 (6´-0˝)

1,610 (5´-3˝) 1,970 (6´-6˝) 2,480 (8´-2˝) 4,080 (13´-5˝) 5,300 (17´-5˝)

02 –1–4

340 (13.4˝)

A. CANOPY

KAI

140 (5.5˝)

SK45SR-2

400 (15.7˝) 1,560 (5´-1˝) 1,960 (6´-5˝)

3. SPECIFICATIONS AND PERFORMANCE SK40SR-2

SPEED AND GRADEABILITY SK40SR-2 (with Rubber Shoe)

Model Serial No

PH03-02001~

Item min-1 {rpm}

Slewing Speed

9.3 {9.3}

km/h (mph)

Travel Speed Gradeability

Low (1st.)

High (2nd.)

2.5 (1.5)

4.5 (2.8)

%(degree)

58 (30)

ENGINE Model (YANMAR)

[4TNE84] 4TNE84-EYB

Type

Vertical,4-cycle,water cooled diesel engine 4-Ø84 mm X 90 mm

Number of cylinders-Bore X Stroke L

Total Displacement kW/min-1

Rated Output

1.99

{PS/rpm}

22.8 / 2,100 {31.0 / 2,100}

Maximum Torque N·m/min-1 {kgf·m/rpm} Starter

V X kW

12 X 2.0

VXA

12 X 40

Generator (Dynamo) Note)

118 / 1,400 {12 /1,400}

• The model name in [

] is for the earlier one before the improvement / change.

HYDRAULIC COMPONENTS Hydraulic Pump

Variable displacement axial piston + gearpump

Slewing Motor

Axial piston

Travel Motor

Axial psiton, 2 speed motor

Control Valve

10 spool multiple control valve

Cylinder

Boom,Arm,Swing Bucket,Dozer

Return filter

Double acting cylinder Paper filter with safety valve (30 )

OFFSET DIGGING · DOZER Boom swing operation by cylinder stroke

Mechanism Boom swing angle

degree

Stroke of dozer (Up / Down)

Right

Approx.58

Left

Approx.83 (Cab spec : 73) 360 /320 (14.2 / 12.6)

mm (in)

WEIGHT

Unit : kg (lb) Rubber shoe, Canopy

Machine Weight

4,060 (8,950)

Upper slewing body

1,770 (3,900)

Travel system

1,660 (3,660)

Attachment (Boom+STD Arm+STD Bucket)

450 (990)

Oil & Water

104 (230) Note) This figure is calculated with Japanese standard bucket. Bucket weight 100 kg (220 lb)

02 – 1 – 5

SK45SR-2

SPEED AND GRADEABILITY SK45SR-2 (with Rubber Shoe)

Model Serial No

PJ02-00101~

Item min-1 {rpm}

Slewing Speed

km/h (mph)

Travel Speed Gradeability

9.5 {9.5} Low (1st.)

High (2nd.)

2.6 (1.6)

4.6 (2.9)

%(degree)

58 (30)

ENGINE Model (YANMAR)

[4TNE88-NYBB (EU), 4TNE88-EYBD (KAI)] 4TNE88-EYBC

Type

Vertical,4-cycle,water cooled diesel engine 4-Ø88 mm X 90 mm

Number of cylinders-Bore X Stroke L

Total Displacement

2.18

kW/min-1 {PS/rpm}

Rated Output

27.2 / 2,200 {37.0 / 2,200}

Maximum Torque N·m/min-1 {kgf·m/rpm} Starter

147 / 1,400 {15 / 1,400}

V X kW

12 X 2.0

VXA

12 X 40

Generator (Dynamo)

•

Note) The model name in [ ] are for the earlier one before the improvement / change. HYDRAULIC COMPONENTS Hydraulic Pump

Variable displacement axial piston + gearpump

Slewing Motor

Axial piston

Travel Motor

Axial psiton, 2 speed motor

Control Valve

10 spool multiple control valve

Cylinder

Boom,Arm,Swing Bucket,Dozer

Return filter

Double acting cylinder Paper filter with safety valve (30 )

OFFSET DIGGING · DOZER Boom swing operation by cylinder stroke

Mechanism Boom swing angle

degree

Stroke of dozer (Up / Down)

Right

Approx.58

Left

Approx.83 (Cab spec : 73) 360 /380 (14.2 / 15.0)

mm (in)

Unit:kg (lb) WEIGHT Machine Weight

Rubber shoe, Canopy 4,630 (10,210)

Upper slewing body

2,100 (4,630)

Travel system

1,870 (4,120)

Attachment (Boom+STD Arm+STD Bucket) Oil & Water

600 (1,260)

(In case of Japanese STD bucket)

109 (240) Note) This figure is calculated with Japanese standard bucket. Bucket weight 104 kg (230 lb)

02 – 1 – 6

4. MACHINE&COMPONENTS WEIGHT (DRY) Unit : kg(lb) Model

SK40SR-2 Rubber shoe

Specification Item Complete Machine 1. Upper Structure (Assy of followings) 1.1 Upper frame 1.2 Canopy/Cab 1.3 Engine 1.4 Hydraulic pump 1.5 Radiator 1.6 Hydraulic tank 1.7 Fuel tank 1.8 Swing bracket 1.9 Swing cylinder 1.10 Slewing motor (with reduction) 1.11 Control valve 1.12 Counterweight 1.13 Guard • Bonnet 1.14 Boom cylinder 2. Undercarriage (Assy of followings) 2.1 Lower frame 2.2 Slewing bearing 2.3 Travel motor (with reduction) 2.4 Upper roller 2.5 Lower roller 2.6 Front idler 2.7 Idler adjuster 2.8 Sprocket 2.9 Rubber crawler (400mm width) 2.10 Swivel joint 2.11 Dozer 2.12 Dozer cylinder 3. Attachment(Assy of followings) 3.1 Boom assy 3.1.1 Boom 3.1.2 Arm cylinder 3.2 Arm assy 3.2.1 Arm 3.2.2 Bucket cylinder 3.2.3 Bucket Link 3.2.4 Idler Link 3.3 Bucket assy (0.13m3) (0.17 cu·yd) 4. Fluid,Water (Assy of followings) 4.1 Hydraulic oil 4.2 Fuel 4.3 Engine oil 4.4 Water (Coolant)

Canopy 4,060 (8,950) 1,770 (3,900) 490 (1,080) 82 (180) 180 (400) 35 (77) 19 (40) 36 (79) 23 (50) 99 (220) 48 (105) 43 (95) 35 (77) 260 (570) 130 (287) 49 (110) 1,660 (3,660) 480 (1,060) 76 (170) 56 (120) X 2 5 (11) X 2 10 (22) X 2 32 (70) X 2 23 (50) X 2 15 (33) X 2 230 (510) X 2 22 (48) 180 (400) 26 (57) 450 (990) 190 (420) 150 (320) 41 (90) 130 (290) 73 (160) 26 (57) 11 (24) 4 (9) X 2 100 (220) 104 (230) 57 (125) 42 (92) 5 (11) 5 (11)

Cab 4,160 (9,170) 1,870 (4,120) 180 (400)

Note : (1) In case of iron crawlers, add 40kg (88 lb) to the weight of complete machine. (2) Bucket weight is shown with Japanese standard bucket weight.

02 –1–7

Unit : kg(lb) Model

Specification Item Complete Machine 1. Upper Structure (Assy of followings) 1.1 Upper frame 1.2 Canopy/Cab 1.3 Engine 1.4 Hydraulic pump 1.5 Radiator 1.6 Hydraulic tank 1.7 Fuel tank 1.8 Swing bracket 1.9 Swing cylinder 1.10 Slewing motor (with reduction) 1.11 Control valve 1.12 Counterweight 1.13 Guard • Bonnet 1.14 Boom cylinder 2. Undercarriage (Assy of followings) 2.1 Lower frame 2.2 Slewing bearing 2.3 Travel motor (with reduction) 2.4 Upper roller 2.5 Lower roller 2.6 Front idler 2.7 Idler adjuster 2.8 Sprocket 2.9 Rubber crawler (400mm width) 2.10 Swivel joint 2.11 Dozer 2.12 Dozer cylinder 3. Attachment(Assy of followings) 3.1 Boom assy 3.1.1 Boom 3.1.2 Arm cylinder 3.2 Arm assy 3.2.1 Arm 3.2.2 Bucket cylinder 3.2.3 Bucket Link 3.2.4 Idler Link 3.3 Bucket assy (0.14m3) (0.18 cu·yd) 4. Fluid,Water (Assy of followings) 4.1 Hydraulic oil 4.2 Fuel 4.3 Engine oil 4.4 Water (Coolant)

SK45SR-2 • Rubber shoe Canopy Cab 4,630 (10,210) 4,730 (10,430) 2,100 (4,630) 2,200 (4,850) 620 (1,370) 82 (180) 180 (400) 180 (400) 35 (77) 19 (40) 36 (79) 23 (50) 99 (220) 48 (105) 43 (95) 35 (77) 550 (1,210) 130 (287) 58 (730) 1,870 (4,120) 620 (1,370) 76 (170) 56 (120) X 2 5 (11) X 2 10 (22) X 2 32 (70) X 2 23 (50) X 2 15 (33) X 2 246 (540) X 2 22 (48) 190 (420) 26 (57) 600 (1,260) 220 (485) 170 (370) 46 (100) 140 (310) 110 (240) 26 (57) 11 (24) 4 (9) X 2 104 (230) 109 (240) 57 (125) 42 (92) 5 (11) 5 (11)

Note : (1) In case of iron crawlers, add 40kg (88 lb) to the weight of complete machine. (2) Bucket weight is shown with Japanese standard bucket weight.

02 –1–8

5. TRANSPORTATION 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.

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. Lower all attachment.

4. If machine cannot be transported with arm cylinder fully extended, remove bucket or attachment and extend arm cylinder.

5. Stop engine. Remove key from switch. Do not put chains over or against hydraulic lines, hoses or rubber tracks. 6. Fasten machine to trailer with chains or cables.

(2) Transportation Dimention and Weight of Attachment (1) Boom Model Length X Height X Width mm (ft-in) Weight kg (lb)

SK40SR-2 2,785 X 1,025 X 290 (9´-2˝ X 3´-4˝ X 11.4˝) 190 (420)

SK45SR-2 3,015 X 1,045 X 290 (9´-11˝ X 3´-5˝ X 11.4˝) 220 (420)

L (2) Arm and Bucket (Japanese standard bucket) Model Arm length m (ft-in) Length X Height X Width mm (ft-in) Weight kg (lb)

SK40SR-2 1.36 (4´-6˝) 2,570 X 510 X 600 (8´-5˝ X 1´-8˝ X 2´-0˝) 230 (510)

SK45SR-2 1.48 (4´-10˝) 2,700 X 510 X 600 (8´10˝ X 1´8˝ X 2´0˝) 250 (550)

02 –1–9

(3) Arm Model Arm length m (ft-in) Length X Height X Width mm (ft-in) Weight kg (lb)

SK45SR-2 1.48 (4´-10˝) 1,945 X 425 X 250 (6´-5˝ X 1´-5˝ X 9.8˝) 140 (310)

SK40SR-2 1.36 (4´-6˝) 1,815 X 425 X 250 (5´-11˝ X 1´-5˝ X 9.8˝) 130 (290)

H L

(4) Bucket (Japanese standard bucket) Model Bucket capacity m3(cu·yd) (SAE heaped) Length X Height X Width mm (ft-in) Weight kg (lb)

SK40SR-2

SK45SR-2

0.13 (0.17)

0.14 (0.18)

780 X 695 X 600 (2´-7˝ X 2´-3˝ X 2´-0˝) 100 (220)

780 X 695 X 650 (2´-7˝ X 2´-3˝ X 2´-2˝) 104 (230)

(5) Dozer Model Length X Height X Width mm (ft-in) Weight kg (lb)

SK45SR-2 1,125 X 335 X 1,960 (3´-8˝ X 1´-1˝ X 6´-5˝) 190 (420)

SK40SR-2 1,050 X 335 X 1,960 (3´-5˝ X 1´-1˝ X 6´-5˝) 180 (400)

H L

02 –1–10

6. TYPE OF CRAWLER SHOES

Type

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

Model

Ground pressure kgf/cm2 (psi) Canopy

Cab

Rubber shoe SK40SR-2

400 (15.7)

1,960 (6´-5˝)

0.25 (3.6)

SK45SR-2

400 (15.7)

1,960 (6´-5˝)

0.27 (3.8)

SK40SR-2

400 (15.7)

1,960 (6´-5˝)

0.26 (3.7)

0.27 (3.8)

SK45SR-2

400 (15.7)

1,960 (6´-5˝)

0.27 (3.8)

0.28 (3.9)

Iron shoe(option)

7. TYPE OF BUCKET

(Japanese standard bucket) Outer width mm (in)

Type

Heaped capacity m3(cu·yd)

with side cutter

without side cutter

Back hoe bucket

0.09 (0.11)

450 (17.7˝)

0.12 (0.16)

Number of tooth

Weight kg (lb)

370 (14.5˝)

83 (182)

550 (21.6˝)

470 (18.5˝)

96 (210)

600 (23.6˝)

520 (20.4˝)

100 (220)

0.14 (0.18)*

650 (25.3˝)

570 (22.4˝)

104 (230)

0.16 (0.20)

700 (27.5˝)

620 (24.4˝)

107 (235)

0.18 (0.24)

750 (29.5˝)

670 (26.3˝)

117 (258)

0.13 (0.17)*

Note) : Marked *1 shows standard bucket of SK40SR-2. Marked *2 shows standard bucket of SK45SR-2.

02 –1–11

8. MACHINE LIFTING PROCEDURE LIFTING PROCEDURES FOR THE MACHINE COMPLETE

• The wire ropes to be used for lifting the machine should have sufficient strength against the machine weight. • Improper lifting method and/or rope rigging manner might cause for a movement or slip of the machine while it is being lifted, resulting serious injury or damages to the machine. • Do not impose a load suddenly on the wire ropes and slings. • When the lifting work is carried out in cooperation with multiple persons, make sure to check every situation by exchanging signals with each other. • During the lifting work, keep any persons away from the lifted machine, especially under the machine

MACHINE MODEL

WEIGHT

SK40SR-2

4,060 kg (8,950 lb)

SK45SR-2

4,630 kg (10,210 lb)

• SK40SR-2 SIZE

Q'TY

CABLE (A)

Ø 1˝ X 2,700 mm

CABLE (B)

Ø 1˝ X 5,100 mm

SIZE

Q'TY

CABLE (A)

Ø 1˝ X 2,600 mm

CABLE (B)

Ø 1˝ X 5,100 mm

ITEM

• SK45SR-2 ITEM

Model SK40SR-2 Weight : 4,060 kg (8,950 lb)

Carry out the lifting work on a level ground. [1] Manipulate each operating lever to take the machine to a position as shown in the figure. [2] Operate the boom swing lever to face the boom directly in front, and raise the dozer blade.

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

5,500 (18´1˝)

[3] Stop the engine, and set the safety lock lever to “LOCKED” position. Then get off the machine after ensuring for no abnormalities around the operator’s seat.

(A)

19 (15 .4 ° .0° )

.0 17 4° ) . 1 ( 6 (B)

(D) CAB LINE

[5] Put the wire ropes on the (D) portion of the boom.

(C)

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

Note : This figure is calculated with Japanese

02 –1–12

standard bucket. Bucket weight : 100 kg (220 lb)

Model SK45SR-2

KAI

Weight : 4,630 kg (10,210 lb)

Model SK45SR-2

Weight : 4,630 kg (10,210 lb)

.4 °

(A)

5,500 (18´1˝)

.4 °

(B)

(A)

(D) CAB LINE

5,500 (18´1˝)

(B)

(D)

CAB LINE

Note : This figure is calculated with Japanese

standard bucket.

Bucket weight : 104 kg (230 lb)

02 –1–13

9. WORKING RANGES SK40SR-2

A A'

Y X

Unit : mm (ft-in) Model Attachment Arm Item Bucket A Max. digging reach A' Max. digging reach at ground level B Max. digging depth C Max. digging height D Max. dumping clearance E Min. dumping clearance F Max. vertical wall digging depth G Min. front slew radius H Height at min. slew radius J 8-feet level digging depth Stroke K Horizontal digging Minimum L stroke at ground level Above X Dozer strokes Below Y

SK40SR-2 Standard Arm 1.36 m (4´-6˝) 0.13 m3 (0.17 cu·yd) 5,560 (18´-3˝) 5,410 (17´-9˝) 3,400 (11´-2˝) 5,480 (18´-0˝) 3,900 (12´-10˝) 1,610 (5´-3˝) 2,570 (8´-5˝) 1,990 (6´-6˝) 4,180 (13´-9˝) 2,920 (9´-7˝) 2,420 (7´-11˝) 1,790 (5´-10˝) 360 (1´-2˝) 320 (1´-1˝)

Note : This table is calculated with Japanese standard bucket.

02 –1–14

Long Arm 1.66 m (5´-5˝) 0.13 m3 (0.17 cu·yd) 5,840 (19´-2˝) 5,700 (18´-8˝) 3,670 (12´-0˝) 5,690 (18´-8˝) 4,100 (13´-5˝) 1,320 (4´-4˝) 2,870 (9´-5˝) 2,100 (6´-11˝) 4,190 (13´-9˝) 3,270 (10´-9˝) 2,840 (9´-4˝) 1,650 (5´-5˝) 360 (1´-2˝) 320 (1´-1˝)

SK45SR-2

A A'

Y X

SK45SR-2 Standard Arm 1.48 m (4´-10˝) 0.14 m3 (0.18 cu·yd) 5,860 (19´-3˝) 5,720 (18´-9˝) 3,600 (11´-10˝) 5,200 (17´-1˝) 3,680 (12´-1˝) 1,490 (4´-11˝) 2,700 (8´-10˝) 2,490 (8´-2˝) 4,160 (13´-8˝) 3,140 (10´-4˝) 2,680 (8´-10˝) 1,830 (6´-0˝) 360 (1´-2˝) 380 (1´-3˝)

Note : This table is calculated with Japanese standard bucket. This fugure is drawn according to EU specification

02 –1–15

Long Arm 1.78 m (5´-10˝) 0.14 m3 (0.18 cu·yd) 6,150 (20´-2˝) 6,010 (19´-9˝) 3,900 (12´-10˝) 5,380 (17´-8˝) 3,850 (12´-8˝) 1,190 (3´-11˝) 3,030 (9´-11˝) 2,500 (8´-2˝) 4,170 (13´-8˝) 3,480 (11´-5˝) 3,120 (10´-3˝) 1,680 (5´-6˝) 360 (1´-2˝) 380 (1´-3˝)

10. LIFTING CAPACITIES SK40SR-2

(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) Unit : ton, Crawler : 400mm (16 in), Rubber crawler shoe. 6) Set hydraulic pressure 230 kgf / cm2 (3270 psi) (2) Lifting conditions (With Japanese standard bucket.) Machine : SK40SR-2 Arm length : 1.36m (4´6²) Bucket weight 100 kg (220 lb) Bucket capacity : 0.13m3 (0.17 cu·yd) Dozer blade : Up position

02 –1–16

SK45SR-2

(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) Unit : ton, Crawler : 400mm (16 in), Rubber crawler shoe. 6) Set hydraulic pressure 230 kgf / cm2 (3270 psi) (2) Lifting conditions (With Japanese standard bucket.) Machine : SK45SR-2 Arm length : 1.48m (4´10²) Bucket weight 104 kg (230 lb) Bucket capacity : 0.14m3 (0.18 cu·yd) Dozer blade : Up position

02 –1–17

11. ENGINE SPECIFICATIONS 11.1 SPECIFICATIONS SK40SR-2

Model Applicable machine Engine Model Type mmXmm No. of cylinders - BoreXStroke L Total displacement Compression ratio kW/min-1{PS/rpm} Rated output N·m/min-1{kgf·m/rpm} Maximum torque min-1{rpm} Low idling min-1{rpm} High idling g/kW·h {g/PS·h} Fuel consumption rate Allowable tilting angles Rotating direction Firing order degree (˚ ) Fuel injection timing (b.T.D.C.) 2 MPa {kgf/cm } Fuel injection pressure

SK40SR-2 PH03-02001~ [4TNE84] 4TNE84-EYB Vertical, 4-cycle water-cooled diesel engine 4-ø84 X 90 1.99 18 22.8 / 2,100 {31 / 2,100} 117.6~130.3 / 1,400 {12.0 ~ 13.3 / 1,400} 1,075 ± 25 {1,075 ± 25} 2,290 ± 25 {2,290 ± 25} 238 {175} or less Back and forth, left and right 25° (momentary 30°) Counterclockwise as seen from flywheel side 1-3-4-2 [12 ± 1] 10 ± 1 19.6 +10 {200+10 0 } Open

Close degree (˚ ) 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 Valve clearance Exhaust valve 0.2 mm (0.008 in) in cold condition Thermostat action Start/ Full open 71 ± 1.5 / 85 ˚C 2 -1 Compression pressure MPa {kgf/cm } at min {rpm} 3.2 ± 0.1 {33 ± 1} 250 2 -1 +1.0 Lubrication oil pressure MPa {kgf/cm } at min {rpm} 0.37 +0.1 -0.05 {3.8 -0.5 } 2,100 Dimensions L X W X H 700 X 500 X 630 mm Dry weight 180 kg Governor Mechanical centrifugal governor (All speed type) Fuel filtration Full flow,Paper filter Lubrication system Forced lubrication with trochoid pump Engine oil filtration Full flow,Paper filter cartridge Cooling system Liquid cooling / Radiator, Plastic 6 bladed,OD : ø335 (Discharge type) Crank pully / Fan Pully : ø120 / ø110 V X kW Starter capacity 12 X 2.0 VXA Generator capacity (Dynamo) 12 X 40 Starting aid Air heater (pre-heat : 15 sec) L Cooling water capacity : Max / Engine 2.7 L Engine oil volume : Max / Effective 5.8 / 2.3 Note) The model name & value in [ ] are for the earlier ones before the improvement / change. Valve action

•

02 – 1 – 18

SK45SR-2

Model SK45SR-2 Applicable machine PJ02-00101~ Engine Model [4TNE88-NYBB (EU), 4TNE88-EYBD (KAI)] 4TNE88-EYBC Type Vertical, 4-cycle water-cooled diesel engine mmXmm No. of cylinders - BoreXStroke 4-ø88 X 90 L Total displacement 2.18 Compression ratio 18 -1 kW/min {PS/rpm} Rated output 27.2 / 2,200 {37 / 2,200} -1 N·m/min {kgf·m/rpm} Maximum torque 135.2~147.1 / 1,400 {13.8 ~ 15.0 / 1,400} min-1{rpm} Low idling 1,075 ± 25 {1,075 ± 25} -1 min {rpm} High idling 2,400 ± 25 {2,400 ± 25} g/kW·h {g/PS·h} Fuel consumption rate 238 {175} or less Allowable tilting angles Back and forth, left and right 25° (momentary 30°) Rotating direction Counterclockwise as seen from flywheel side Firing order 1-3-4-2 degree (˚ ) Fuel injection timing (b.T.D.C.) [12 ± 1] 10 ± 1 2 MPa {kgf/cm } Fuel injection pressure 19.6 +10 {200+10 0 } Open Close degree (˚ ) Intake valve Valve action 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 Valve clearance Exhaust valve 0.2 mm (0.008 in) in cold condition Thermostat action Start/ Full open 71 ± 1.5 / 85 ˚C 2 -1 Compression pressure MPa {kgf/cm } at min {rpm} 3.4 ± 0.1 {35 ± 1} 250 +1.0 Lubrication oil pressure MPa {kgf/cm2} at min-1{rpm} 0.37 +0.1 -0.05 {3.8 -0.5 } 2,200 Dimensions L X W X H 700 X 500 X 630 mm Dry weight 180 kg Governor Mechanical centrifugal governor (All speed type) Fuel filtration Full flow,Paper filter Lubrication system Forced lubrication with trochoid pump Engine oil filtration Full flow,Paper filter cartridge Cooling system Liquid cooling / Radiator, Plastic 6 bladed,OD : ø335 (Discharge type) Crank pully / Fan Pully : ø120 / ø96 V X kW Starter capacity 12 X 2.0 VXA Generator capacity (Dynamo) 12 X 40 Starting aid Air heater (pre-heat : 15 sec) L Cooling water capacity : Max / Engine 2.7 L Engine oil volume : Max / Effective 5.8 / 2.3 Note) The model names & value in [ ] are for the earlier ones before the improvement / change.

•

02 – 1 – 19

11.2 ENGINE PERFORMANCE CURVE SK40SR-2 Model : [4TNE84] 4TNE84-EYB Rated Output : 22.8 kW / 2,100 min-1 {31 PS / 2,100 rpm} Note)

• The model name in [

] is for the earlier one before the improvement / change.

4.5

6 Smoke (Bosch)

2.5

Shaft Output

N·m {kgf·m}

kW {PS}

{kgf·m}

(14) 140 0 (12) 120 (10) 100 Max.torque 117.6~130.3N·m (12.0~13.3 kgf·m) kW /1,400 min-1 (PS)

Rated 22.8kw Output (31 PS) /2,100 min-1

(30) 20

(20) g/kW·h {g/PS·h}

238 g / kW·h { 175 g / PS·h}

10 (10)

260 240

(180)

220 (160) 10

15 Engine speed

g/kW·h {g/PS·h}

F : Fuel consumption rate (g/PS·h) P : Shaft output (PS) : Speific gravity : Standard load factor (0.60~0.70)

238 X 22.8 X 0.835 X 1000

= 6.5

02 – 1 – 20

min-1{rpm}X102

F X PX X 1000

Fuel consumption volume=

Fuel Consumption Rate

Shaft Torque

4 N·m

Fuel consumption in normal operation; 3.9~4.55 /h (load factor : (0.60~0.70))

SK45SR-2 Model : [4TNE88-NYBB (EU)] [4TNE88-EYBD (KAI)] 4TNE88-EYBC Rated Output : 27.7 kW / 2,200 min-1 {37 PS / 2,200 rpm} Note)

• The model names in [

] are for the earlier one before the improvement / change.

4.5

Smoke (Bosch)

4.5

Shaft Output

N·m {kgf·m}

kW {PS}

{kgf·m}

(14) 140 0 (12) 120 (10) 100 Max.torque 135.2~147.1N·m (13.8~15.0 kgf·m) kW /1,400 min-1 (PS)

Rated 27.2kw Output (37 PS) /2,200 min-1

(30) 20

(20)

10 g/kW·h {g/PS·h}

238 g / kW·h { 175 g / PS·h}

(10)

260 240

(180)

220 (160) 10

15 Engine speed

Fuel consumption volume=

Fuel Consumption Rate

Shaft Torque

4 N·m

g/kW·h {g/PS·h}

min-1{rpm}X102 F : Fuel consumption rate (g/PS·h) P : Shaft output (PS) : Speific gravity : Standard load factor (0.60~0.70)

F X PX X 1000 238 X 27.2 X 0.835 X 1000

= 7.75

02 – 1 – 21

Fuel consumption in normal operation; 4.65~5.43 /h (load factor : (0.60~0.70))

NOTES

Book Code No.

PJ03

02E ➁

NEW HOLLAND EH45 Model Cross-reference: SK45SR-2 is NEW HOLLAND Model EH45

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 .........................................................................1-4 2.2 Arm maintenance standards ......................................................................1-6 3. BUCKET 3.1 Bucket dimensional drawings ....................................................................1-8 3.2 Detail dimensional drawings of lug section ................................................1-9 3.3 Detail dimensional drawings of boss section ...........................................1-10 4. DOZER 4.1 Dozer dimensional drawings ....................................................................1-11 4.2 Dozer maintenance standards .................................................................1-12 5. SWING. 5.1 Swing bracket dimensional drawings .......................................................1-13 5.2 Swing portion maintenance standards.....................................................1-14

03 –0–1 ➀

PJ03

REVISION

DATE OF ISSUE

REMARKS

First Edition

October, 2001

S5PJ0302E

Second Revision

January, 2003

S5PJ0302E ➀ K·E

K·E

03 –0–2 ➀

1. BOOM 1.1 BOOM DIMENSION

Fig. 1-1 Boom dimension

Table 1-1 Code A B C D E F G H J K d1 d2 d3 d4

Item Boom length Distance between pins of boss Distance between pins of bracket Height of boom cylinder rod pin Height of arm cylinder (head side) pin Boom foot width Bracket inner width for boom cylinder (rod side) Boom end inner width Boom end outer width Bracket inner width for arm cylinder (head side) Boom foot pin dia.(O.D of bushing) Boom cylinder (rod side) pin dia. Pin dia. of arm end Arm cylinder (head side) pin dia.

Unit : mm (ft-in)

DIMENSIONS SK45SR-2 SK40SR-2 2669 (8´9.1˝) 2900 (9´6.2˝) R1393.5 (4´6.9˝) R1407.5 (4´7.4˝) R1475 (4´10.1˝) R1487.5 (4´10.6˝) 467.5 (1´6.4˝) 513.5 (1´8.2˝) 893 (2´11.2˝) 909 (2´11.8˝) 250 (9.84˝) 71 (2.80˝) 76 (2.99˝) 175 (6.89˝) 265 (10.43˝) 66 (2.60˝) ø50 (1.9˝) OD: ø60 (2.4˝) ø50 (1.9˝) ø60 (2.4˝) ø45 (1.8˝)

03 –1–1

1.2 BOOM MAINTENANCE STANDARDS (1) Clearance of pin and bushing

Fig. 1-2 Clearance of pin and bushing

SK40SR-2

Pos.

Table 1-2

SK45SR-2

Item

Pin parts No.

Boom foot

PH02B01046P1

Boom cylinder (Head side)

PH02B01052P1

Boom cylinder (Rod side)

PH02B01054P1

Arm cylinder (Head side)

PH02B01060P1

Unit : mm (in) Standard dimensions Clearance Remedy Tolerance Pin dia. Tolerance on bushing Standard Repairable Service value on pin dia. bore dia. level limit

( ø50 (1.969)

(

-0.020 -0.080 -0.0008 -0.0031

) (

+0.061 0 +0.0024 0

+0.250 +0.050 +0.0098 +0.0020

) ( ) (

0.111 0.020 0.0044 0.0008

0.330 0.070 0.0130 0.0028

) Replace 0.7 1.0 bushing (0.028) (0.039) or pin

)

ø45 (1.772)

03 – 1 – 2

(2) Clearance in thrust direction on boom and cylinder installation section

SECTION A-A

SECTION B-B

SECTION C-C

SECTION D-D

Fig. 1-3 Clearance in thrust direction on boom

SK40SR-2

SK45SR-2

Table 1-3 Clearance X adjusted by shim (total of both sides)

Standard dimensions

Pos.

Unit : mm (in) Pin length Remedy

Item Code Dimensions

Standard Repairable Service value level limit

-0.008 Boom 250 -0.2 -0.3 (9.84 -0.012 ) 0.1~0.5 See "NOTE" L1 +0.008 (0.004~0.020) Swing bracket ) 250+0.5 0 (9.84 0 0 0 Boom cylinder Head side (2.95 -0.020 ) 0.1~0.5 75 -0.5 B-B L2 +1 +0.039 (Head side) Swing bracket 77 0 (3.03 0 ) (0.004~0.020) Adjusted 0 0 by shim 1.0 Boom cylinder Rod side 1.5 (2.76 -0.020 ) 0.5~0.9 70 -0.5 C-C L3 +1 +0.039 (Rod side) Boom 71 0 (2.80 0 ) (0.020~0.035) (0.039) (0.059) 0 0 Arm cylinder Head side (2.56 -0.020 ) 0.1~0.5 65 -0.5 D-D L4 +1 +0.039 (Head side) Boom 66 0 (2.60 0 ) (0.004~0.020) (Note) Clearance "X" shall be adjusted with shims, if clearance exceeds the standard value.

A-A Boom foot

03 –1–3

Code Dimensions 377 (14.84) 264 2 (10.39) 213 3 (8.39) 200 4 (7.87) 1

2. ARM

Only KAI model is not provided this hole.

2.1 ARM DIMENSION

Reinforcing plate ( KAI only)

SECTION Z- Z

SECTION X-X SECTION Y-Y

Fig. 2-1 Arm dimension

Table 2-1 (1 / 2)

SK40SR-2 Code

Item

Dimensions

Code

A B C D E F G H J K L

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

1360 (4´5.5˝) R405 (15.94˝) R1118 (3´8.0˝) R230.5 (9.07˝) 311 (12.24˝) 190 (7.48˝) 12 (0.47˝) 150 (5.91˝) 175 (6.89˝) 61 (2.40˝) 61 (2.40˝)

M N D1 D2 D3 d1 d2 d3 d4 d5

Unit : mm (ft-in) Item

Link dimension (Idler) Link dimension (Bucket link) I.D. of boss I.D. of boss I.D. of boss Pin dia. Pin dia. Pin dia. Pin dia. Pin dia.

03 –1–4

Dimensions

320 (12.60˝) 310 (12.20˝) ø55 (2.17˝) ø55 (2.17˝) ø75 (2.95˝) ø45 (1.77˝) ø45 (1.77˝) ø60 (2.36˝) ø45 (1.77˝) ø45 (1.77˝)

Table 2-1 (2 / 2)

SK45SR-2 Code

Item

Dimensions

Code

A B C D E F G H J K L

1480 (4´10.3˝) R405 (15.94˝) R1118 (3´8.0˝) R230.5 (9.07˝) 311 (12.24˝) 165 (6.50˝) 12 (0.47˝) 150 (5.91˝) 175 (6.89˝) 61 (2.40˝) 66 (2.60˝)

M N D1 D2 D3 d1 d2 d3 d4 d5

Unit : mm (ft-in) Item

Link dimension (Idler) Link dimension (Bucket link) I.D. of boss I.D. of boss I.D. of boss Pin dia. Pin dia. Pin dia. Pin dia. Pin dia.

03 –1–5

Dimensions

320 (12.60˝) 310 (12.20˝) ø55 (2.17˝) ø55 (2.17˝) ø75 (2.95˝) ø45 (1.77˝) ø45 (1.77˝) ø60 (2.36˝) ø45 (1.77˝) ø45 (1.77˝)

2.2 ARM MAINTENANCE STANDARDS (1) Clearance of pin and bushing

Fig. 2-2 Clearance of pin and bushing

SK40SR-2

Table 2-2

SK45SR-2

Unit : mm (in) Clearance

Pos.

Item

Pin parts No.

Standard dimensions Tolerance Tolerance Standard Repairable Service Remedy Pin dia. level limit on pin dia. on bushing value

Arm point 0.114 +0.064 (Connected part of bucket) 0.025 +0.005 PH12B01114P1 +0.0025 0.0045 Bucket link +0.0002 0.0010 B (Bucket side) Idler link +0.076 +0.0030 0.126 0.0050 C +0.035 +0.0014 0.055 0.0022 (Connected part of arm) ø45 [PH12B01103P1] (1.772) Bucket link +0.073 +0.0029 0.123 0.0048 D -0.020 +0.032 +0.0013 0.052 0.0020 PH12B01141P1 (Idler link side) 0.7 1.0 Replace -0.050 (0.028) (0.039) Bucket cylinder bushing -0.0008 0.300 +0.250 D’ -0.0020 or pin (Rod side) 0.070 +0.050 +0.0098 0.0118 Bucket cylinder +0.0020 0.0028 PH12B01084P1 E (Head side) Arm foot ø60 +0.061 +0.0024 0.111 0.0044 PH12B01085P2 F 0 0 0.020 0.0008 (2.362) (Connected part of boom) Arm cylinder ø45 +0.250 +0.0098 0.300 0.0118 PH12B01084P1 G +0.050 +0.0020 0.070 0.0028 (1.772) (Rod side) (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 number in [ ] is for the earlier one before the improvement / change. A

)(

(

)

(

)

(

)

(

)

(

)(

(

03 – 1 – 6

)

(

)

(

)

(

)

(

)

(2) Clearance in thrust direction on arm and cylinder installation section

SECTION A-A

SECTION C-C

SECTION B-B

SECTION D-D

SECTION E-E

SECTION G-G

SECTION F-F

Fig. 2-3 Clearance in thrust direction

* Total clearance of both sides to be 0.1 ~ 0.5 mm (0.004² ~ 0.020²) or less after adjusting by shims. SK40SR-2

Table 2-3

SK45SR-2

Standard dimensions

Pos.

Item Code

A-A Arm point B-B Bucket link Idler link (Connected part of arm) Bucket link (Rod side) D-D Bucket link (Idler link side) Bucket cylinder E-E (Head side)

Arm Bucket Link side Bucket Arm

Dimensions

150 (5.894) +0.004 150 +0.1 +0.5 (5.894 +0.020 ) -0.2 150 -0.3 (5.894 -0.008 -0.012 ) L2 +0.035 151 +0.9 (5.894 -0.5 -0.020 ) 150 (5.894) L3 _ L1

Unit : mm (in) Clearance X adjusted by shim (total of both sides)

Standard Repairable Service value level limit Less than 1.0 (0.039) Less than 2.2 (0.087)

Pin length Remedy Code Dimensions 287.5 1 (11.30)

See "NOTE"

0.1~0.5 (0.004~0.020) Link side 0 0 55 -0.5 (2.161 -0.020 ) 0.6~1.0 Rod side 1.5 2.0 L4 (0.024~0.039) (0.059) (0.079) Adjusted 57±0.2 (2.240±0.008) Link side -0.008 -0.2 by shim Bucket link 150 -0.4 (5.894 -0.016 ) 0.1~0.5 L5 _ (0.004~0.020) Idler link 0 0 Head side 60 -0.5 (2.358 -0.020 ) 0.5~0.9 1.0 1.5 L6 +0.039 (0.020~0.035) (0.039) +1 (0.059) 61 0 (2.397 0 ) Arm Less than 175 (6.876) Arm 0.5 See "NOTE" F-F Arm foot L7 +0.012 +0.3 175 +0.1 (6.876 +0.004) (0.020) Boom 0 0 60 -0.5 (2.358 -0.020 ) Less than Arm cylinder Rod side 1.0 1.5 0.5 G-G L8 +1 +0.039 61 0 (2.397 0 ) (0.020) (0.039) (0.059) (Rod side) Arm (Note) Clearance "X" shall be adjusted by shims, if clearance exceeds the standard value for repair. C-C

03 – 1 – 7

287.5 2 (11.30) 209.5 3 (8.23) 5 209.5 (8.23) 183 6 (7.19) 265 7 (10.41) 183 8 (7.19)

3. BUCKET 3.1 BUCKET DIMENSION

Fig. 3-1 Bucket dimension

Table 3-1 Code A B C D E F G H I d1 d2

Item

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 Outer tooth distance Pitch between teeth Pin dia. Pin dia.

Note : Japanese standard bucket.

03 –1–8

Unit : mm (ft-in) SK40SR-2 0.13 (0.17) R228.5 (8.98˝) R800 (31.43˝) 518 (20.39˝) 197 (7.74˝) 151 (5.93˝) 600 (23.62˝) 461 (18.15˝) 450 (17.72˝) 150 (5.91˝) ø45 (1.768˝) ø45 (1.768˝)

SK45SR-2 0.14 (0.18)

568 (22.32˝)

650 (25.54˝) 511 (20.08˝) 501 (19.69˝) 167 (6.56˝)

3.2 DETAIL DIMENSION OF LUG SECTION 3-12 DRILL THROUGH

DETAIL OF PLATE

SHIM (t = 0.5) CAPSCREW M10 X 35 BUSHING

PLATE

DETAIL OF Y

SECTION X-X Fig. 3-2 Dimension of lug section Table 3-2

Plate outer dia.

Thread size.

Plate thickness.

Boss outer dia.

Boss thickness.

Screw hole P.C.D.

Dimension

Spring pin dia.

øA

Bore.

Code

Bushing length.

Portion

Unit : mm (in)

Lug plate thickness

SK45SR-2

Pin bore dia.

SK40SR-2

øD

øE

øF

øJ

øN

44 (1.73)

60 (2.36)

8 (0.31)

108 (4.24)

M10

8 (0.31)

95 (3.37)

23 (0.90)

85 (3.34)

45+0.10 14 0 (0.55) (1.768 +0.004 ) 0

Note : Japanese standard bucket.

03 –1–9

3.3 DETAIL DIMENSION OF BOSS SECTION

X øG

10 5

30 °

øD

øC

øB

øA

2 0.

(2)

C 2-

15 DETAIL X

E F

Fig. 3-3 Dimension of boss section

SK40SR-2

Table 3-3

SK45SR-2

Unit : mm (in)

Code

øA

øB

øC

øD

øG

Dimension

75 (2.95)

49 (1.93)

69 (2.71)

73 (2.87)

15 (0.59)

30 (1.18)

13 (0.51)

03 –1–10

4. DOZER 4.1 DOZER DIMENSION

Standard type

Cutting edge type

Fig. 4-1 Dozer dimension

Table 4-1

Code A A1 A2 B C D E F G d1 d2

Item

Unit : mm (ft-in) SK40SR-2 SK45SR-2 Standard type Cutting edge type Standard type Cutting edge type

Blade width 1960 (6´52˝) _ _ 400 (15.72˝) 400 (15.72˝) Cutting edge length (LH & RH) _ _ 1156 (45.42˝) 1156 (45.42˝) Cutting edge length (Center) Blade height 345 (13.56˝) Distance from dozer attaching pin R1079 (42.40˝) R1002 (39.45˝) center to cutting edge end Inner width of dozer attaching bracket 531 (20.86˝) Width of dozer attaching bracket 69 (2.71˝) Distance from dozer attaching pin center to R735 (28.88˝) R659 (25.94˝) attaching pin on dozer cylinder head side Attaching bracket inner width on dozer 62 (2.44˝) cylinder head side Dozer attaching pin dia. ø40 (1.572˝) Attaching pin dia. on dozer cylinder head side ø55 (2.165˝)

03 –1–11

4.2 DOZER MAINTENANCE STANDARDS

1~1.5

2 Pin A, B

0.5~1

B (Bushing O.D) Bore ø50 +0 -0.03

Fig. 4-2 Dozer maintenance standards (1) Clearance of pin and bushing SK40SR-2 SK45SR-2

Pos.

A B

Table 4-2

Pin part No.

Item

Dozer blade cylinder (Rod side) YJ51B01009P1 Dozer blade cylinder (Head side)

Dozer blade foot

Pin C

Unit : mm (in) Clearance

Standard dimensions Tolerance Tolerance Pin dia. on pin dia. on bushing bore dia.

Standard Repairable Service Remedy value level limit

-0.150 +0.25~ -0.210 0.05 ø55 (2.161) -0.0059 +0.0098 -0.0083 ~0.0020

+0.46 0.20 -0.0181 ~0.0079

)

+0.305~ 0.175 +0.0120 ~0.0069

)

(

)(

-0.060 +0.215~ -0.090 0.115 ø40 PH51B01001P1 0.0024 +0.0084 (1.572) -0.0035 ~0.0045

(

)(

Replace 1.5 2.0 (0.060) (0.079) 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. (2) Clearance in thrust direction on the dozer and cylinder installation section SK40SR-2 SK45SR-2 Table 4-3

Unit : mm (in) Pin length

Standard dimensions Pos.

Remedy

Item Code

Clearance X adjusted by shims (total of both sides)

Dimensions

Code Dimensions

0 0 (2.36 -0.020 ) Rod side 60-0.5 L1 1 ) Lower frame 62+10 (2.44 +0.039 2.0 ~ 3.5 0 Adjusted 0 0 (0.079 ~ 0.138) (2.36 -0.020 ) Head side 60-0.5 by B L2 2 +1 +0.039 ) Dozer blade 62 0 (2.44 0 shim 69±0.5 (2.71± 0.020) Dozer blade 2.5 ~ 4.5 C Dozer blade foot L3 3 (0.098 ~ 0.177) ) Lower frame 72 +10 (2.83+0.039 0 (Note) Clearance "X" shall be adjusted by shims, if clearance exceeds the standard value for repair.

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

03 – 1 – 12

141 (5.54) 141 (5.54) 137 (5.38)

5. SWING 5.1 SWING BRACKET DIMENSION

Fig. 5-1 Swing bracket dimension Table 5-1

Unit : mm (in)

Code.

Item

SK40SR-2

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 attaching boom cylinder Pin dia. of attaching swing cylinder

67 (2.63) 211.5 (8.31) 307.5 (12.08) R312 (12.26) 305.1 (11.99) 325 (12.77) 78.5 (3.08) 76 (2.99) 250 (9.82) 77 (3.03) 72 (2.83) ø80 (3.14) ø50 (1.96) ø50 (1.96) ø50 (1.96)

03 –1–13

SK45SR-2

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

View I Fig. 5-2 Clearance of pin and bushing

SK40SR-2

SK45SR-2

Pos.

Item

A B

Swing cylinder (Rod side) Swing cylinder (Head side)

Table 5-2 Pin part No.

PH02B01062P1

Standard dimensions Tolerance Tolerance Pin dia. on bushing on pin dia. bore dia.

ø50 (1.965)

PH02B01063P1

Swing center (Upper) PH02B01047P1

Swing center (Lower) PH02B01048P1

Unit : mm (in)

-0.020 -0.050 -0.0008 -0.0020

( ø80 (3.143)

+0.150 0 +0.0059 0

(

Standard Repairable Service Remedy value level limit

)(

0.200 0.020 0.0079 0.0008

)

)(

0.111 0.029 0.0044 0.0011

)

( )

Clearance

+0.061 +0.009 +0.0024 +0.0004

Replace 1.5 2.0 bushing (0.059) (0.079) or pin

03 –1–14

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

SECTION A-A

SECTION B-B Washer (Thickness2.3) Washer (Thickness2.3)

SECTION C-C, D-D

Fig. 5-3 Clearance of pin and bushing

SK40SR-2

Section

Unit : mm (in)

Standard dimensions

Clearance X reconditioned with shims (total of both sides)

Code Dimensions

Standard Repairable value level

Service limit

0.5~0.9 1.5 (0.020~0.035) (0.059)

0.1~0.5 1.0 (0.004~0.020) (0.039)

Item

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

Table 5-3

SK45SR-2

Rod side Bracket Head side Upper frame Upper frame Bracket Upper frame Bracket

Pin length Remedy

0 0 70 -0.5 (2.75 -0.020 ) +0.039 +1 72 0 (2.83 0 ) 0 0 70 -0.5 (2.75 -0.020 ) L2 +1 +0.039 72 0 (2.83 0 ) +0.020 73 +0.5 ) 0 (2.87 0 L3 +0.5 +0.020 78.5 0 (3.08 0 ) +0.020 73 +0.5 ) 0 (2.87 0 L4 +0.5 +0.020 74 0 (2.91 0 )

03 –1–15

_ _

Code Dimensions

Adjusted by shim Replace washer Adjusted by shim

161 (6.33)

151 (5.93)

153 (6.01)

142 (5.58)

NOTES

Book Code No.

PJ11

02E ➀

NEW HOLLAND EH45 Model Cross-reference: SK45SR-2 is NEW HOLLAND Model EH45

PJ11

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

DATE OF ISSUE

REMARKS

First Edition

October, 2001

S5PJ1102E

Second Revision

January, 2003

S5PJ1102E ➀ K·E

K·E

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 of as the genuine parts. Refer to the below table for the tightening and retightening of capscrews. • The below table 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 for 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 below table.

• 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.

11–1–1

2. SCREW SIZES TO TOOL SIZES 1)

Capscrew

Socket bolt d

B Table 2-1

Table 2-2

Tool size

Nominal screw size (d)

Tool size

M10

M12

M16

(M14)

M20

M16

M24

(M18)

M30

M20

M36

M24

M30

M36

Nominal screw size (d)

B mm

3. TORQUE SPECIFICATIONS FOR JOINTS AND HOSES A. JOINTS FOR PIPING (O-RING SEALING TYPE)

Nominal screw size (PF) Spanner size (mm) Tightening torque kgf·m (lbf·ft) 14 1.7 ± 0.2 (12.3 ± 1.4) 1/8 19 3.7 ± 0.2 (26.8 ± 1.4) 1/4 22 7.5 ± 0.5 (54.2 ± 3.6) 3/8 27 11 ± 1.0 (79.6 ± 7.2) 1/2 36 16.5 ± 1.5 (119 ± 11) 3/4 41 26.0 ± 1.0 (188 ± 7.2) 1

Z2-0081

B. HYDRAULIC HOSE (30º FLARE TYPE)

Nominal screw size (PF) Spanner size (mm) Tightening torque kgf·m (lbf·ft) 14 1.5 ± 0.2 (11 ± 1.5) 1/8 19 3 ± 0.5 (21.7 ± 3.6) 1/4 22 5 ± 0.5 (36.2 ± 3.6) 3/8 27 8 ± 0.5 (57.9 ± 3.6) 1/2 36 12 ± 1.0 (86.8 ± 7.2) 3/4 41 14 ± 1.5 (101 ± 11) 1 NOTE : The application of the tightening torque is subject to a dry condition.

11 – 1 – 3 1

Z2-0051

4. TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS A. SLEEVE TYPE TUBE FITTINGS

Tube size Spanner size (mm) OD X Thickness (mm) 10X1.5 15X2.0 18X2.5 22X3.0 28X4.0 35X5.0

19 27 32 36 41 55

Tightening torque kgf·m (lbf·ft) 5 ± 1 (36 ± 7) 12 ± 1.2 (87 ± 9) 15 ± 1.5 (108 ± 11) 22 ± 2.2 (159 ± 16) 28 ± 2.8 (203 ± 20) 45 ± 4.5 (325 ± 33)

Z2-0061

B. PART NO.

SLEEVE

NUT

Ød

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

Ød

Part No. Nippon A.M.C Ihara Koatu — ZF93S06000 — ZF93S08000 ZF93S10000 ZF93S12000 ZF93S15000 ZF93S18000 ZF93S22000 ZF93S28000 ZF93S32000 ZF93S35000 ZF93S38000

ZA93S10000 — ZA93S15000 ZA93S18000 ZA93S22000 ZA93S28000 — ZA93S35000 —

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. Nippon A.M.C Ihara Koatu — ZF93N06000 — ZF93N08000 ZA93N10000 ZF93N10000 — ZF93N12000 ZF93N15000 ZF93N18000 ZF93N22000 ZF93N28000 ZF93N32000 ZF93N35000 ZF93N38000

ZA93N15000 ZA93N18000 ZA93N22000 ZA93N28000 — ZA93N35000 —

5. PLUGS (1) Plug for hydraulic pipe joint 1) Cap nut (Joint plug)

ØA

Table 5-1

T screw

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

2) Plug (Tube plug)

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

ØA

Sleeve type joint body

Cap nut parts No.

Nut

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

Plug parts No. ZF83P06000 ZF83P08000 ZF83P10000 ZF83P12000 ZF83P15000 ZF83P18000 ZF83P22000 ZF83P28000

Table 5-3

3) Nut

ØA

D screw

Applicable tube O. D A 6 8 10 12 15 18 22 28 32 35 38

11 – 1 – 5 1

Nut parts No.

D screw

Opposing flat

ZF93N06000 ZF93N08000 ZF93N10000 ZF93N12000 ZF93N15000 ZF93N18000 ZF93N22000 ZF93N28000 ZF93N32000 ZF93N35000 ZF93N38000

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

14 17 19 22 27 32 36 41 50 55 60

Table 5-4

(2) Plug for hydraulic equipment 1) PF screw

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

B O ring

Plug parts No. B mm ZE72X04000 19 ZE72X06000 22 ZE72X08000 27 ZE72X12000 36 ZE72X16000 41

O ring parts No. Nominal O ring ZD12P01100 1B P11 ZD12P01400 1B P14 ZD12P01800 1B P18 ZD12P02400 1B P24 ZD12P02900 1B P29

PF screw

2) PT screw

Table 5-5 PT screw PT1/8 PT1/4 PT3/8 PT1/2 PT3/4 PT1 PT1 1/4 PT1 1/2

B PT screw

(3) Plug for (F) flare hose

Plug parts No. B mm ZE82T02000 5 ZE82T04000 6 ZE82T06000 8 ZE82T08000 10 ZE82T12000 14 ZE82T16000 17 ZE82T20000 22 ZE82T24000 22

Table 5-6

PF screw

Opposing flat B

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

Plug parts No. B mm 2444Z2728D1 14 2444Z2728D2 17 2444Z2728D3 22 2444Z2728D4 27 2444Z2728D5 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. E mm F mm 2444Z2729D1 14 19 2444Z2729D2 17 22 2444Z2729D3 23 27 2444Z2729D4 27 36 2444Z2729D5 36 41 2444Z2729D6 40 50

11–1–5

6. SPECIAL SPANNERS 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)

40(1.57)

+0.012 12.7 +0.3 -0.1 (0.05 -0.004 )

70(2.76)

18 (0.709)

2421T138

19(0.748)

22(0.866) 2(0.866)

+0.012 12.7 +0.3 -0.1 (0.05 -0.004 )

70(2.76)

22 (0.866)

2421T130

22(0.866)

23(0.906)

+0.012 12.7 +0.3 -0.1 (0.05 -0.004 )

60(2.36)

28 (1.102)

2421T115

109(4.29) 11.5(0.453)

29(1.142)

22(0.866)

+0.012 12.7 +0.3 -0.1 (0.05 -0.004 )

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

Service

Screw locking compound Sealing compound

Loctite

Three-Bond

#242

1360K

#262

1374

Middle strength

#271

1305

High strength

#515

1215

Sealing

11–1–6

Low strength

8. COUNTERWEIGHT LIFTING JIG

Q’ty : 1 set (2 pcs.) Material : Steel

Fig. 8-1 Counterweight lifting jig

11–1–7

NOTES

Book Code No.

PJ12

02E ➀

NEW HOLLAND EH45 Model Cross-reference: SK45SR-2 is NEW HOLLAND Model EH45

STANDARD MAINTENANCE TIME TABLE TABLE OF CONTENTS 1. STANDARD WORKING TIME TABLE for MAINTENANCE OF EXCAVATOR 01 02 03 04

Attachment ................................................................................................1-1 Canopy & Guard .......................................................................................1-2 Upper structure .........................................................................................1-3 Upper carriage ..........................................................................................1-6

12 –0–1 ➀

PJ12

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.

3) Place :

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 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 midnight 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) Applicable Machine for Estimation of Standard Maintenance Time 1) Standard machine. 2) A well maintained machine combined with standard attachments which has operated in a normal circumstances.

REVISION

DATE OF ISSUE

REMARKS

First Edition

October, 2001

S5PJ1202E

Second Revision

January, 2003

S5PJ1202E ➀ K·E

K·E

12 –0–2 ➀

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) 3) When more than one work are done, a) Add each standard maintenance time b) Assy works include the following works marked with black dot •

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

GROUP Attachment Canopy and Guard Upper Structure Under carriage

WORK TO BE DONE To indicate removing, installing, replacement and overhaul.

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

REMARKS

Refer to 32-I item2 1 pc. Include adjustment 1 pc. 1 pc. Include stopper pin. 1 pc. 1 pc. 1 pc. Not include removing and installing 1 pc. Refer to 32-I item 3 Removal/Inst. 1 pc. Preparation 1 pc. Removal/Inst. Preparation Removal/Inst. - ditto Preparation O/H Replace

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. 1 pc. – ditto – Removal/Inst. 1 pc. Include stopper pin. 1 pc. – ditto – 1 pc. – ditto –

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

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 (Option)

11 12 20 21 22 23 24

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

WORK TO BE UNIT DONE 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

REMARKS

Include stopper pin.

Include seal. Include seal. Include seal. Refer to 32-I item 5

1 pc. 1 pc. 1 pc. 1 pc. 1 pc. After removing swing bracket. Removal / Inst. 2 pcs. 1 pc. – ditto – 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. 2 pcs. – ditto – 1 pc. – ditto – 2 pcs. – ditto – 1 pc. O/H 1 set Include seal. Replace Refer to 33-I item 1 Removal / Inst. – ditto – – ditto – – ditto – – ditto –

– ditto – – ditto –

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

1 pc. 1 pc. Refer to 33-I item 1

0.4 0.1

Removal / Inst. 1 pc. Removal / Inst. 1 pc. Refer to 33-I item 2 Removal / Inst. Removal / Inst. Removal / Inst. Removal / Inst.

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 Other necessary works Counterweight portion Counter weight ASSY • Lifting tools • Slinging • Counterweight fixing bolt Other necessary works Control portion E / G control cable Dozer yoke Dozer cable Swing yoke Swing cable Other necessary works Intake portion Air cleaner ASSY • Hose (1) • Hose (2) • Element Exhaust portion Muffler ASSY • Muffler attaching bolts (13) (14) • Clamp Other necessary works E / G Accessory portion Dynamo (Generator) • Connector • Dynamo fixing bolt • V-bolt Other necessary works Starter • B-terminal • S-terminal connector • Starter fixing bolt Other necessary works

WORK TO BE DONE Removal / Inst. Removal / Inst. Removal / Inst. ----------------Removal / Inst. Removal / Inst. Removal / Inst. Removal / Inst. Removal / Inst. Removal / Inst. Preparation Removal / Inst. – ditto – – ditto – Removal / Inst. – ditto – – ditto – – ditto – – ditto – – ditto –

UNIT

REMARKS

1 pc. 1 pc. 1 pc. ------ ------------------1 pc. 1 pc. 1 pc. 1 pc. Refer to 33-1 item3 1 set 1 pc. Canopy removal/inst Refer to 33-I item 6 1 pc. 1set 1 pc. 1 set 3 pcs. Guard

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

12 –1–3

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 0.5 0.1 0.1 0.3 0.1 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 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 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78

Pump portion Pump ASSY • 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 fixing bolt • Radiator lifing or slinging Other necessary works

WORK TO BE UNIT DONE

REMARKS

Refer to 33-I item 7 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 3 pcs. 1 pc. Guard Refer to 33-I item 8 Removal / Inst. 1 pc. After removing fuel tank ; Preparation 1 pc. 1 pc. Include O-ring replacing Replace 1 pc. – ditto – Removal / Inst. 1 pc. 1 pc. Include O-ring replacing Replace Removal / Inst. 1 pc. 1 pc. – ditto – 1 pc. – ditto – 2 pcs. – ditto – 5 pcs. – ditto – 1 pc. Guard – ditto – Preparation 1 pc. Hyd.Oil pressurize Removal / Inst. Replace Removal / Inst. – ditto – – ditto – Removal / Inst. – ditto –

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

Refer to 33-I item 13 1 pc. After removing fuel tank 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. Counterweight 1 pc. Guard,Under cover

UNIT : HOUR 0.7 0.2 0.1 0.1 0.1 0.2 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

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

GROUP No.

03 Upper structure

80 81 82 83 84 85

EQUIPMENT PORTION Engine (E / G) Installing portion Engine ASSY • Fuel hose • Harness, connector and cable • Engine fixing double 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

REMARKS

Refer to 33-I item 15 Removal / Inst. 1 pc. 4 pcs. For injection pump - 2 pcs. – ditto – For feed pump - 2 pcs. Removal / Inst. 1 set. 1 pc. – ditto – 1 set. – ditto – Removal / Inst. 1 pc. Canopy 1 set Guard – ditto – 1 pc. Counterweight – ditto – 1 pc. Air cleaner – ditto – 1 pc. Muffler – ditto – 1 pc. Pump – ditto – 1 pc. Radiator – ditto – Refer to 33-I item 16 Removal / Inst. 1 pc. 1 set Include attaching hose's – ditto – tag and plug 1 set – ditto – 1 set – ditto – 1 pc. O/H Removal / Inst. 1 pc. Canopy 1 set Floor plate – ditto – 1 set Cover (7) – ditto – Refer to 33-I item 19 Removal / Inst. 1 pc. 6 pcs. Include attaching hose's – ditto – tag and plug 1 pc. – ditto – 1 pc. – ditto – 1 pc. Greasing 1 pc. O/H Removal / Inst. 1 set Canopy 1 set Floor plate – ditto – Refer to 33-I item 20 Removal / Inst. 1 pc. After removing slewing motor 1 pc. – ditto – – 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.

UNIT : HOUR 1.0 0.2 0.3 0.2 0.2 0.2 1.5 0.4 0.2 0.4 1.2 1.2 1.6 0.1 0.4 0.1 3.0 0.2 0.5 0.2 1.5 0.6 0.1 0.5 0.1 3.0 0.2 0.5 2.5 0.1

1.5 0.1 0.2 2.0 0.1 0.2 0.1

04 Under carriage

03 Upper structure

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

00 01 02 03 04

Travel portion Rubber crawler • Rubber shoe removing / inst. position. • Tension adjusting • Crawler shoe

10 11 12 20 21 22 30 31 32 33 34 40 41 50 51 52 53

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

WORK TO BE UNIT DONE

REMARKS

UNIT : HOUR

Refer to 33-I item 21 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) Counterweight Hydraulic oil Swivel joint hose Boom, Swing bracket Refer to 34-I item 2 & 3

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 frame 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.

PJ13

02E ➁

NEW HOLLAND EH45 Model Cross-reference: SK45SR-2 is NEW HOLLAND Model EH45

MAINTENANCE STANDARDS AND TEST PROCEDURES TABLE OF CONTENTS 1. HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS ..............1-1 2. PERFORMANCE STANDARD TABLE .............................................................1-2 3. ENGINE SPEED ..............................................................................................1-6 4. HYDRAULIC OIL PRESSURE .........................................................................1-7 5. TRAVEL PERFORMANCE .............................................................................1-10 6. SLEW PERFORMANCE ................................................................................1-12 7. ATTACHMENT OPERATING PERFORMANCE .............................................1-14 8. SLEW BEARING PERFORMANCE ...............................................................1-16 9. CRAWLER TENSION ....................................................................................1-16

13 –0–1 ➀

PJ13

REVISION

DATE OF ISSUE

REMARKS

First Edition

October, 2001

S5PJ1302E

Second Revision

January, 2003

S5PJ1302E ➀ K·E

K·E

13 –0–2 ➀

Book Code No.

PJ22

02E ➁

NEW HOLLAND EH45 Model Cross-reference: SK45SR-2 is NEW HOLLAND Model EH45

HYDRAULIC SYSTEM TABLE OF CONTENTS

PJ22 1. SUMMARY ........................................................................................................1-1 2. HYDRAULIC CIRCUITS AND COMPONENTS 2.1

Standard Circuit Diagram .........................................................................1-3

3. HYDRAULIC CIRCUIT OPERATION 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12

Outline of Hydraulic Circuit.......................................................................1-6 Neutral Circuit ..........................................................................................1-7 Travel Operating Circuit............................................................................1-8 Slew Operating Circuit............................................................................1-10 Bucket Operating Circuit ........................................................................1-12 Boom Operating Circuit..........................................................................1-14 Arm Operating Circuit.............................................................................1-16 Swing Operating Circuit .........................................................................1-18 Dozer Operating Circuit..........................................................................1-20 Travel/Dozer Combined Operating Circuit ..............................................1-22 Travel/Boom Raise Combined Circuit.....................................................1-24 Nibbler/Breaker Operating Circuit ..........................................................1-28

4.SCHEMATIC PIPING FOR HYDRAULIC SYSTEM........................................1-28

22 –0–1 ➀

REVISION

DATE OF ISSUE

REMARKS

First Edition

October, 2001

S5PJ2202E

Second Revision

January, 2003

S5PJ2202E ➀ K·E

K·E

22 –0–2 ➀

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. Table. 1-1

PerforDevice mance

Function

Travel

• Straight traveling (at combined operation with dozer). • Travel 1-2 speed change. • Preventing overrunning of travel motor. • Travel pilot control by means of hydraulic system. • Travel lock. • Automatic parking brake.

Slewing

• Auto slewing parking brake. • Slewing shockless function.

• Hydraulic pilot control system. • Dozer (with slewing) independent circuit. Attachment

Easy Operation and Safety

• Slwing (with dozer) independent circuit.

• John Deere pattern multi control valve (KAI Option).

• Securing straight traveling at combined operations of travel and other operations. • Travel 1-2 speed select and auto return to 1st speed. • Preventing overrunning on a slope. • Preventing hunting by built-in travel shockless mechanism. • Safety lock lever locks operation of travel lever • Automatic braking at parking. • Constant slewing speed when operating in simultaneous operation condition. • Protecting against slewing overrun at slope. • Smooth feeling when starting and stopping slewing operation. • Responsive operability. • Secure the travel straight when travelling and working with dozer. • The shift lever is available to change in two control patterns.

Others

• Preventing contamination of hydraulic oil and improving self sucking up efficiency. • Removing dirt of suction side. • Preventing malfunction in pilot operating circuit. • Preventing contamination of hydraulic oil. • Preventing deterioration of hydraulic oil.

• Suction strainer. • Line filter in pilot circuit. • Return filter. • Cooling hydraulic oil by oil cooler.

Electricity Attachment Travel Pump

Low Fuel High Working Performance Consumption

• Closed pressurized hydraulic oil tank.

Features

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

• Efficient use of engine power with variable pump (Power shifting by P3 pump).

• 2 speeds traveling.

• Improving working efficiency with 2 travel speeds shifting.

• Recirculation of return oil at light load digging • Speed-up for light load digging with arm. 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 COMPONENTS OCEANIA No.

SK40SR-2

COMPONENTS

PARTS No.

MODEL No.

EU & OCEANIA No.

COMPONENTS

SK45SR-2 PARTS No.

PUMP

PH10V00004F1

CONTROL VALVE

[PH30V00019F1] BCV65-AE10 PH30V00019F2

CANOPY SPEC. PY10V00009F1 PY10V00010F1 CAB. SPEC. [PY30V00012F1] CONTROL VALVE PY30V00012F2

SLEWING MOTOR

PH15V00007F1

SG015E-501

SLEWING MOTOR

TRAVEL MOTOR

GM06VN

TRAVEL MOTOR

BOOM CYLINDER

75-40-546

ARM CYLINDER

90-50-587

BUCKET CYLINDER

95-55-180

SWING CYLINDER

AP2D25LV1RS7

PUMP

PY15V00007F1

MODEL No. AP2D25LV1RS7 BCV65-AF10 SG015E-502A

ARM CYLINDER

BUCKET CYLINDER

SWING CYLINDER

DOZER CYLINDER

[PH15V00009F2] PH15V00009F3 [PH01V00014F2] PH01V00014F3 [PH01V00021F1] PH01V00021F2 [PH01V00016F2] PH01V00016F3 [PH01V00017F2] PH01V00017F3 [PH01V00018F1] PH01V00018F2

SWIVEL JOINT

24100J12703F1

PV48M1007B

DOZER CYLINDER

[PY15V00009F2] PY01V00009F3 [PY01V00031F2] PY01V00031F3 [PY01V00030F2] PY01V00030F3 [PY01V00034F1] PY01V00034F2 [PH01V00016F2] PH01V00016F3 [PH01V00017F2] PH01V00017F3 [PY01V00033F1] PY01V00033F2

PILOT VALVE (ATT)

PA30V00002F2

PVD6P4001

SWIVEL JOINT

24100J12703F1

PILOT VALVE (TRAVEL)

PM30V00019F1

2KWE5A-20 / G12WS-206A

PILOT VALVE (ATT)

PA30V00002F2

PV48M1007B

SOLENOID VALVE

PH35V00001F2

K16AR6-11

PILOT VALVE (TRAVEL)

PM30V00019F1

PVD6P4001

SHUTTLE VALVE

PH26V00001F1

SOLENOID VALVE

PH35V00001F2

2KWE5A-20 / G12WS-206A

RETURN FILTER

PH50V00005F1

Y-168600

SHUTTLE VALVE

PH26V00001F1

VALVE

PH21V00002F1

SB12B50A014A

SUCTION STRAINER

PM50V00017F3

Y-426800

RETURN FILTER

PH50V00005F1

Y-462900

INLINE FILTER

PY50V00001F1

S15A-K2

VALVE

PH21V00002F1

Y-168600

CHECK VALVE

2436R1062D62

SUCTION STRAINER

PM50V00017F3

SB12B50A014A

STOP VALVE

INLINE FILTER

PY50V00001F1

Y-426800

HYDRAULIC TANK

CHECK VALVE

2436R1062D62

S15A-K2

OIL COOLER

STOP VALVE

2436R912F2 (Applicable Machines : PJ02-00101~) PF25V00001F1 (Applicable Machines : PJ03-01001~)

SELECTOR VALVE

PH30V00007F1

EU ONLY

RELIEF VALVE

PM22V00005F3

EU ONLY

HYDRAULIC TANK

PH33H00009P1 (Applicable Machines : PJ02-00101~) PH33H00010P1 (Applicable Machines : PJ03-01001~)

OIL COOLER

PY53V00002P1

PH53V00002P1 Note :

22 – 1 – 2 1

2436R912F2 PF25V00001F1 PH33H00009P1 PH33H00010P1

90-50-696 80-50-717

(Applicable Machines : PH03-02001~) (Applicable Machines : PH04-02801~) (Applicable Machines : PH03-02001~) (Applicable Machines : PH04-02801~) Z452-138-1002

is for reference only, because the model numbers and • This part numbers might be changed due to improvement. part Nos. in [ ] are for the earlier ones before the • The improvement / change.

GM06VN 100-55-654 EU 100-55-684 OCEANIA 90-50-720 75-40-546 90-50-587 95-55-175

1452-067-1000

Note : 1) This is for reference only, because the model numbers and part numbers might be changed due to improvement. 2) EU machine has N / B piping as a standard specification. OCEANIA machine has Breaker piping as a standard specification. 3) The part Nos. in [ ] are for the earlier ones before the improvement / change.

2.1-1

EU & OCEANIA SPECIFICATION BREAKER

DOZER D2 R1

( EU only)

NIBBLER

BOOM FORWARD A

A REVERSE

B REVERSE

6 NIBBLER ARM BREAKER

7 Z

TRAVEL RIGHT

TRAVEL LEFT

G6 D2

22 23

( EU only)

BUCKET A

D G7

BOOM SWING

IN OUT C A PG

RED

FORWARD B

C B Mu A LEFT RIGHT

UP DOWN

B DFE

BUCKET DUMP BOOM DOWN

20 16

ARM IN SLEWING LEFT

UP DOWN

SLEWING RIGHT ARM OUT

RIGHT LEFT

BOOM UP BUCKET DIGGING

DIGGING DUMP

2 G3

Pa9 Pa8' Dr1 B8 BUCKET

A8 Pa8

B7 BOOM

A7 Pa7 G1 P1

P2 G2 Pa6

B6 Pa5

A5 ARM

B5 Pa4 A4 BOOM SWING

B4 B3 BREAKER NIBBLER

Pa2 SLEWING

A2 B1 DOZER

4 2

* Pb9

TRAVEL LEFT

Pb8

Pb7

TRAVEL RIGHT

Pb6

Pb5

TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE

4 4

*4 T1

Pb2

LEVER LOCK A2

TRAVEL 1-2SPEED A1 CHANGEOVER

13 19 P1 P2

TRAVEL RIGHT FORWARD TRAVEL LEFT FORWARD

Valve pressure Mark 1

4 ( EU only)

* *2 *3

Valve name

kgf/cm

psi

Mark

3270

2840

Main relief valve P1,P2

230kgf/cm

Main relief valve P3

200kgf/cm

Over load relief valve

280kgf/cm

3980

* *5 *6

Valve name

kgf/cm

psi 2

3700

2570

Over load relief valve

260kgf/cm

Slewing relief valve

180kgf/cm

Pilot relief valve

35kgf/cm

500

Note). 1) Codes G1 to G8 show the gauge ports. 2) Following parts are not equipped in Oceania machine. 1. Selector valve (23),and piping between the selector valve and B3 port of C/V (2). 2 . Relief valve (24).

22 – 1 – 3

KAI (Applicable Machines : PJ02-00101~) No. 1 2

COMPONENTS

SK45SR-2 PARTS No.

CANOPY SPEC. PY10V00009F1 PY10V00010F1 CAB. SPEC. [PY30V00023F1] CONTROL VALVE PY30V00023F2 PUMP

PY15V00007F1

MODEL No. AP2D25LV1RS7 BCV65-AL10 SG015E-502A

SLEWING MOTOR

TRAVEL MOTOR

BOOM CYLINDER

ARM CYLINDER

BUCKET CYLINDER

SWING CYLINDER

DOZER CYLINDER

[PY15V00009F2] PY15V00009F3 [PY01V00031F2] PY01V00031F3 [PY01V00034F1] PY01V00034F2 [PH01V00016F2] PH01V00016F3 [PH01V00017F2] PH01V00017F3 [PY01V00033F1] PY01V00033F2

SWIVEL JOINT

24100J12703F1

PILOT VALVE (ATT)

PA30V00002F2

PV48M1007B

PILOT VALVE (TRAVEL)

PM30V00019F1

PVD6P4001

SOLENOID VALVE

PH35V00001F2

2KWE5A-20 / G12WS-206A

SHUTTLE VALVE

PH26V00001F1

SELECTOR VALVE (OPT)

RETURN FILTER

PH50V00005F1

Y-462900

VALVE

PH21V00002F1

Y-168600

SUCTION STRAINER

PM50V00017F3

SB12B50A014A

INLINE FILTER

PY50V00001F1

Y-426800

CHECK VALVE

2436R1062D62

S15A-K2

SOLENOID VALVE

PE35V00001F1

STOP VALVE

SELECTOR VALVE

PH30V00007F1

HYDRAULIC TANK

PH33H00009P1

OIL COOLER

PY53V00002P1

2436U1458F3

GM06VN 100-55-654 90-50-720 75-40-546 90-50-587 95-55-175

K8AR8 (John Deere pattern multi-C/V)

2436R912F2

• •

1452-067-1000

Note : : This Note This is is for for reference reference only, only, because because the the model model numbers numbers and and part part numbers numbers might might be be changed changed due due to to improvement. improvement. The part Nos. in [ ] are for the earlier ones before the improvement / change.

22 – 1 – 4 1

2.1-2

Applicable Machines : PH03-02001~ : PJ02-00101~

KAI SPECIFICATION

D2 R1

9 G5

BREAKER

DOZER

NIBBLER

FORWARD A

A REVERSE

B REVERSE

RED

BOOM FORWARD B

ARM

NIBBLER BREAKER BUCKET D1 Z

TRAVEL RIGHT

TRAVEL LEFT

G6 D2

14 Au

BOOM SWING

D IN OUT C A PG

RED

B DFE

*5 G7

UP DOWN

B Mu A LEFT RIGHT

BOOM SWING LEFT SLEWING LEFT BOOM SWING RIGHT SLEWING RIGHT T A2 B2 A1 B1

BUCKET DUMP

20 16

RIGHT LEFT DIGGING DUMP B9

A8 Pa8

B7 BOOM

A7 Pa7 G1 P1

B6 Pa5

B5 Pa4

ARM

P2 G2 Pa6

A4 B4 B3 BOOM BREAKER SWING NIBBLER

G3 Pa2 P3 SLEWING

P SW30

ARM OUT BOOM DOWN ARM IN BOOM UP

Pa9 Pa8' Dr1 B8 BUCKET

P2 P SW31

UP DOWN

(OPT.)

15 DBHF

B1 DOZER

D BUCKET DIGGING A C E G

25 42

4 2

* Pb9

TRAVEL LEFT

Pb8

Pb7

TRAVEL RIGHT

*4 Pb5

Pb6

Pb4

TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE

Pb2

TRAVEL RIGHT FORWARD TRAVEL LEFT FORWARD TRAVEL 1-2SPEED A1 CHANGEOVER

13 19 P1 P2

Valve pressure Mark 1

LEVER LOCK A2

* *2 *3

Valve name

kgf/cm

psi 2

3270

2840

3980

Main relief valve P1,P2

230kgf/cm

Main relief valve P3

200kgf/cm

Over load relief valve

280kgf/cm

Mark 4

* *5 *6

Valve name

kgf/cm

psi 2

3700

2570

Over load relief valve

260kgf/cm

Slewing relief valve

180kgf/cm

Pilot relief valve

35kgf/cm

Note).Codes G1 to G8 show the gauge ports.

500

22 – 1 – 5 1

KCMA (Applicable Machines : PJ03-01001~) No.

COMPONENTS

PARTS No.

CANOPY SPEC. PY10V00009F1 PY10V00010F1 CAB. SPEC.

MODEL No. AP2D25LV1RS7

PUMP

CONTROL VALVE

PY30V00029F1

BCV65-AL10

SLEWING MOTOR

PY15V00007F1

SG015E-502A

TRAVEL MOTOR

PY15V00009F3

GM06VN

BOOM CYLINDER

PY01V00031F3

100-55-654

ARM CYLINDER

PY01V00034F2

90-50-720

BUCKET CYLINDER

PH01V00016F3

75-40-546

SWING CYLINDER

PH01V00017F3

90-50-587

DOZER CYLINDER

PY01V00033F2

95-55-175

SWIVEL JOINT

24100J12703F1

PILOT VALVE (ATT)

PA30V00002F2

PV48M1007B

PILOT VALVE (TRAVEL)

PM30V00019F1

PVD6P4001

SOLENOID VALVE

PH35V00001F2

2KWE5A-20 / G12WS-206A

SHUTTLE VALVE

PH26V00001F1

SELECTOR VALVE (OPT)

RETURN FILTER

PH50V00005F1

Y-462900

CHAECK VALVE

PH21V00002F1

Y-168600

SUCTION STRAINER

PM50V00017F3

SB12B50A014A

INLINE FILTER

PY50V00001F1

Y-426800

CHECK VALVE

2436R1062D62

S15A-K2

SOLENOID VALVE

PE35V00001F1

STOP VALVE

PF25V00001F1

SELECTOR VALVE

PH30V00007F1

SOLENOID VALVE

PY35V00005F1

ELBOW

PV64H01042P1

HYDRAULIC TANK

PH33H00010P1

OIL COOLER

PY53V00002P1 Note :

22 – 1 – 5 A

SK45SR-2

2436U1458F3

K8AR8 (John Deere pattern multi-C/V)

16105-00000

1452-067-1000

is for reference only, because the model numbers and • This part numbers might be changed due to improvement.

2.1-2 b

KCMA SPECIFICATION

(Applicable Machines SK45SR-2:PJ03-01001~)

9 D2 R1

BREAKER

DOZER

NIBBLER

FORWARD A

A REVERSE

B REVERSE

RED

BOOM FORWARD B

ARM

NIBBLER BREAKER BUCKET D1 Z

TRAVEL RIGHT

TRAVEL LEFT

G6 D2

14 Au

BOOM SWING

D IN OUT C A PG

RED

B DFE

*5 G7

UP DOWN

B Mu A LEFT RIGHT

BOOM SWING LEFT SLEWING LEFT BOOM SWING RIGHT SLEWING RIGHT T A2 B2 A1 B1

BUCKET DUMP

20 16

P2 P SW31

UP DOWN RIGHT LEFT DIGGING DUMP

P SW30

ARM OUT BOOM DOWN ARM IN BOOM UP

(OPT.)

15 DBHF

Pa9 Pa8' Dr1 B8 BUCKET

A8 Pa8

B7 BOOM

A7 Pa7 G1 P1

B6 Pa5

B5 Pa4

ARM

P2 G2 Pa6

A4 B4 BOOM SWING

Pa3 B3

Pa2 SLEWING

B1 DOZER

D BUCKET DIGGING A C E G

27 42

4 2

* Pb9

TRAVEL LEFT

Pb8

Pb7

TRAVEL RIGHT

*4 Pb5

Pb6

Pb4

TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE

Pb2

TRAVEL RIGHT FORWARD TRAVEL LEFT FORWARD LEVER LOCK A2

TRAVEL 1-2SPEED A1 CHANGEOVER

25 A

Valve pressure Mark

* *2 *3

P P1 P2

Valve name

kgf/cm

psi

Mark

3270

2840

Main relief valve P1,P2

230kgf/cm

Main relief valve P3

200kgf/cm

Over load relief valve

280kgf/cm

Note).Codes G1 to G8 show the gauge ports.

3980

* *5 *6

Valve name

kgf/cm

psi 2

3700

2570

Over load relief valve

260kgf/cm

Slewing relief valve

180kgf/cm

Pilot relief valve

35kgf/cm

500

22 – 1 – 5 B

3. HYDRAULIC CIRCUIT OPERATION

3.2 NEUTRAL CIRCUIT (1) Pilot circuit 1) Pilot primary pressure circuit

This explanation is described as SK45SR-2 of earlier KAI model before improvement.

The delivery oil from A4 port of pump Assy (1)

The difference between KAI, EU and OCEANIA are shown in following table. No.

flows into solenoid valve (13) through line filter KAI

(19). The delivery pressure from A2 port of solenoid

Hydraulic pilot type

valve (13) is led to pilot valve (11) for attach-

Item Boom swing section of control valve (2) John deere pattern multi-control valve (15)

EU Direct pulling with cable of pedal Without

With in option

Solenoid valve (21)

Without

With

Selector valve (23)

With

Without

With

Relief valve (24)

With

Without

With

1 2

OCEANIA

ments and P port of pilot valve (12) and Pp port of solenoid valve (21) for travel by releasing the lever lock(operating condition). Since the control circuit is completely closed at neutral position,the delivery oil, having nowhere to flow, is released by the relief valve(set pressure 35kgf/cm2 (500psi) built in solenoid valve (13) and returns into hydraulic oil tank (25). The solenoid valve (21) is installed on only ma-

3.1 COLOR CODING STANDARDS

chines in KAI specification to switch operating

Blue

circuits of slewing and boom swing motions.

: Supply/Drain circuit 3.5 kgf/cm2 (50 psi)

Green : Return/Make-up circuit 3.5~6 kgf/cm2 (50~85 psi) Purple : Secondary pilot pressure 6.0~35 Red

kgf/cm2

(85~500 psi)

: Primary pilot pressure 35~40 kgf/cm2 (500~570 psi)

Orange: Main pump drive pressure 50~280 kgf/cm2 (710~3980 psi) Blue tone

: Shifted condition of valve (spool)

Red valve : Indication for opened condition on valve Red solenoid : Energized condition

Displaying the flow circuit and standby circuit when operating. Regarding the electrical symbols in this manual,refer to the electric circuit diagram.

2) Pilot secondary pressue circuit While the pilot valve (11),(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 valve. (2) Main circuit 1) Variable displacement pump circuit The delivery oil from A1 and A2 ports of the pump

A part of return oil from control valve (2) returns

is led to P1 and P2 ports of control valve (2).

into hydraulic oil tank (25) through check valve

The oil in P1 port flows through each valve for

(20), which made up the slewing boost circuit.

travel straight, travel left, boom and bucket operations, and the oil in P2 port flows through each valve for travel straight, travel right, arm, swing and breaker / nibbler operations, and all oil from P1 and P2 ports returns in hydraulic oil tank (25) from T2 port through oil cooler (26). 2) The 3rd pump circuit The delivery oil from A3 port of the 3rd pump flows into P3 port of control valve (2). The oil led to P3 port flows through valve for slewing and dozer, confluxes with the oil led to P2 port in breaker/nibbler valve, and the oil returns into hydraulic oil tank (25) through T2 port.

22 â&#x20AC;&#x201C; 1 â&#x20AC;&#x201C; 6 1

Notes:

9 D2 R1

BREAKER

DOZER

NIBBLER

FORWARD A

A REVERSE

B REVERSE

RED

BOOM FORWARD B

ARM

NIBBLER BREAKER BUCKET D1 Z

TRAVEL RIGHT

TRAVEL LEFT

G6 D2

14 Au

BOOM SWING

D IN OUT C A PG

RED

B DFE

*5 G7

UP DOWN

B Mu A LEFT RIGHT

BOOM SWING LEFT SLEWING LEFT BOOM SWING RIGHT SLEWING RIGHT T A2 B2 A1 B1

BUCKET DUMP

20 16

RIGHT LEFT DIGGING DUMP B9

A8 Pa8

B7 BOOM

A7 Pa7 G1 P1

B6 Pa5

B5 Pa4

ARM

P2 G2 Pa6

A4 B4 B3 BOOM BREAKER SWING NIBBLER

G3 Pa2 P3 SLEWING

P SW30

ARM OUT BOOM DOWN ARM IN BOOM UP

Pa9 Pa8' Dr1 B8 BUCKET

P2 P SW31

UP DOWN

(OPT.)

15 DBHF

B1 DOZER

D BUCKET DIGGING A C E G

25 42

4 2

* Pb9

TRAVEL LEFT

Pb8

Pb7

TRAVEL RIGHT

*4 Pb5

Pb6

Pb4

TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE

Pb2

TRAVEL RIGHT FORWARD TRAVEL LEFT FORWARD TRAVEL 1-2SPEED A1 CHANGEOVER

13 19 P1 P2

Valve pressure Mark 1

LEVER LOCK A2

Valve name Main relief valve P1,P2

* * 2 Main relief valve P3 * 3 Over load relief valve NEUTRAL CIRCUIT

kgf/cm

psi 2

3270

2840

3980

230kgf/cm 200kgf/cm 280kgf/cm

Mark 4

* *5 *6

Valve name

kgf/cm

psi 2

3700

2570

Over load relief valve

260kgf/cm

Slewing relief valve

180kgf/cm

Pilot relief valve

35kgf/cm

Note).Codes G1 to G8 show the gauge ports.

500

22 – 1 – 7

3.3 TRAVEL CONTROL CIRCUIT Pilot hydraulic system by means of control lever 3.3.1 Travel independent (forward) 2-speed control circuit (1) Pilot circuit 1) Travel 2-speed change signal Press the mark “Rabbit and Turtle” on the right lever knob for travel (cut the power, and it returns to the 1st speed.), and the travel 1,2-speed change valve of solenoid valve (13) actuates. The 2nd-speed command pressure oil flows from A1 port of solenoid valve (13) into P port of travel motor (4) through swivel joint (10), and switches the speed change valve. 2) Switching travel valve spool The pilot secondary pressure is delivered to pilot valve (12) by travel forward operation. The pressure oil flows into Pb7 and Pb6 ports of control valve (2) and switches the travel spool. (2) Main circuit 1) Circuit to travel motor (4) The delivery oil from A1 and A2 ports of the variable pump flows into P1 and P2 ports of control valve(2), and is led to B7 and B6 ports through the travel valve. And then reaches to B port of the right travel motor and A port of the left travel motor through swivel joint (10). 2) Travel motor The supplied pressure oil switches the spool of

to the speed well-balanced with the oil flow de-

counter balance valve, and opens the return oil

livered by pump.

circuit closed by the function of the check valve, and release parking brake then consequently starts rotating the travel motor. In 2nd-speed command condition, the pressure oil passed through the speed change valve acts on the 2speed change piston and changes the motor in high speed and low torques. When running down a steep slope, etc., the pressure on the supply side reduces as the motor reaches close to the overrunning condition, then the counter balance valve spool is shifted to the neutral position by the spring force. Consequently the passage on the return oil side is throttled and the motor reduction is suppressed by the back-pressure, and the motor is controlled

22 – 1 – 8

The counter balance valve spool is slowly switched by the effect of throttling. Consequently the motor rotates or stops, absorbing the shock when starting or stopping rotating. When the oil pressure rises to 185 kgf/cm2 (2630 psi) or higher, traveling at 2nd-speed, the selfpressure pushes back the speed change valve, consequently the speed automatically returns to 1st-speed because the pressure oil of 2-speed change piston is led to the drain.

1.2speed select piston 1.2speed select valve D2 R1

Counter balance valve

BREAKER

DOZER

NIBBLER

FORWARD A

A REVERSE

B REVERSE

RED

BOOM FORWARD B

ARM

NIBBLER BREAKER BUCKET D1 Z

TRAVEL RIGHT Parking brake valve

TRAVEL LEFT

G6 D2

14 Au

BOOM SWING

Parking brake

D IN OUT C A PG

RED

B DFE

*5 G7

UP DOWN

B Mu A LEFT RIGHT

BOOM SWING LEFT SLEWING LEFT BOOM SWING RIGHT SLEWING RIGHT T A2 B2 A1 B1

BUCKET DUMP

20 16

RIGHT LEFT DIGGING DUMP B9

A8 Pa8

B7 BOOM

A7 Pa7 G1 P1

B6 Pa5

B5 Pa4

ARM

P2 G2 Pa6

A4 B4 B3 BOOM BREAKER SWING NIBBLER

G3 Pa2 P3 SLEWING

P SW30

ARM OUT BOOM DOWN ARM IN BOOM UP

Pa9 Pa8' Dr1 B8 BUCKET

P2 P SW31

UP DOWN

(OPT.)

15 DBHF

B1 DOZER

D BUCKET DIGGING A C E G

25 3

4 2

* Pb9

TRAVEL LEFT

Pb8

Pb7

TRAVEL RIGHT

*4 Pb5

Pb6

Pb4

TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE

Pb2

TRAVEL RIGHT FORWARD TRAVEL LEFT FORWARD TRAVEL 1-2SPEED A1 CHANGEOVER

13 19

Valve name Main relief valve P1,P2

kgf/cm

230kgf/cm

psi

Mark

3270

Valve name Over load relief valve

kgf/cm

psi 2

260kgf/cm

Note).Codes G1 to G8 show the gauge ports.

3700

* * 180kgf/cm 2570 200kgf/cm 2840 * 5 Slewing relief valve * 2 Main relief valve P3 Over load relief valve 280kgf/cm 3980 3 Pilot relief valve 35kgf/cm 500 6 * * TRAVEL CIRCUIT: Right & Left travel simultaneously at travel 2nd speed 2

Valve pressure Mark 1

LEVER LOCK A2

22 – 1 – 9

3.4 SLEWING OPERATION CIRCUIT Pilot hydraulic system by means of control lever

(2) Main circuit 1) Supply circuit to slewing motor (3) The delivery oil from A3 port of hydraulic pump (1) is led to P 3 port of control valve (2), passes

3.4.1 Slewing (left) operation circuit

through the slewing valve, and flows from its A2

(1) Pilot circuit 1) Switching slewing valve spool Pilot valve (11) produces the pilot secondary

port into A port of slewing motor (3), and starts the slewing motor rotating.

pressure after the slewing (left) operation. The pressure oil flows into Pb2 port of control

2) Slewing motor (3)

valve (2) through solenoid valve (21), and

The relief valve starts up and allows release from

switches the spool of the slewing valve.

the sudden increasing of pressure when start-

The solenoid valve (21) is installed on only ma-

ing or stopping the motor to relieve the shock.

chines in KAI specification to switch operating

The make-up valve (check valve) supplies oil

circuits of slewing and boom swing motions.

into the slewing motor by way of the return circuit (control valve (2) T1 port) to prevent the

2) Releasing parking brake The PG port of oil pressure timer is constantly controlled by the pilot primary pressure. After the slewing operation, the operation pilot secondary

stopping the slewing operation. The check valve (20) is installed between con-

pressure oil is led to SH port of the hydraulic

trol valve (2) T1 port and hydraulic oil tank (25),

timer through shuttle valve (14), and when the

making it a boost circuit to make up oil loss into

pressure exceeds 6kgf / cm , the spool is

the slewing motor.

switched, consequently the pilot primary pressure 35kgf / cm2 is led into the mechanical brake and the slewing brake is released. (Similarly, the slewing brake is released after the arm-in operation.) 3) Delay braking by means of hydraulic timer when stopping slewing operation Return the control lever to the neutral position to stop the slewing operation, and the return circuit of the selector spool closes and the passage of return oil from the mechanical brake is cut. The trapped oil is throttled and drained. Consequently the slewing parking brake functions after a delay of 5 to 7 seconds.

22 â&#x20AC;&#x201C; 1 â&#x20AC;&#x201C; 10

negative pressure in the slewing motor produced by the inertia force of the upperstructure when

9 D2 R1

BREAKER

DOZER

NIBBLER

Select spool

Hydraulic timer

Mechanical brake

FORWARD A

A REVERSE

B REVERSE

RED

BOOM FORWARD B

ARM

NIBBLER BREAKER BUCKET D1 Z

TRAVEL RIGHT

TRAVEL LEFT

G6 D2

14 Au

BOOM SWING

D IN OUT C A PG

RED

B DFE

*5 G7

UP DOWN

B Mu A LEFT RIGHT

BOOM SWING LEFT SLEWING LEFT BOOM SWING RIGHT SLEWING RIGHT T A2 B2 A1 B1

BUCKET DUMP

20 16

RIGHT LEFT DIGGING DUMP B9

A8 Pa8

B7 BOOM

A7 Pa7 G1 P1

B6 Pa5

B5 Pa4

ARM

P2 G2 Pa6

A4 B4 B3 BOOM BREAKER SWING NIBBLER

G3 Pa2 P3 SLEWING

P SW30

ARM OUT BOOM DOWN ARM IN BOOM UP

Pa9 Pa8' Dr1 B8 BUCKET

P2 P SW31

UP DOWN

(OPT.)

15 DBHF

B1 DOZER

D BUCKET DIGGING A C E G

25 42

4 2

* Pb9

TRAVEL LEFT

Pb8

Pb7

TRAVEL RIGHT

*4 Pb5

Pb6

Pb4

TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE

Pb2

TRAVEL RIGHT FORWARD TRAVEL LEFT FORWARD TRAVEL 1-2SPEED A1 CHANGEOVER

13 19

Valve name Main relief valve P1,P2

kgf/cm

psi 2

230kgf/cm

3270

Mark 4

Valve name Over load relief valve

* * 200kgf/cm 2840 * 5 Slewing relief valve * 2 Main relief valve P3 Over load relief valve 280kgf/cm 3980 3 * * 6 Pilot relief valve SLEWING CIRCUIT: Slewing left operation 2

Valve pressure Mark 1

LEVER LOCK A2

kgf/cm

psi 2

3700

2570

260kgf/cm 180kgf/cm 2

35kgf/cm

Note).Codes G1 to G8 show the gauge ports.

500

22 – 1 – 11

3.5 BUCKET OPERATION CIRCUIT Pilot hydraulic system by means of control lever 3.5.1 Bucket digging operation circuit (1) Pilot circuit 1) Switching bucket spool By shifting the control lever to the bucket digging position, pilot valve (11) delivers the pilot secondary pressure. The pressure oil in Pb9 port of control valve (2) switches the spool of the bucket valve. (2) Main circuit 1) Supply circuit to cylinder (7) The delivery oil from A1 port of the main pump (1) flows into P1 port of control valve (2). The pressure oil delivered through B9 port by way of the bucket valve is supplied into the H side of bucket cylinder (7), and carries out the bucket digging operation. The return oil from the R side of cylinder (7) flows into A9 port of control valve (2) and returns into the tank through the bucket valve. Consequently the digging speed is stabilized by taking advantage of the throttling effect of the bucket valve. 3.5.2 Bucket dumping operation circuit (1) Pilot circuit 1) Switching bucket spool By shifting the control lever to the bucket dumping position, pilot valve (11) delivers the pilot secondary pressure. The pressure oil flows into Pa9 port of control valve (2) and switches the spool of the bucket valve. (2) Main circuit 1) Supply circuit to cylinder (7) Similar to the bucket digging operation, the delivery oil from A1 port of the variable pump flows into P1 port of control valve (2). The pressure oil delivered through A9 port by way of the bucket valve is supplied into the R side of the bucket cylinder and carries out the bucket dumping operation.

22 â&#x20AC;&#x201C; 1 â&#x20AC;&#x201C; 12

9 D2 R1

BREAKER

DOZER

NIBBLER

FORWARD A

A REVERSE

B REVERSE

RED

BOOM FORWARD B

ARM

NIBBLER BREAKER BUCKET D1 Z

TRAVEL RIGHT

TRAVEL LEFT

G6 D2

14 Au

BOOM SWING

D IN OUT C A PG

RED

B DFE

*5 G7

UP DOWN

B Mu A LEFT RIGHT

BOOM SWING LEFT SLEWING LEFT BOOM SWING RIGHT SLEWING RIGHT T A2 B2 A1 B1

BUCKET DUMP

20 16

RIGHT LEFT DIGGING DUMP B9

A8 Pa8

B7 BOOM

A7 Pa7 G1 P1

B6 Pa5

B5 Pa4

ARM

P2 G2 Pa6

A4 B4 B3 BOOM BREAKER SWING NIBBLER

G3 Pa2 P3 SLEWING

P SW30

ARM OUT BOOM DOWN ARM IN BOOM UP

Pa9 Pa8' Dr1 B8 BUCKET

P2 P SW31

UP DOWN

(OPT.)

15 DBHF

B1 DOZER

D BUCKET DIGGING A C E G

25 42

4 2

* Pb9

TRAVEL LEFT

Pb8

Pb7

TRAVEL RIGHT

*4 Pb5

Pb6

Pb4

TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE

Pb2

TRAVEL RIGHT FORWARD TRAVEL LEFT FORWARD TRAVEL 1-2SPEED A1 CHANGEOVER

13 19

Valve name Main relief valve P1,P2

kgf/cm

psi 2

230kgf/cm

3270

Mark 4

Valve name Over load relief valve

* * 200kgf/cm 2840 * 5 Slewing relief valve * 2 Main relief valve P3 Over load relief valve 280kgf/cm 3980 3 * * 6 Pilot relief valve BUCKET CIRCUIT: Bucket digging operation 2

Valve pressure Mark 1

LEVER LOCK A2

kgf/cm

psi 2

3700

2570

260kgf/cm 180kgf/cm 2

35kgf/cm

Note).Codes G1 to G8 show the gauge ports.

500

22 – 1 – 13

3.6 BOOM OPERATION CIRCUIT Pilot hydraulic system by means of control lever 3.6.1 Boom raise(up) operation circuit (1) Pilot circuit 1) Switching boom spool By shifting the control lever to boom raise position, pilot valve (11) delivers the pilot secondary pressure. The pressure oil in Pb8 port of control valve (2) switches the spool of the boom valve. (2) Main circuit 1) Supply circuit to cylinder (5) The delivery oil from A1 port of the main pump (1) flows into P1 port of control valve(2). The pressure oil delivered through B8 port by way of the boom valve is supplied to the H side of the boom cylinder (5) and carries out the boom raise operation. 3.6.2 Boom lower (down) operation circuit (1) Pilot circuit 1) Switching boom spool By shifting the control lever to boom lower operation, pilot valve (11) delivers the pilot secondary pressure. And the pressure oil flows into Pa8 port of control valve (2) and switches the spool of boom valve.Consequently pilot secondary pressure enter into Pa8’ port and release boom lock valve. (2) Main circuit 1) Supply and return oil circuit to / from cylinder (5) The delivery oil from A1 port of the main pump is supplied to the R side of the boom cylinder (5) through the boom valve of control valve (2), and carries out the boom lower operation. The return oil from the H side of cylinder (5) flows into B8 port of control valve (2) and returns into the tank through the boom valve, and the flow rate is controlled by taking advantage of the throttling effect. Consequently the boom lowering speed is stabilized. The boom lock valve blocks the oil on the boom cylinder H side with poppet seat when the control valve is on the neutral position, preventing the natural drop of the boom.

22 – 1 – 14

9 D2 R1

BREAKER

DOZER

NIBBLER

FORWARD A

A REVERSE

B REVERSE

RED

BOOM FORWARD B

ARM

NIBBLER BREAKER BUCKET D1 Z

TRAVEL RIGHT

TRAVEL LEFT

G6 D2

14 Au

BOOM SWING

D IN OUT C A PG

RED

B DFE

*5 G7

UP DOWN

B Mu A LEFT RIGHT

BOOM SWING LEFT SLEWING LEFT BOOM SWING RIGHT SLEWING RIGHT T A2 B2 A1 B1

BUCKET DUMP

20 16

RIGHT LEFT DIGGING DUMP B9

A8 Pa8

B7 BOOM

A7 Pa7 G1 P1

B6 Pa5

B5 Pa4

ARM

P2 G2 Pa6

A4 B4 B3 BOOM BREAKER SWING NIBBLER

G3 Pa2 P3 SLEWING

P SW30

ARM OUT BOOM DOWN ARM IN BOOM UP

Pa9 Pa8' Dr1 B8 BUCKET

P2 P SW31

UP DOWN

(OPT.)

15 DBHF

B1 DOZER

D BUCKET DIGGING A C E G

25 42

4 2

* Pb9

TRAVEL LEFT

Pb8

Pb7

TRAVEL RIGHT

*4 Pb5

Pb6

Pb4

TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE

Pb2

TRAVEL RIGHT FORWARD TRAVEL LEFT FORWARD TRAVEL 1-2SPEED A1 CHANGEOVER

13 19

Valve name Main relief valve P1,P2

kgf/cm

psi 2

230kgf/cm

3270

Mark 4

* * 200kgf/cm 2840 *5 * 2 Main relief valve P3 Over load relief valve 280kgf/cm 3980 3 * *6 BOOM CIRCUIT: Boom up operation 2

Valve pressure Mark 1

LEVER LOCK A2

Valve name

kgf/cm

psi 2

3700

2570

Over load relief valve

260kgf/cm

Slewing relief valve

180kgf/cm

Pilot relief valve

35kgf/cm

Note).Codes G1 to G8 show the gauge ports.

500

22 – 1 – 15

3.7 ARM OPERATION CIRCUIT Pilot hydraulic system by means of control lever When digging in the light load, with a function of the return oil recirculation, 3.7.1 Arm in operation circuit (1) Pilot circuit 1) Switching arm spool With the arm in operation, pilot valve (11) delivers the pilot secondary pressure. And the pressure oil flows into Pa5 port of control valve (2) and switches the spool of the arm valve. And the pilot secondary pressure acts on the SH port of the slewing motor delay valve by way of shuttle valve (14), and releases the swing parking brake. (2) Main circuit 1) Supply circuit to cylinder (6) Supply oil from A2 port of the main pump flows into P2 port of control valve (2). The pressure oil from A5 port through the arm valve is supplied into the H side of arm cylinder (6) and carries out the arm operation. 2) Return circuit from cylinder (6) The return oil from the R side of the arm cylinder flows into B5 port of control valve (2), is led into the return circuit from T2 port through the arm valve, and returns into the tank. When operating in the light load, the pressure of the return oil from the cylinder rises taking advantage of the throttling effect of the arm valve, and opens the check valve leading to the supply circuit of a part of the return oil, and is recirculated. Consequently the arm in speed rises. 3.7.2 Arm out operation circuit (1) Pilot circuit With the arm out operation, pilot valve (11) delivers the pilot secondary pressure, and the pressure oil is led to Pb5 port of control valve (2) and switches the spool of the arm valve. (2) Main circuit Similar to the arm in operation, the pressure oil led into B5 port of control valve (2) is supplied from the B5 port into the R side of the arm cylinder and carries out the arm out operation.

22 â&#x20AC;&#x201C; 1 â&#x20AC;&#x201C; 16

9 D2 R1

BREAKER

DOZER

NIBBLER

FORWARD A

A REVERSE

B REVERSE

RED

BOOM FORWARD B

ARM

NIBBLER BREAKER BUCKET D1 Z

TRAVEL RIGHT

TRAVEL LEFT

G6 D2

14 Au

BOOM SWING

D IN OUT C A PG

RED

B DFE

*5 G7

UP DOWN

B Mu A LEFT RIGHT

BOOM SWING LEFT SLEWING LEFT BOOM SWING RIGHT SLEWING RIGHT T A2 B2 A1 B1

BUCKET DUMP

20 16

RIGHT LEFT DIGGING DUMP B9

A8 Pa8

B7 BOOM

A7 Pa7 G1 P1

B6 Pa5

B5 Pa4

ARM

P2 G2 Pa6

A4 B4 B3 BOOM BREAKER SWING NIBBLER

G3 Pa2 P3 SLEWING

P SW30

ARM OUT BOOM DOWN ARM IN BOOM UP

Pa9 Pa8' Dr1 B8 BUCKET

P2 P SW31

UP DOWN

(OPT.)

15 DBHF

B1 DOZER

D BUCKET DIGGING A C E G

25 42

4 2

* Pb9

TRAVEL LEFT

Pb8

Pb7

TRAVEL RIGHT

*4 Pb5

Pb6

Pb4

TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE

Pb2

TRAVEL RIGHT FORWARD TRAVEL LEFT FORWARD TRAVEL 1-2SPEED A1 CHANGEOVER

13 19

Valve name Main relief valve P1,P2

kgf/cm

psi 2

230kgf/cm

3270

Mark 4

* * 200kgf/cm 2840 *5 * 2 Main relief valve P3 Over load relief valve 280kgf/cm 3980 3 * *6 ARM CIRCUIT: Arm in operation 2

Valve pressure Mark 1

LEVER LOCK A2

Valve name

kgf/cm

psi 2

3700

2570

Over load relief valve

260kgf/cm

Slewing relief valve

180kgf/cm

Pilot relief valve

35kgf/cm

Note).Codes G1 to G8 show the gauge ports.

500

22 – 1 – 17

3.8-1 SWING OPERATION CIRCUIT KAI Pilot hydraulic control type with control lever 3.8.1-1 Swing (left) operation circuit (1) Swing operation

3.8-2 SWING OPERATION CIRCUIT EU & OCEANIA Cable driving type by means of control pedal 3.8.1-2 Swing (left) operation circuit (1) Swing operation

The pilot secondary pressure oil is discharged from pilot valve (11) by the left swing operation.

By sifting the control pedal to swing (left) operation position, the cable is drawn and the spool of

The pressure oil flows into Pb4 port on the con-

swing valve is switched. The swing operation is

trol valve (2) through solenoid valve (21), and

carried out regardless of the lever lock similar to

changes the swing valve spool.

the dozer because the pilot pressure oil control is not applied.

Operate the swing lever regularly, leaving the switch on the upper part of the left control lever pressed,the function of pilot line for slewing changes to swing function while solenoid valve (21) is actuated, and the swing operation starts. If this switch is released,swing operation is continued till the left control lever is placed in neutral position. When returning left control lever to neutral position,solenoid valve (21) changes to former state and pilot control line returns to slewing circuit. (2) Main circuit 1) Supply circuit to cylinder (8)

22 â&#x20AC;&#x201C; 1 â&#x20AC;&#x201C; 18

(2) Main circuit 1) Supply circuit to cylinder (8)

The delivery oil from A2 port of the main pump

flows into P2 port of control valve (2), and is

supplied to the H side of cylinder (8) through B4 port by way of the swing valve.

The spool of the swing valve controls the oil quantity supplied to the cylinder because the appro-

priate oil quantity is returned in the tank

circuit taking advantage of the throttling effect of

P2 by-pass when the swing is operated. There-

fore both swing left and right operations are

gradually moved.

9 D2 R1

BREAKER

DOZER

NIBBLER

FORWARD A

A REVERSE

B REVERSE

RED

BOOM FORWARD B

ARM

NIBBLER BREAKER BUCKET D1 Z

TRAVEL RIGHT

TRAVEL LEFT

G6 D2

14 Au

BOOM SWING

D IN OUT C A PG

RED

B DFE

*5 G7

UP DOWN

B Mu A LEFT RIGHT

BOOM SWING LEFT SLEWING LEFT BOOM SWING RIGHT SLEWING RIGHT T A2 B2 A1 B1

BUCKET DUMP

20 16

RIGHT LEFT DIGGING DUMP B9

A8 Pa8

B7 BOOM

A7 Pa7 G1 P1

B6 Pa5

B5 Pa4

ARM

P2 G2 Pa6

A4 B4 B3 BOOM BREAKER SWING NIBBLER

G3 Pa2 P3 SLEWING

P SW30

ARM OUT BOOM DOWN ARM IN BOOM UP

Pa9 Pa8' Dr1 B8 BUCKET

P2 P SW31

UP DOWN

(OPT.)

15 DBHF

B1 DOZER

D BUCKET DIGGING A C E G

25 42

4 2

* Pb9

TRAVEL LEFT

Pb8

Pb7

TRAVEL RIGHT

*4 Pb5

Pb6

Pb4

TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE

Pb2

TRAVEL RIGHT FORWARD TRAVEL LEFT FORWARD TRAVEL 1-2SPEED A1 CHANGEOVER

13 19

Valve name Main relief valve P1,P2

kgf/cm

psi 2

230kgf/cm

3270

Mark 4

Valve name Over load relief valve

* * 200kgf/cm 2840 * 5 Slewing relief valve * 2 Main relief valve P3 Over load relief valve 280kgf/cm 3980 3 * * 6 Pilot relief valve SWING CIRCUIT: Boom swing left operation 2

Valve pressure Mark 1

LEVER LOCK A2

kgf/cm

psi 2

3700

2570

260kgf/cm 180kgf/cm 2

35kgf/cm

Note).Codes G1 to G8 show the gauge ports.

500

22 – 1 – 19

3.9 DOZER OPERATION CIRCUIT Cable driving type by means of exclusive control lever 3.9.1 Dozer lowering operation (1) Dozer operation By pushing the control lever frontward, the cable is drawn and the spool of the dozer of control valve (2) is switched. The dozer operation is carried out regardless of the lever lock similar to the swing operation in EU specification because the pilot oil pressure is not applied. (2) Main circuit 1) Supply circuit to cylinder (9) The delivery oil from A3 port of the 3rd pump flows into P3 port of control valve (2), and is led to B1 port through the dozer valve. And the pressure oil supplied through swivel joint (10) is supplied to the H side of dozer cylinder (9) and lowers the dozer. When the engine is stopped holding the dozer blade raised, never operate the lever to lower the dozer blade. If operated, the dozer blade drops.

22 â&#x20AC;&#x201C; 1 â&#x20AC;&#x201C; 20

9 D2 R1

BREAKER

DOZER

NIBBLER

FORWARD A

A REVERSE

B REVERSE

RED

BOOM FORWARD B

ARM

NIBBLER BREAKER BUCKET D1 Z

TRAVEL RIGHT

TRAVEL LEFT

G6 D2

14 Au

BOOM SWING

D IN OUT C A PG

RED

B DFE

*5 G7

UP DOWN

B Mu A LEFT RIGHT

BOOM SWING LEFT SLEWING LEFT BOOM SWING RIGHT SLEWING RIGHT T A2 B2 A1 B1

BUCKET DUMP

20 16

RIGHT LEFT DIGGING DUMP B9

A8 Pa8

B7 BOOM

A7 Pa7 G1 P1

B6 Pa5

B5 Pa4

ARM

P2 G2 Pa6

A4 B4 B3 BOOM BREAKER SWING NIBBLER

G3 Pa2 P3 SLEWING

P SW30

ARM OUT BOOM DOWN ARM IN BOOM UP

Pa9 Pa8' Dr1 B8 BUCKET

P2 P SW31

UP DOWN

(OPT.)

15 DBHF

B1 DOZER

D BUCKET DIGGING A C E G

25 42

4 2

* Pb9

TRAVEL LEFT

Pb8

Pb7

TRAVEL RIGHT

*4 Pb5

Pb6

Pb4

TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE

Pb2

TRAVEL RIGHT FORWARD TRAVEL LEFT FORWARD TRAVEL 1-2SPEED A1 CHANGEOVER

13 19

Valve name Main relief valve P1,P2

kgf/cm

psi 2

230kgf/cm

3270

Mark 4

Valve name Over load relief valve

* * 200kgf/cm 2840 * 5 Slewing relief valve * 2 Main relief valve P3 Over load relief valve 280kgf/cm 3980 3 * * 6 Pilot relief valve DOZER CIRCUIT: Dozer down operation 2

Valve pressure Mark 1

LEVER LOCK A2

kgf/cm

psi 2

3700

2570

260kgf/cm 180kgf/cm 2

35kgf/cm

Note).Codes G1 to G8 show the gauge ports.

500

22 – 1 – 21

3.10 TRAVEL / DOZER COMBINED OPERATION CIRCUIT The travel straight is maintained when operating the travel and dozer simultaneously. 3.10.1 Travel (forward 1st-speed) / dozer down operation circuit (1) Pilot circuit The travel operation is controlled by the pilot hydraulic system, and the dozer operation is operated by the cable driving system. By pushing down each control lever, the spool of the travel valve and dozer valve of control valve (2) are switches. (2) Main circuit The delivery oil from A1 and A2 ports of the variable pump flows into P1 and P2 ports of control valve (2) respectively, is led into swivel joint (10) and travel motor (4) through respective travel valve on both sides. The delivery oil from A3 port of the 3rd pump is led to dozer cylinder (9) through swivel joint (10). The pressure oil for dozer operation is applied to the flow of the 3rd pump regardless of the travel circuit, therefore the supply oil quantity to the right and left travel motors does not differ each other holding the travel straight when the dozer is used during the travel operation. The travel speed after the above operation does not differ from the travel independent operation and the travel straight is maintained.

22 â&#x20AC;&#x201C; 1 â&#x20AC;&#x201C; 22

9 D2 R1

BREAKER

DOZER

NIBBLER

FORWARD A

A REVERSE

B REVERSE

RED

BOOM FORWARD B

ARM

NIBBLER BREAKER BUCKET D1 Z

TRAVEL RIGHT

TRAVEL LEFT

G6 D2

14 Au

BOOM SWING

D IN OUT C A PG

RED

B DFE

*5 G7

UP DOWN

B Mu A LEFT RIGHT

BOOM SWING LEFT SLEWING LEFT BOOM SWING RIGHT SLEWING RIGHT T A2 B2 A1 B1

BUCKET DUMP

20 16

RIGHT LEFT DIGGING DUMP B9

A8 Pa8

B7 BOOM

A7 Pa7 G1 P1

B6 Pa5

B5 Pa4

ARM

P2 G2 Pa6

A4 B4 B3 BOOM BREAKER SWING NIBBLER

G3 Pa2 P3 SLEWING

P SW30

ARM OUT BOOM DOWN ARM IN BOOM UP

Pa9 Pa8' Dr1 B8 BUCKET

P2 P SW31

UP DOWN

(OPT.)

15 DBHF

B1 DOZER

D BUCKET DIGGING A C E G

25 42

4 2

* Pb9

TRAVEL LEFT

Pb8

Pb7

TRAVEL RIGHT

*4 Pb5

Pb6

Pb4

TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE

Pb2

TRAVEL RIGHT FORWARD TRAVEL LEFT FORWARD LEVER LOCK A2

TRAVEL 1-2SPEED A1 CHANGEOVER

Valve pressure Mark 1

Valve name Main relief valve P1,P2

kgf/cm

230kgf/cm

Mark

3270

Valve name Over load relief valve

kgf/cm

psi 2

260kgf/cm

Note).Codes G1 to G8 show the gauge ports.

3700

* * 180kgf/cm 2570 200kgf/cm 2840 * 5 Slewing relief valve * 2 Main relief valve P3 Over load relief valve 280kgf/cm 3980 3 Pilot relief valve 35kgf/cm 500 6 * * COMBINED OPERATION CIRCUIT: Travel 1st speed forward / Dozer down,Travel straight function 2

psi

22 – 1 – 23

3.11 TRAVEL / BOOM COMBINED OPERATION CIRCUIT The travel straight is maintained when carrying out the travel and boom operations simultaneously. 3.11.1 Travel (forward 1st-speed) / boom raise operation circuit (1) Pilot circuit The travel / boom raise operation is carried out with the pilot hydraulic system by the control lever. By pushing down the travel control lever frontward or pulling the boom raise control lever, the pilot secondary pressure switches the spool of the travel valve and boom spool of control valve (2). At the same time, the pilot primary pressure switches the spool of the travel straight valve because the pilot circuit for the travel straight of control valve (2) is blocked by the movement of the travel and boom spool. (2) Main circuit The delivery oil from A1 and A2 ports of the main pump flows into P1 and P2 ports of control valve (2). The pressure oil in P1 and P2 ports confluxes in the travel straight valve, and branches off in the attachment circuit and the right and left travel circuits. The pressure oil flown into the attachment circuit is fed in boom cylinder (5) through the boom valve. The pressure oil flown in the right and left travel circuits is fed in swivel joint (10) and travel motor (4) through the travel spool. When the travel/boom motions are operated simultaneously, the pressure oil from P1 and P2 ports confluxes in the travel straight valve, having the same pressure, and the pressure oil is fed in the travel motor through the restriction of the spool notch on the travel straight valve, in preference to others. The oil quantity to be distributed in the boom (ATT) and the travel motor is regulated by the opening of this restriction Consequently, the travel speed is reduced after the above operation, but the travel and boom raise operations become possible and the travel straight is maintained.

22 â&#x20AC;&#x201C; 1 â&#x20AC;&#x201C; 24

9 D2 R1

BREAKER

DOZER

NIBBLER

FORWARD A

A REVERSE

B REVERSE

RED

BOOM FORWARD B

ARM

NIBBLER BREAKER BUCKET D1 Z

TRAVEL RIGHT

TRAVEL LEFT

G6 D2

14 Au

BOOM SWING

D IN OUT C A PG

RED

B DFE

*5 G7

UP DOWN

B Mu A LEFT RIGHT

BOOM SWING LEFT SLEWING LEFT BOOM SWING RIGHT SLEWING RIGHT T A2 B2 A1 B1

BUCKET DUMP

20 16

RIGHT LEFT DIGGING DUMP B9

A8 Pa8

B7 BOOM

A7 Pa7 G1 P1

B6 Pa5

B5 Pa4

ARM

P2 G2 Pa6

A4 B4 B3 BOOM BREAKER SWING NIBBLER

G3 Pa2 P3 SLEWING

P SW30

ARM OUT BOOM DOWN ARM IN BOOM UP

Pa9 Pa8' Dr1 B8 BUCKET

P2 P SW31

UP DOWN

(OPT.)

15 DBHF

B1 DOZER

D BUCKET DIGGING A C E G

25 42

4 2

* Pb9

TRAVEL LEFT

Pb8

Pb7

TRAVEL RIGHT

*4 Pb5

Pb6

Pb4

TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE

Pb2

TRAVEL RIGHT FORWARD TRAVEL LEFT FORWARD LEVER LOCK A2

TRAVEL 1-2SPEED A1 CHANGEOVER

Valve pressure Mark 1

Valve name Main relief valve P1,P2

kgf/cm

230kgf/cm

psi

Mark

3270

Valve name Over load relief valve

kgf/cm

psi 2

260kgf/cm

Note).Codes G1 to G8 show the gauge ports.

3700

22 – 1 – 25

3.12a NIBBLER/BREAKER OPERATION CIRCUIT Cable drive type with control pedal Link drive type in EU and Oceania. 3.12a.1 Nibbler “close” operation (1) Nibbler operation Press the left side of the control pedal, and the cable is pulled and consequently the nibbler/ breaker valve spool of control valve (2) is switched. The nibbler can be operated regardless of the lever lock, like dozer. For link drive in EU and Oceania, press the front side of the pedal, and the similar operation can be obtained. (2) Main circuit 1) Supply circuit to nibbler cylinder The delivery oil from the A2 port of the 2nd pump of pump assy (1) flows in the P2 port of control valve (2) and is fed in the B3 port through nibbler / breaker valve. And it is fed in the H side of the nibbler cylinder and consequently the nibbler “close” operation is executed. 3.12a.2 Breaker ON operation (1) Breaker operation Press the right side of the control pedal, and the cable is pushed and consequently the nibbler/ breaker valve spool of control valve (2) is switched. The breaker can be operated / regardless of the lever lock, like dozer. For link drive in EU and Oceania, press the rear side of the pedal, and the similar operation can be obtained. (2) Main circuit The delivery oil from the A2 port of the 2nd pump of pump assy (1) flows in the P2 port of control valve (2) and is fed in the A3 port through nibbler/ breaker valve. And it is fed in the breaker inlet and the breaker starts operating. Then, selector valve (23) of the return circuit is switched to the breaker side, consequently the return oil returns in hydraulic oil tank (25) directly. Oceania machine has exclusive piping for breaker,so solenoid valve (23) is not equipped, and return oil flows into hydraulic tank directly.

22 – 1 – 26

Applicable Machines : PN03-02001~ : PJ02-00101~

9 D2 R1

BREAKER

DOZER

NIBBLER

FORWARD A

A REVERSE

B REVERSE

RED

BOOM FORWARD B

ARM

NIBBLER BREAKER BUCKET D1 Z

TRAVEL RIGHT

TRAVEL LEFT

G6 D2

14 Au

BOOM SWING

D IN OUT C A PG

RED

B DFE

*5 G7

UP DOWN

B Mu A LEFT RIGHT

BOOM SWING LEFT SLEWING LEFT BOOM SWING RIGHT SLEWING RIGHT T A2 B2 A1 B1

BUCKET DUMP

20 16

RIGHT LEFT DIGGING DUMP B9

A8 Pa8

B7 BOOM

A7 Pa7 G1 P1

B6 Pa5

B5 Pa4

ARM

P2 G2 Pa6

A4 B4 B3 BOOM BREAKER SWING NIBBLER

G3 Pa2 P3 SLEWING

P SW30

ARM OUT BOOM DOWN ARM IN BOOM UP

Pa9 Pa8' Dr1 B8 BUCKET

P2 P SW31

UP DOWN

(OPT.)

15 DBHF

B1 DOZER

D BUCKET DIGGING A C E G

25 42

4 2

* Pb9

TRAVEL LEFT

Pb8

Pb7

TRAVEL RIGHT

*4 Pb5

Pb6

Pb4

TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE

Pb2

TRAVEL RIGHT FORWARD TRAVEL LEFT FORWARD TRAVEL 1-2SPEED A1 CHANGEOVER

13 19

Valve name Main relief valve P1,P2

kgf/cm

psi 2

230kgf/cm

3270

Mark 4

Valve name Over load relief valve

kgf/cm

psi 2

3700

2570

260kgf/cm

* * 180kgf/cm 200kgf/cm 2840 * 5 Slewing relief valve * 2 Main relief valve P3 Over load relief valve 280kgf/cm 3980 3 Pilot relief valve 35kgf/cm 6 * * NIBBLER / BREAKER CIRCUIT: Nibbler close operation 2

Valve pressure Mark 1

LEVER LOCK A2

Note).Codes G1 to G8 show the gauge ports.

500

22 – 1 – 27

3.12.b NIBBLER/BREAKER OPERATION CIRCUIT (Applicable machines : PJ03-01001~) 3.12.b.1 Nibbler "close" operation (1) Pilot circuit Press the red colored "Close" button on the left operation lever, and secondary pilot pressure flows out from A port of solenoid valve (25). The pressurized oil which entered into Pb3 port of control valve (2) switches the spool for Nibbler/ Breaker. (2) Main circuit 1) Supply circuit to nibbler cylinder The delivery oil from the A2 port of the 2nd pump of pump assy (1) flows in the P2 port of control valve (2) and is fed in the B3 port through nibbler/ breaker valve. And it is fed in the H side of the nibbler cylinder and consequently the nibbler "close" operation is executed. 3.12.b.2 Breaker "ON" operation (1) Pilot circuit Press the white colored "Open" button on the left operation lever, and secondary pilot pressure flows out from B port of solenoid valve (25). The pressurized oil which entered into Pa3 port of control valve (2) switches the spool for Nibbler/ Breaker. (2) Main circuit The delivery oil from the A2 port of the 2nd pump of pump assy (1) flows in the P2 port of control valve (2) and is fed in the A3 port through nibbler/ breaker valve. And is fed in the breaker inlet and the breaker starts operating. Then, selector valve (23) of the return circuit is switched to the breaker side, consequently the return oil return in hydraulic oil tank (25) directly.

22 â&#x20AC;&#x201C; 1 â&#x20AC;&#x201C; 27 A

9 D2 R1

BREAKER

DOZER

NIBBLER

FORWARD A

A REVERSE

B REVERSE

RED

BOOM FORWARD B

ARM

NIBBLER BREAKER BUCKET D1 Z

TRAVEL RIGHT

TRAVEL LEFT

G6 D2

14 Au

BOOM SWING

D IN OUT C A PG

RED

B DFE

*5 G7

UP DOWN

B Mu A LEFT RIGHT

BOOM SWING LEFT SLEWING LEFT BOOM SWING RIGHT SLEWING RIGHT T A2 B2 A1 B1

BUCKET DUMP

20 16

RIGHT LEFT DIGGING DUMP B9

A8 Pa8

B7 BOOM

A7 Pa7 G1 P1

B6 Pa5

B5 Pa4

ARM

P2 G2 Pa6

A4 B4 B3 BOOM BREAKER SWING NIBBLER

G3 Pa2 P3 SLEWING

P SW30

ARM OUT BOOM DOWN ARM IN BOOM UP

Pa9 Pa8' Dr1 B8 BUCKET

P2 P SW31

UP DOWN

(OPT.)

15 DBHF

B1 DOZER

D BUCKET DIGGING A C E G

27 42

4 2

* Pb9

TRAVEL LEFT

Pb8

Pb7

TRAVEL RIGHT

*4 Pb5

Pb6

Pb4

TRAVEL RIGHT REVERSE TRAVEL LEFT REVERSE

Pb2

TRAVEL RIGHT FORWARD TRAVEL LEFT FORWARD LEVER LOCK A2

TRAVEL 1-2SPEED A1 CHANGEOVER

25 A

Valve pressure Mark

*1 *2 *3

P P1 P2

Valve name

kgf/cm

psi 2

3270

2840

3980

Main relief valve P1,P2

230kgf/cm

Main relief valve P3

200kgf/cm

Over load relief valve

280kgf/cm

Note).Codes G1 to G8 show the gauge ports.

Mark

*4 *5 *6

Valve name

kgf/cm

psi 2

3700

2570

Over load relief valve

260kgf/cm

Slewing relief valve

180kgf/cm

Pilot relief valve

35kgf/cm

500

NIBBLER / BREAKER CIRCUIT: Nibbler close operation

22 – 1 – 27 B

4.2-1 SCHEMATIC PIPING FOR HYDRAULIC SYSTEM

EU & OCEANIA

Hyd.tank Swing cylinder

H Return filter (with relief)

Arm cylinder

Suction strainer

Travel motor(RH)

Dozer cylinder Boom cylinder Slewing motor

Dr Mu A

H PG

Check V

Right slew R

E F D B P A C

Breaker

Stop valve

Dozer A1

ATT pilot V(RH)

Bucket dump

Breaker

Slewing

Filter

Nibbler

Boom down P3

Selector valve ( EU only)

2 T

Nibbler B3 Breaker

P 4

Bucket dig Swing

Travel Pilot valve 4

Arm

T P

Right travel

Oil cooler

Boom up

D1 A

Engine

Filter

Left travel

Shuttle valve

B Boom

D A

ATT pilot V(LH)

Right slew

Reverse

Bucket cylinder

D2 B

Swivel joint

Left slew SH

Reverse

Forward

( EU only) Nibbler cylinder

Bucket

Arm out Dr1

Pb8'

P 4

A1 A4

A2 Z

Travel motor(LH)

Hyd.pump

Left slew Arm in

Control valve 1 2

7 6 5

Pilot circuit Block Bottom side

Top side

Main drive circuit

Solenoid valve P1

Filter Relief valve

Travel 1,2 speed

22 – 1 – 28

Supply,Return (Drain) circuit

Lever lock

Note).

Following parts are not equipped in Oceania machine. 1. Selector valve,and piping between the selector valve and B3 port of C/V.

4.2-2a SCHEMATIC PIPING FOR HYDRAULIC SYSTEM

KAI

(Applicable machines : PJ02-00101~) Return filter (with relief)

Hyd.tank

Swing cylinder Solenoid valve R

B1 A1B2 A2 PP

Arm cylinder

P SW30 R

Suction strainer

T P1

P2 P SW31

H Travel motor(RH)

Dozer cylinder Boom cylinder Slewing motor

Dr Mu A

H PG

D2 B

Swivel joint G

Breaker

Dozer A1

B1 ATT pilot V(RH)

Bucket dump

Breaker

Slewing

Filter

Nibbler

Boom down P3

Selector valve

2 T

Nibbler B3 Breaker

Swing

Arm

P 4

Bucket dig Travel Pilot valve 4

T P

Right travel

Oil cooler

Boom up

D1 A

Engine

Filter

ATT (Right swing) Right slew pilot V(LH)

Filter

Left travel

Shuttle valve

B C

Reverse

E F D B P A C

Stop valve

Reverse

Bucket cylinder

Check V

SH Left slew Right slew

Forward

Nibbler cylinder

Boom

D A

Bucket

Arm out Dr1

2 T

Pb8'

P 4

A2 Z

Travel motor(LH)

Hyd.pump

(Left swing) Left slew T2

Arm in

Control valve Multi C/V (John Deere pattern)

G E

C A

F H

B D

Pilot circuit

Solenoid valve P1

Main drive circuit

Filter Relief valve

Supply,Return (Drain) circuit Travel 1,2 speed

Lever lock

22 – 1 – 29

4.2-2b SCHEMATIC PIPING FOR HYDRAULIC SYSTEM

KAI

(Applicable machines : PJ03-01001~) Return filter (with relief)

Hyd.tank

Swing cylinder Solenoid valve

Solenoid valve R

B1 A1B2 A2 PP

Suction strainer

T P1

Arm cylinder

P SW30 R

Filter B

P SW31

H Travel motor(RH)

Dozer cylinder Boom cylinder Slewing motor

Dr Mu A

H PG

D2 B

Swivel joint G

Breaker

Dozer A1

B1 ATT pilot V(RH)

Bucket dump

Breaker

Slewing

Filter

Nibbler

Boom down P3

Selector valve

2 T

Nibbler B3 Breaker

Swing

Arm

P 4

Bucket dig Travel Pilot valve 4

T P

Right travel

Oil cooler

Boom up

D1 A

Engine

Filter

ATT (Right swing) Right slew pilot V(LH)

Filter

Left travel

Shuttle valve

B C

Reverse

E F D B P A C

Stop valve

Reverse

Bucket cylinder

Check V

SH Left slew Right slew

Forward

Nibbler cylinder

Boom

D A

Bucket

Arm out Dr1

2 T

Pb8'

P 4

A2 Z

Travel motor(LH)

Hyd.pump

(Left swing) Left slew T2

Arm in

Control valve Multi C/V (John Deere pattern)

G E

C A

F H

B D

Pilot circuit

Solenoid valve P1

Main drive circuit

Filter Relief valve

Supply,Return (Drain) circuit Travel 1,2 speed

22 – 1 – 30

Lever lock

Book Code No.

PJ23

02E ➁

NEW HOLLAND EH45 Model Cross-reference: SK45SR-2 is NEW HOLLAND Model EH45

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 3.1 Electrical Equipment List ...........................................................................1-5 3.2 Harness & Cable List ................................................................................1-6 3.3 Electrical Equipment & Harness Connection Drawing ...............................1-7 3.4 Arrangement Drawing for Components & Harness ....................................1-8 3.5 Detail of Harness & Cable .......................................................................1-15 3.6 Cab work light Equipment & Harness ......................................................1-28 4.ELECTRICAL EQUIPMENT & HARNESS.......................................................1-29 4.1 Electrical Equipment List .........................................................................1-29 4.2 Harness & Cable List ..............................................................................1-30 4.3 Electrical Equipment & Harness Connection Drawing .............................1-31 4.4 Arrangement Drawing for Components & Harness ..................................1-32 4.5 Detail of Harness & Cable .......................................................................1-39

23 –0–1 ➀

PJ23

REVISION

DATE OF ISSUE

REMARKS

First Edition

October, 2001

S5PJ2302E

Second Revision

January, 2003

S5PJ2302E ➀ K·E

K·E

23 –0–2 ➀

1. HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION 1.1 ELECTRIC CIRCUIT DIAGRAM (1) In the diagram, the number, size and color of wires are shown on the wiring line. The size of the wire is to be 0.75 sq (square mm = mm2 )unless otherwise specified. Example : 6 2 R Wire Color : Red Wire Size : 2 sq (mm2) Wire No. : 6

WIRING COLOR TABLE Symbol B G L R W Y P

Color BLACK GREEN BLUE RED WHITE YELLOW PINK

Symbol O Br Lg Gr Sb V

Color ORANGE BROWN LIGHT GREEN GRAY SKY BLUE VIOLET

1.2 HARNESS CONNECTION (1) Indication for Connector Lock

Wire No.

(3) Connector No.

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

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

(5) The wire size is 0.75 sq, unless otherwise specified.

Wire color

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

(6) The treatment for the harness end is to be as follows : 1) After roughly applying harness taping, wires are installed in a corrugated tube. 2) Harness taping by two ply. 3) No harness treatment for connection. (7) The length for the above (6)-3) is to be 30 ± 10 mm. (1.2 ± 0.4 in), and the length includes in the total length of wire shown in the diagram.

23 –1–1

NOTES

23 –1–2

EXAMPLE OF WIRE COLOR W L

2. ELECTRIC CIRCUIT DIAGRAM (1 / 2)

Applicable machines : PH03-02001~ : PJ02-00101~

STRIPE COLOR (BLUE) BASE COLOR (WHITE)

B G L R

6 WG

BLACK GREEN BLUE RED

W Y P O

WHITE YELLOW PINK ORANGE

Br BROWN Lg LIGHT GREEN Gr GRAY Sb SKY BLUE

VIOLET

ENGINE E-13: BATTERY 20B

B S

20B

M-1: STARTER MOTOR

STANDARDS OF WIRE COLOR ELECTRIC POWER SOURCE CIRCUIT E-1 FUSE BOX

POWER AND CONTROL CIRCUIT R-1: BATTERY RELAY

GROUND CIRCUIT 14 2WR

8 3R

E-4: FUSIBLE LINK

8 5R

47 3L

13 BW 1.25

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

9 8R

8 8R B C

47 3L

14 2WR

B (D-12)

9 8R

10A

30A

10A

POSITION

11 WY

R-8: CHARGE INDICATOR RELAY

6 WG

BAT P

11 WY 81 GW 6 WG

IG IC REG

R-2: SAFETY RELAY

7 2RB

ACC

WIRE COLOR TABLE SYMBOL COLOR SYMBOL COLOR SYMBOL COLOR SYMBOL COLOR

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

47 3L

E 2B 5 W 70 2GR

E-2: GENERATOR

E-8: AIR HEATER

72 L 13 BW 1.25

SW-1: KEY SW. 2B 5 5 15 16

5 2W

5 W

(D-2)

W 2W YG RW

R-7: ENG. STOP RELAY

D-14

(D-3)

R-6: TIMER UNIT

17 PB

1 WY

(D-1) E-3: HORN

SW-7: HORN SW. POSITION

E-10: RADIO (FOR CAB)

O L H F F O I

SW-23: Travel alarm select sw. WY 54 PL 1

18 LY

19 LB

M POSITION

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

L-1: ROOM LAMP (FOR CAB)

TERMINAL

SW-10: HEATER SW.

SV-3: ENG. STOP SOL.

4 RG

1 WY

HOLD PULL

TO (2/2)

4 RG

TERMINAL

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 GAUGE CLUSTER

INST-PANEL AND RELAY ASSY

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

22 Br

21 WB

1 WY

E-20 Travel alarm

SW-25: Travel right(backward) press.sw.

1 WY

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

SW-24: Travel right (forward)press.sw. 55 YL B

SW-26: Travel left(forward) press.sw.

B L

E-12: HEATER

SW-27: Travel left(backward) press.sw. EU OPT. OCEANIA STD.

B M M-3: WASHER MOTOR (FOR CAB) TO (2/2)

23 – 1 – 3 1

ELECTRIC CIRCUIT DIAGRAM (2 / 2) INST-PANEL AND RELAY ASSY

E-6: GAUGE CLUSTER

R-9: OPT WORK LIGHT RELAY

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

3 YG 2 YB

ENGINE FROM (1/2)

B L-2: BOOM WORKING LIGHT LEFT SW-9: LEVER LOCK SW. (LEFT)

SW-8: LEVER LOCK SW. (RIGHT)

10 PL SV-1: OPERATING LEVER LOCK SOL. 39 GW

60 GY 64 LW

A P1

3 YG

63 BY

OPT.

63 BY 64 LW

51 YG

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

M-4: B DECEL MOTOR

50 GW 52 YR

60 GY

91 L 6

6 WG 1 B

2 61 LB 4 45 BW

HOLD

YB B

HOLD

DECEL SW. SV-2: TWO-SPEED SELECT SOL

2 YB

3 43 Lg 5 46 WB

COOLER (FOR CAB)

SW-3: TWO-SPEED SELECT SW.

E-15: FUSE

E-6: GAUGE CLUSTER

4 1

TWO-SPEED

LB 7 57 GB 6 58

EMPTY ENG. WATER TEMP.

CHARGE 0000

2 86 LgR

HOUR METER

48 LgB

81 GW 1

89 1.25RL 1 LR

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

SV-5: POWER SHIFT SOL. 90 RW

R-8: CHARGE INDICATOR RELAY

E-2: GENERATOR E-15: FUSE

SW-2: WORKING LIGHT SW.

20A 4 1.25RG

SE-1: FUEL SENSOR

E-17: CONDENSER MOTOR

R-11: CONDENSER RELAY

E-16: COOLING UNIT

THERMO METER 20 52 YR ILLUMINATION B 15

R-13: COOLER RELAY

50 GW

P 17 49 YB 56 14

FUEL METER

20A 4 1.25RG

(D-5)

YG 4 51

ENG. OIL PRESS.

2 SW-11:

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

M E-18: COMPRESSOR

SW-15: HI. LOW PRESS. SW. 91 1.25 O

B (OPT)

AIR FILTER RESTRICTION 9

M-6: FUEL PUMP (AUTO AIR BLEED) 1

KAI 1 SOCKET

SW-28: SLEW / SWING R-22: SW. SELECT RELAY SELECT SW.

E-7: POWER SOCKET

3 YG

EU (OPT)

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

23 – 1 – 4

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

B B

(D-7)

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

105 LG SW-31: SLEW / SWING LEVER PRESS. SW. RH SW-30: SLEW / SWING LEVER PRESS. SW. LH

106 W B

R-14: SLEW / SWING SELECT RELAY

SV-12: SLEW / SWING SELECT SOL. B

(OPT)

101 GW

107 WR B 100 Lg

R-23: SLEW / SWING PRESERVATION RELAY

D-13:

54 PL

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

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.

2B. ELECTRIC CIRCUIT DIAGRAM (1 / 2)

Applicable Machines : SK40SR-2 : PH04-02801~ : SK45SR-2 : PH03-01001~

CLUSTER GAUGE

14 2WR

B ACC M G1 G2 ST

14 2WR

E-4:FUSIBLE LINK(45A) 8 C

S T A R T

M-1:STARTER MOTOR M

R-1:BATTERY RELAY

AC O

B S

D-12

O F F

20B

2R 3Y 2RB L

PREHEATING

P E

11 WY 6

R-8:CHARGE INDICATOR RELAY

11 WY 81 O 6 WG

BAT P

61 61 61 61 62 63

BrY BrY BrY BrY GrB WY

IG E-2:GENERATOR

IC REG

R-2: SAFETY RELAY 47 3LY

E-8:AIR HEATER

EXAMPLE OF WIRE COLOR

L STRIPE COLOR(BLUE) BASE COLOR(WHITE)

WIRE COLOR CODING TABLE

D-14

2B 5

E 2B 5 W 70 2BR

70 2BR R-7:ENG.STOP RELAY

15 YG

5 W R-6:TIMER UNIT

D-2

W 2W

5 5

HOLD PULL

SV-3: ENG.STOP SOL

16 RW

Sign

Color

Sign

Color

Sign

Color

Sign

Color

Black

White

Brown

Violet

Green

Yellow

Lg Light Green

Blue

Pink

red

Orange

Gray

Sb Sky Blue

D-3

STANDARDS OF WIRE COLOR 4 RG 17 PB

POSITION

SW-10: HEATER SW.

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

1 O L F F O

H I

O L F F O

E L M M

E-10: RADIO (FOR CAB)

R-22: SW. SELECT RELAY M-2: WIPER MOTOR(FOR CAB)

H H I

GROUND CIRCUIT

B 18 LY 19 LB 1 WY

POSITION

E L M

POWER AND CONTROL CIRCUIT

TERMINAL

TO 2/2

L-1: ROOM LAMP (FOR CAB)

D-1 E-3:HORN 1

ELECTRIC POWER SOURCE CIRCUIT

SW-7:HORN SW.

TERMINAL

POSITION

E-1:FUSE BOX

8 71 7 72

TERMINAL

ENGINE

TIMER,RELAY

HORN,ROOM LAMP

WORK LIGHT

RELAY,SOL

E-13:BATTERY 20B

30A

WY 1 1.25 10A YB 2 30A 2YG 3 30A 2RG 4 30A 2W 5 10A WG 6

RADIO,HEATER.WIPER

INST-PANEL AND RELAY ASSY(PART IN RELAY ASSY CONSOLE)

20 22 21 1

G Br WB WY

R +1 Y S

- B +B L

M E-12: HEATER

B M M-3: WASHER MOTOR(FOR CAB)

SW-31: SWING LEVER PRESS.SW.RIGHT

SW-28: SWING SELECT SW.

106 W 105 LG

R-14: SWIING SELECT RELAY SV-12: WING SELECT SOL. B

101 GW

B D-13 107 WR

SW-30: SWING LEVER PRESS.SW.LEFT

B 100 Lg R-23:SWIVEL SWING PRESERVATION RELAY

TO 2/2

23 – 1 – 4 A

ELECTRIC CIRCUIT DIAGRAM (2 / 2)

SW-2: WORKING LIGHT SW.

3 2

ENGINE

FROM 1/2

POSITION

TERMINAL

INST-PANEL AND RELAY ASSY

O O F F N

E L

LgR

E-6: GAUGE CLUSTER

R-9: OPT WORK LIGHT RELAY

FROM 1/2

B L-2: BOOM WORKING LIGHT LEFT

SW-9: LEVER LOCK SW.(LEFT)

A P1

63 BY

R-24,25: NIBBLER OPEN·CLOSE RELAY (NORTH AMERICA STD)

60 GY 64 LW

M B

M-4: DECELE MOTOR

SV-1:OPERATING LEVER LOCK SOL B 39 GW 63 BY 64 LW R-3: DECEL RELAY 2 6

HOLD

61 LB

SW-6:ENG.OIL PRESS.SW

52 YR

SE-2:COOLANT THERMO SENSOR B

45 BW

3 HOLD

SW-12: AIR FILTER RESTRICTION SW.

COOLER(FOR CAB) 2

E-15: FUSE 20A 4 1.25RG

SW-11:DECEL SW. YB

SV-2:TWO-SPEED SELECT SOL

4 1

43 Lg B

46 WB

R-13:COOLER RELAY 89 1.25RL 1 WY

M BLOWER MOTOR

D-4

TWO-SPEED

EMPTY

ENG.WATER TEMP. ENG.OIL PRESS.

CHARGE H·M

HOUR METER

FUEL METER

THERMO METER

86 LgR

ILLUMINATION

90 RW

58 GB

48 LgB 49 P 56 YB

81 O

1 E-2:GENERATOR

E-15: FUSE 20A 1.25RG

E-18:COMPRESSOR

SW-15: HI,LOW PRESS SW.

92 1.25 O

E-17: CONDENSER MOTOR

50 GW

R-8: CHARGE INDICATOR RELAY

52 YR B

SE-1:FUEL SENSOR

SW-23: TRAVEL ALARM SELECT SW. WY 54 PL

SW-24: TRAVEL RIGHT (FORWARD) PRESS.SW. 55 YL E-20: TRAVEL ALARM B SW-25: TRAVEL RIGHT (BACKWARD) PRESS.SW.

52 YR

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

SW-24: TRAVEL RIGHT (FORWARD) PRESS.SW. 1

55 YL

54 PL

OPT.

E-20: TRAVEL ALARM

R-9: OPT.WORK LIGHT RELAY 1.25YG 3 86 LgR 3 SW-2: WORKING LIGHT SW.

R-11: CONDENSER RELAY

E-16: COOLING UNIT

51 YG

B 9

SW-16: CONDENSER SPEED SHIFT SW.

57 LB

SW-2: WORKING LIGHT SW. AIR FILTER RESTRICTION

R-10: CONDENSER SPEED SHIFT RELAY

SW-3:TWO-SPEED SELECT SW. SV-5:POWER SHIFT SOL.

E-6:GAUGE CLUSTER

NORTH AMERICA:STD

60 GY

2 B

SW-5:ENG.WATER TEMP SW.

50 GW

91 L

E-14:SEQUENCE BOX

51 YG

M-6:UEL PUMP

87 1.25BrR B

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

OPT.

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

SW-26: TRAVEL LEFT (FORWARD) PRESS.SW. SW-9: LEVER LOCK SW.(LEFT)

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

OPT.

39 GW

R-24: NIBBLER OPEN RELAY 112 WR 108 LW

NORTH AMERICA·OPT. B

SV-9: NIBBLER OPEN SOL.

SW-33:NIBBLER OPEN SW. 110 G

SV-8:TILT ANGLE SELECT SOL. 1 YB

95 RW

2 SW-17:TILT ANGLE SELECT SW.

WY B

SOCKET

113 OW 109 LO

OPT.

E-7:POWER SOCKET EU · STD

23 – 1 – 4 B

SW-34: NIBBLER CLOSE SW. R-25: 111 GL NIBBLER CLOSE RELAY

SV-10: NIBBLER CLOSE SOL.

NORTH AMERICA·STD HAND CONTROL FOR NIBBLER OPEN/CLOSE

3. ELECTRICAL EQUIPMENT & HARNESS Applicable machines SK40SR-2 : PH03-02001~ SK45SR-2 : PJ02-00101~

3.1 ELECTRICAL EQUIPMENT LIST

Electrical Fittings

E-7 E-8 E-10 E-12 E-13 E-14 E-15 E-20

Light

PM73E00004F3 E/G accessory (119836-77201) PH53S00001P1 PH73S00001P1 [PM59S00002F1] EU,OCE PM59S00002F2 [PV59S00001F1] KAI PV59S00001F2 POWER SOCKET [EU] YN81S00001P1 E/G accessory AIR HEATER (129100-77500) Cab accessory RADIO (OPT) (PY54S00001P1) PM21M00005F1 HEATER (OPT) [PH72S00004P1] BATTERY PH72S00005P1 [PA24S00002P2] SEQUENCE BOX PA24S00002P3 PH73E00004F1 FUSE BOX (OPT) (FOR COOLER) TRAVEL ALARM [OCE] [PM53S00001F1] PM53S00001F2 FUSE BOX GENERATOR (ALTERNATOR) HORN FUSIBLE LINK GAUGE CLUSTER

L-2 L-3 L-4

M-1

STARTER MOTOR

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

Relay

YN02D01001P1

Cab accessory (2456U114) BOOM WORKING LIGHT (LH) 2456R243F2 CAB WORKING LIGHT (OPT) PY80S00002F1 CAB WORKING LIGHT (OPT)

L-1

Motor

YN02DO1001P1 2475U38

Group Code R-1 R-2 R-3 R-6 R-7 R-8 R-9 R-14 R-22 R-23

Sensor

E-3 E-4 E-6

Part No. 2475U38

Solenoid

E-1 E-2

Part Name DIODE DIODE DIODE DIODE DIODE DIODE DIODE

SV-1 SV-2 SV-3

[PH35V00001F1] LEVER LOCK SOL. 2 SPEED SELECT SOL. PH35V00001F2 E/G accessory E/G STOP SOL. (119233-77931) YJ35V00004F1 POWER SHIFT SOL. (Cooler Spec) YJ35V00004F1 TILT ANGLE SOL. PE35V00001F1 SLEW / SWING SELECT SOL. [KAI] PM50E00001F1 KEY SWITCH WORKING LIGHT SW. PV24E01001P1 2 SPEED SELECT SW. YN03M01286S002 WIPER WASHER SW. PY50S00004P1 E/G COOLANT TEMP.SW. PM50S00006P1 E/G OIL PRESSURE SW. E/G accessory [(24160-39450)] (114250-39450) EU,OCE YN50E01001P1 HORN SW. KAI LF03M01005F1 LEVER LOCK SW. (RH) PA50S00001P1 LEVER LOCK SW. (LH) PY50S00003P1 HEATER SW. (OPT) DECELERATION SW. PM50S00005P1 AIR FILTER CLOGGING [LE11P01015S001] YR11P00008S005 SW. [KAI] TILT ANGLE SELECT SW. PW03M01225F1 TRAVEL ALARM SELECT SW. 2479U1190F16 GB50S00049F1 TRAVEL RIGHT (FORWARD) PRESS.SW. TRAVEL RIGHT (REVERSE) PRESS.SW. TRAVEL LEFT (FORWARD) PRESS.SW. TRAVEL LEFT (REVERSE) PRESS.SW. LF03M01005F3 SLEW / SWING SELECT SW. [KAI] GB50S00049F1 SLEW/SWING LEVER PRESSURE SW. (LH) [KAI] SLEW/SWING LEVER PRESSURE SW. (RH) [KAI]

SV-8 SV-12 SW-1 SW-2 SW-3 SW-4 SW-5 SW-6

SW-7 SW-8 SW-9 SW-10 SW-11 SW-12 SW-17 SW-23 SW-24 SW-25 SW-26 SW-27

Note) This is for reference only, because the part No. might be change due to improvement. The part Nos. in [ ] are for the earlier ones before the improvement / change.

SW-28

•

SW-30

•

23 – 1 – 5

SW-31

Part No. PH24S00001P1 PH24S00002P1 PM24S00001P1 PH25S00002P1 PH24S00001P1 PA24E01001P1

PH52S00002P1 FUEL SENSOR ENGINE THERMO SENSOR PA24S00003P1

ROOM LAMP

E/G accessory (129400-77012) Cab accessory WIPER MOTOR (YJ76S00001P1) 2427R1350 WASHER MOTOR DECELERATION MOTOR [PM20S00001F3] PM20S00004F3 PM22P00001P1 FUEL PUMP (OPT) (AUTO AIR BLEED)

Part Name BATTERY RELAY SAFETY RELAY DECELERATION RELAY TIMER UNIT E/G STOP RELAY CHARGE INDICATOR RELAY OPT.WORK LIGHT RELAY SLEW / SWING SELECT RELAY [KAI] S.V.SELECT RELAY [KAI] SLEW/SWING PRESERVATION RELAY [KAI]

SE-1 SE-2

SV-5

Switch

Diode

Group Code D-1 D-2 D-3 D-5 D-7 D-12 D-13

3.2 HARNESS & CABLE LIST

Code H-1-1 H-1-2 H-2-1 H-2-2

Item Main harness Instrument panel harness

H-3-1

Engine harness H-3-2

Part No. PH13E01050P5 PY13E01043P2 PY11E01013P3 PY11E01015P3 [PH16E01003P3] PH16E01007P1 [PY16E01001P1] PY16E01002P1

Remarks EU KAI EU KAI EU KAI

H-4

Battery cable

PH13E01053P1

H-5

Battery cable

PH13E01048D2

H-6

Engine ground cable

PH13E01047D1

H-7

Boom harness

PH15E01002D4 PY15E01001P3

SK40SR-2 SK45SR-2

H-8

Key switch harness

PH50E01003P1

(Opt.)

H-9

Auto air bleed harness

PH13E01051P1

(Opt.)

H-10

Connection harness with cab

PY11E01014P1

(Opt.)

H-11

Cab harness

PM02C01046P1

H-13

Travel alarm harness A

PH13E01056P1

(Opt.)

H-14

Travel alarm harness B

PH13E01057P1

(Opt.)

H-15

Travel alarm

PM13E01063P2

Cab light (R.H)

H-16

Cab work light harness

PH14E01001P1

(Opt.)

H-17

Cab work light harness

PM14E01008P1

Note)

is for reference only, because the part No. might be change due to improvement. • This • The part Nos. in [ ] are for the earlier ones before the improvement / change.

23 – 1 – 6

3.3 ELECTRICAL EQUIPMENT & HARNESS CONNECTION DRAWING

SE-1 : FUEL SENSOR H-1 : MAIN HARNESS

SV-12 : SLEW / SWING SELECT SOL. KAI

H-7 : BOOM HARNESS

L-2 : BOOM WORKING LIGHT

H-3 : ENGINE HARNESS ENGINE SW-1 : KEY SWITCH

E-2 : GENERATOR

H-8 : KEY SWITCH HARNESS Gauge cluster

(To engine accessory) M-1 : STARTER MOTOR

Consol box (RH) Lever lock solenoid Horn Boom working light

E-3 : HORN

Tuner (OPT.) Heater switch (OPT.) H-6 : ENGINE GROUND CABLE GND

Charge indicator relay Spare power source Holding circuit unit

H-4 : BATTERY CABLE

(To relay etc)

Travel 1,2 speed switch Instrument panel ground

Safety relay Timer unit

SW-3 : TRAVEL 1,2 SPEED SWITCH

Fuel sensor Engine stop solenoid

Battery relay

Diode (D-2)

H-2 : INSTRUMENT PANEL HARNESS

Deceleration switch

Fuel pump (Auto air bleed) (OPT.) Deceleration motor

Diode (D-12)

Relay box

GND

Diode (D-1)

E-13 : BATTERY

Wiper motor (Cab) (OPT. )

Slew / swing select sol KAI

Washer motor (Cab) (OPT.)

Travel alarm (OPT.)

Filter clogging switch

Solenoid block

Consol box (LH)

GND

BATTERY CABLE

23 – 1 – 7

3.4 ARRANGEMENT DRAWING FOR COMPONENTS & HARNESS 3.4.1 Upper frame portion (1 / 3)

23 – 1 – 8

3.4.1 Upper frame portion (2 / 3)

23 – 1 – 9 1

TO ENGINE HARNESS

3.4.1 Upper frame portion (3 / 3) TO RIGHT CONSOLE BOX

TO INSIDE OF RELAY BOX Torque : 2.4 kgf·m (17.3 lbf·ft)

TO BATTERY

TO STARTER STARTER CABLE

VIEW III

HOW TO CLAMP STARTER CABLE FIX INST-HARNESS BEFORE INSTALLING THIS FRAME

VIEW IV

HOW TO CLAMP ENG. EARTH TERMINAL

INST-PANEL HARNESS

TO LEFT CONSOLE BOX

DETAIL OF E

FIX WHITE TAPING PART. FIX CLIP INSTAL FUSIBLE LINK SIDE HOLE. Torque : 2.4 kgf·m (17.3 lbf·ft) ENG. HARNESS

FIX ENGINE HARNESS FUSIBLE LINK WITH CLIP.

TO FUEL PUMP TO UPPER (MAIN) HARNESS CLIP TOGETHER WITH HARNESS

DETAIL OF FLYWHEEL (AUTO AIR BLEED) (OPT)

H-9 : AUTO AIR BLEED HARNESS CLIP TOGETHER WITH ENG. HARNESS CLIP

M-6 : FUEL PUMP (AUTO AIR BLEED) (OPT)

TIGHTEN TOGETHER WITH BRACKET OF ENG.CONTROL. FIX CONNECTOR WITH CLIP.

23 – 1 – 10

VIEW II

3.4.2 Engine portion

DETAIL OF A “after changes for improvement” (Note)

• This figure shows the earlier one before the changes for improvement.

(The changed portions is shows in a separate box as “after changes for improvement” )

23 – 1 – 11 1

3.4.3 Instrument panel portion PANEL ASSY (RH)

Torque : 4.6 kgf·m (33.2 lbf·ft)

CAP

Torque : 2.8 kgf· m (20 lbf·ft)

RELAY BOX

SECTION A-A (2Places) TO HIGH-REACH CLIP TO MAIN HARNESS

VIEW I

H-10 : CONNECTION HARNESS WITH CAB (OPT)

CLIP WITH ZIP-TIE. JOINT CONNECTOR

CLIP WITH ZIP-TIE AFTER CAPPING

R-2 : SAFETY RELAY

PANEL ASSY (LH)

“Before changes for improvement” CLIP

2 LAYER TAPING

E-1 : H-2 : E-14 : FUSE BOX INST-PANEL HARNESS HOLDING CIRCUIT UNIT

R-6 : TIMER UNIT

DETAIL A

R-7 : ENGINE STOP RELAY

Torque :

R-1 : BATTERY RELAY

4.6 kgf·m (33.2 lbf·ft) UPPER : DECEL RELAY (RED TAPING) LOWER : CHARGE INDICATOR RELAY BACK : SW SELECT RELAY (WITH NAME TAG.)

CLIP

TO MAIN HARNESS

SOCKET

H-10 : CONNECTION HARNESS WITH CAB (OPT)

CLIP WITH ZIP-TIE AFTER CAPPING

R-2 : SAFETY RELAY FUSE FOR COOLER

SLEW / SWING SELECT RELAY KAI ONLY (YELLOW TAPING) CASE OF CAB SPECIFICATION : CONNECT WITH UNDER SIDE. LIGHT RELAY FOR CAB KAI EU GND CASE OF KAI : CONNECT WITH UPPER SIDE. Torque : 2.4 kgf·m (17.3 lbf·ft) SLEW / SWING PRESERVATION RELAY (WHITE TAPING). CASE OF KAI : CONNECT WITH BACK SIDE.

FIX CONNECTOR FOR SAFETY RELAY (Note)

• This figure shows the earlier one after the changes for improvement.

(The changed portions is shows in a separate box as “Before changes for improvement” )

23 – 1 – 12

3.4.4 Attachment portion

VIEW II KAI

TUBE BOOM HARNESS TUBE

BUCKET·H BUCKET·H

BUCKET·R

BOOM CYL·R

HARNESS

SECTION A-A

HARNESS

EYELET TERMINAL TO BE BINDED TO BOLT ARM·H WASHER

BOOM CYL·H

BOOM CYL·R

VIEW II

BUCKET·R

CLIP TERMINAL TO MAIN LINE WITH ZIP-TIE

ARM·R

VIEW III (STD.)

LOCK WASHER

N & B·R BREAKER·P

ARM·H

ARM·R

N & B·H BREAKER·T

VIEW III (B, N & B SPEC.)

LIGHT GREEN / RED

FROM NUT

HARNESS OF POWER SOURCE SIDE TO BE FIXED AT TAPING POSITION

VIEW I

BLACK

DETAIL OF A

CONNECTION

BOOM HARNESS (ORANGE)

MAIN HARNESS (LIGHT GREEN / RED)

BOOM HARNESS (BLACK)

MAIN HARNESS (BLACK)

23 – 1 – 13

3.4.5 Travel alarm

H-3 : TRAVEL ALARM HARNESS A

23 –1–14

3.5 DETAIL OF HARNESS & CABLE 3.5.1-1 Upper (Main) harness EU (Code H-1-1)

23 – 1 – 15

3.5.1-2 Upper (Main) harness KAI (Code H-1-2)

23 – 1 – 16

3.5.2-1 Instrument panel harness EU (Code H-2-1) - (1 / 3)

23 â&#x20AC;&#x201C; 1 â&#x20AC;&#x201C; 17

3.5.2-1 Instrument panel harness EU (Code H-2-1) - (2 / 3)

23 â&#x20AC;&#x201C; 1 â&#x20AC;&#x201C; 18

3.5.2-1 Instrument panel harness EU (Code H-2-1) - (3 / 3)

23 â&#x20AC;&#x201C; 1 â&#x20AC;&#x201C; 19

3.5.2-2 Instrument panel harness KAI (Code H-2-2) - (1 / 3)

23 – 1 – 20

3.5.2-2 Instrument panel harness KAI (Code H-2-2) - (2 / 3)

23 – 1 – 21

3.5.2-2 Instrument panel harness KAI (Code H-2-2) - (3 / 3)

23 – 1 – 22

“Before change for improvement” SE-2 : COOLANT THERMO SENSOR

3.5.3-1 Engine harness EU (Code H-3-1)

WHITE TAPING

SW-5 : ENG. WATER TEMP. SW

E-7 : SUPPLY WITH FUSIBLE LINK

DOUBLE SPLICE

SUPPLIED WITH DIODE DIODE : 2475R132

A CREVICE IS NOT BUILT IN AN INTERFERENCE PART

SW-6 : ENG. OIL PRESS. SW.

WHITE TAPING

WHITE TAPING TO INST HARNESS

WHITE TAPING

SE-2 COOLANT THERMO SENSOR “Before change for improvement”

E-8 : AIR HEATER CAP INSTALLED EQUIVALENT TO YAZAKI : 7034-1279 “Before change for improvement”

DOUBLE SPLICE E-2 : GENERATOR

CAP INSTALLED EQUIVALENT TO SEIWA : SLC-30 (BLACK)

SV-3 : ENG. STOP SOL

CAP INSTALLED EQUIVALENT TO YAZAKI : 7034-1273

M-1 : STARTER MOTOR

WHITE TAPING

(Note)

• This diagram shows the harness connections after the changes for improvement.

(The changed portions is shows in a separate box as “Before changes for improvement” )

23 – 1 – 23 1

“Before change for improvement” SE-2 : COOLANT THERMO SENSOR

3.5.3-2 Engine harness KAI (Code H-3-2)

SV-3 : ENG. STOP SOL. WHITE TAPING

E-7 : SUPPLY WITH FUSIBLE LINK

SW-5 : ENG. WATER TEMP. SW

DOUBLE SPLICE

SUPPLIED WITH DIODE DIODE : 2475R132

A CREVICE IS NOT BUILT IN AN INTERFERENCE PART SW-6 : ENG. OIL PRESS. SW.

WHITE TAPING

WHITE TAPING WHITE TAPING

TO INST HARNESS SE-2 COOLANT THERMO SENSOR

“Before change for improvement” SV-3 : ENG. STOP SOL

E-8 : AIR HEATER CAP INSTALLED EQUIVALENT TO YAZAKI : 7034-1279 “Before change for improvement”

DOUBLE SPLICE E-2 : GENERATOR

CAP INSTALLED EQUIVALENT TO SEIWA : SLC-30 (BLACK)

CAP INSTALLED EQUIVALENT TO YAZAKI : 7034-1273

M-1 : STARTER MOTOR

WHITE TAPING

(Note)

• This diagram shows the harness connections after the changes for improvement.

(The changed portions is shows in a separate box as “Before changes for improvement” )

23 – 1 – 24

3.5.4 Battery cable

(Code H-4)

3.5.7 Boom harness (Code H-7)

Insulation cover (SEIWA : BTC-135-L)

Terminal

Corrugated tube (I.D ø10)

Terminal (with cap)

Tighten with working light Terminal

3 Bla 0 ck To working light White taping

Corrugated tube (I.D ø7)

White taping

350

CB104

30 k c Bla Or an ge

ge an r O

100

290

Parts number

To upper (main) harness

100 L

940

CB104

CA104 SK40SR-2 SK45SR-2

A B TERMINAL TERMINAL JIS D5403 JIS D5403 BC618

3.5.5 Battery cable

BA508

CAP

LENGTH (mm)

SEIWA SLC30-R

940

195

1350

1680

A TERMINAL

LA312

FUNCTION BATTERY

STARTER B TERMINAL

(Code H-5) Terminal

Terminal

Corrugated tube (I.D ø10)

3.5.8 Key switch harness (Code H-8) 7 2RB

White taping

30 250 900

LA205 Terminal ACC 13 LA205 2BW Terminal C

Wind harness tape two layer

8A R

0.75

A B TERMINAL TERMINAL JIS D5403 JIS D5403 BC616

CAP

LENGTH (mm) 900

BA510

FUNCTION BATTERY

To inst-panel harness

8B 2R

4MY-CNA

LA105

LA205

Terminal B

BODY GROUND 8D 5R

LA305

3.5.6 Engine ground (Code H-6) Terminal

Terminal

47A 3L

4MY-312 72 L

47B 3L

0.75

LA205 Terminal R1 LA205 Terminal R2

LA105 Terminal BR

CONNECTORS SELECTION TABLE

A B TERMINAL TERMINAL JIS D5403 JIS D5403 BA510

BA510

PART.NUMBER

CONNECTOR (PIN NUM.)

MANUFUC.

4MY-CNA

YAZAKI

7122-2446 7114-2020

4MY-312

YAZAKI

7282-3040 7114-5041

HOUSING

TERMINAL

7114-6042 CAP

L (mm)

FUNCTION

280

ENGINE GROUND

23 – 1 – 25

3.5.9 Auto air bleed harness (Code H-9) (OPT)

3.5.11 Cab harness (Code H-11) (OPT) 2FY-BS UP SIDE

2MS-HW090

To fuel pump B

RG B

Not to be bared

To upper (main) harness

White taping (2.0) or more

CONNECTORS SELECTION TABLE

CONNECTOR PART NAME MANUFUC. NAME (PIN NUM.) HOUSING TERMINAL 2MS-HW090 SUMITOMO 6181-0070 1500-0105 2FY-BS

YAZAKI

Insulated tube to be installed corrugated tube

7219-3320 7116-1050

3.5.10 Connection harness with cab (Code H-10) (OPT) TO INST-PANEL HARNESS TO CAB HARNESS CAB

FUSE

DOUBLE SPLICE DOUBLE SPLICE

DOUBLE SPLICE

WIPER E-10 : RADIO DOUBLE SPLICE

SW-4 : WIPER WASHER SW

23 – 1 – 26

3.5.12 Travel alarm harness A (Code H-13)

3.5.13 Travel alarm harness B (Code H-14)

3.5.14 Travel alarm switch harness (Code H-15)

23 â&#x20AC;&#x201C; 1 â&#x20AC;&#x201C; 27

3.6 Cab work light equipment & harness

3.6.2 Cab work light harness (Code H-16)

3.6.1 Cab work light

3.6.3 Cab work light harness : Option (Code H-17)

23 – 1 – 28

4. ELECTRICAL EQUIPMENT & HARNESS Applicable machines SK40SR-2 : PH04-02801~ SK45SR-2 : PJ03-01001~

4.1 ELECTRICAL EQUIPMENT LIST

E-10

RADIO (OPT)

E-12 E-13 E-14 E-15

PM73E00004F6 E/G accessory (119836-77201) PH53S00001P1 PH73S00001P1 PM59S00002F2 PV59S00001F2 PF81S01001P1 E/G accessory (129100-77500) Cab accessory (PY54S00001P1) PM21M00005F1 PH72S00005P1 PA24S00002P3 PH73E00004F1

E-20

HEATER (OPT) BATTERY SEQUENCE BOX FUSE BOX (OPT) (FOR COOLER) TRAVEL ALARM [OCE] PM53S00001F2

L-1

ROOM LAMP

Light

Electrical Fittings

E-3 E-4 E-6

L-2

Cab accessory (2456U114) BOOM WORKING LIGHT (LH) PM80S00005F1

Sensor

E-7 E-8

FUSE BOX GENERATOR (ALTERNATOR) HORN FUSIBLE LINK GAUGE CLUSTER KCME,OCE KCMA POWER SOCKET [KCME] AIR HEATER

E-1 E-2

YN02D01001P1

Group Code SE-1 SE-2

Solenoid

Part No. YN02DO1001P1

Diode

Part Name DIODE DIODE DIODE DIODE DIODE DIODE (KCMA only) DIODE

SV-1 SV-2 SV-3 SV-5 SV-8 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

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

SW-17 SW-23 SW-24 SW-25 SW-26

M-1

Relay

Motor

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

R-1 R-2 R-3 R-6 R-7 R-8 R-9 R-14 R-22 R-23

E/G accessory (129400-77012) Cab accessory WIPER MOTOR (PM76S00001F1) PE54C00002S002 WASHER MOTOR DECELERATION MOTOR PH20S00004F1 PM22P00001P1 FUEL PUMP (OPT) (AUTO AIR BLEED) STARTER MOTOR

BATTERY RELAY SAFETY RELAY DECELERATION RELAY TIMER UNIT E/G STOP RELAY CHARGE INDICATOR RELAY OPT.WORK LIGHT RELAY SLEW / SWING SELECT RELAY [KCMA] S.V.SELECT RELAY [KCMA] SLEW/SWING PRESERVATION RELAY [KCMA]

SW-27 SW-28 SW-30 SW-31

Part No. Part Name FUEL SENSOR PH52S00002P1 ENGINE THERMO SENSOR PA24S00003P1

PH35V00001F2 LEVER LOCK SOL. 2 SPEED SELECT SOL. E/G accessory E/G STOP SOL. (119233-77931) YJ35V00004F1 POWER SHIFT SOL. (Cooler Spec) YJ35V00004F1 TILT ANGLE SOL. PE35V00001F1 SLEW / SWING SELECT SOL. [KCMA] PH50S00007S001 KEY SWITCH WORKING LIGHT SW. PV24E01001P1 2 SPEED SELECT SW. YN03M01286S002 WIPER WASHER SW. PY50S00004P1 E/G COOLANT TEMP.SW. PM50S00006P1 E/G OIL PRESSURE SW. E/G accessory (114250-39450) HORN SW. KCME,OCE YN50E01001P1 KCMA LF03M01005F1 LEVER LOCK SW. (LH) PA50S00001P1 PY50S00003P1 HEATER SW. (OPT) DECELERATION SW. PM50S00005P1 KCME,OCE 2446U3365S8 AIR FILTER CLOGGING SW. KCMA YR11P00008S005 TILT ANGLE SELECT SW. PW03M01225F1 TRAVEL ALARM SELECT SW. 2479U1190F16 GB50S00049F1 TRAVEL RIGHT (FORWARD) PRESS.SW. TRAVEL RIGHT (REVERSE) PRESS.SW. TRAVEL LEFT (FORWARD) PRESS.SW. TRAVEL LEFT (REVERSE) PRESS.SW. LF03M01005F3 SLEW / SWING SELECT SW. [KCMA] GB50S00049F1 SLEW/SWING LEVER PRESSURE SW. (LH) [KCMA] SLEW/SWING LEVER PRESSURE SW. (RH) [KCMA]

PH24S00001P1 PH24S00002P1 PM24S00001P1 PH25S00002P1 PH24S00001P1 PA24E01001P1 PA24E01001P1

PM24S00001P1 PA24E01001P1

Note) This is for reference only, because the part No. might be change due to improvement.

•

23 –1–29

4.2 HARNESS & CABLE LIST

Code H-1-1 H-1-2 H-1-3 H-3-1 H-3-2

Item Main / instrument panel harness Engine harness

Part No. PH14E01008P1 PY14E01007P1 PH14E01007P1 PH16E01008P1 PY16E01003P1

Remarks KCME KCMA OCE KCME, OCE KCMA

H-4

Battery cable

PH13E01061P1

H-5

Battery cable

PH13E01048D2

H-6

Engine ground cable

PH13E01047D1

H-7

Boom harness

PM15E01007D4 PM15E01007D5

H-10

Cab harness

PH14E01006P1

H-11

Cab harness (Inside of the cab)

PM02C01357P1

H-13

Travel alarm harness A

PH13E01056P1

SEE. 23-1-27

H-14

Travel alarm harness B

PH13E01057P1

SEE. 23-1-27

H-15

Travel alarm (Harness for switch)

PM13E01063P2

SEE. 23-1-27

Note)

SK40SR-2 SK45SR-2 KCME STD KCMA, OCE OPT. KCME STD KCMA, OCE OPT.

• This is for reference only, because the part No. might be change due to improvement.

23 –1–30

4.3 ELECTRICAL EQUIPMENT & HARNESS CONNECTION DRAWING

23 – 1 – 31

4.4 ARRANGEMENT DRAWING FOR COMPONENTS & HARNESS 4.4.1 Upper frame portion (1 / 3)

23 – 1 – 32

4.4.1 Upper frame portion (2 / 3)

23 – 1 – 33

4.4.1 Upper frame portion (3 / 3)

23 – 1 – 34

4.4.2 Engine portion

23 – 1 – 35

4.4.3 Instrument panel portion

23 – 1 – 36

4.4.4 Attachment portion

23 – 1 – 37

4.4.5 Travel alarm

23 – 1 – 38

4.5 DETAIL OF HARNESS & CABLE 4.5.1-1 Main / Instrument panel harness KCME (Code H-1-1) - (1 / 3)

23 – 1 – 39

4.5.1-1 Main / Instrument panel harness KCME (Code H-1-1) - (2 / 3)

23 – 1 – 40

4.5.1-1 Main / Instrument panel harness KCME (Code H-1-1) - (3 / 3)

23 – 1 – 41

4.5.1-2 Main / Instrument panel harness KCMA (Code H-1-2) - (1 / 3)

23 – 1 – 42

4.5.1-2 Main / Instrument panel harness KCMA (Code H-1-2) - (2 / 3)

23 – 1 – 43

4.5.1-2 Main / Instrument panel harness KCMA (Code H-1-2) - (3 / 3)

23 – 1 – 44

4.5.1-3 Main / Instrument panel harness OCE (Code H-1-3) - (1 / 3)

23 â&#x20AC;&#x201C; 1 â&#x20AC;&#x201C; 45

4.5.1-3 Main / Instrument panel harness OCE (Code H-1-3) - (2 / 3)

23 â&#x20AC;&#x201C; 1 â&#x20AC;&#x201C; 46

4.5.1-3 Main / Instrument panel harness OCE (Code H-1-3) - (3 / 3)

23 â&#x20AC;&#x201C; 1 â&#x20AC;&#x201C; 47

4.5.3-1 Engine harness KCME, OCE (Code H-3-1)

23 – 1 – 48

4.5.3-2 Engine harness KCMA (Code H-3-2)

23 – 1 – 49

4.5.4 Battery cable

(Code H-4)

4.5.7 Boom harness (Code H-7)

MAKER : YAZAKI HOUSING : 7123-4110 1FY-58L TERMINAL : 7116-3250 RETAINER : 7157-6411-70 Insulation cover (SEIWA : BTC-135-L)

Tighten with working light

Terminal

Terminal (with cap)

3 Bla 0 ck

White taping

To working light

Parts number Corrugated tube (I.D ø7)

White taping

30 k c Bla Or an ge

an Or

L1 30

100 L

50 250

350

CB104

CA104 SK40SR-2 SK45SR-2

940 A B TERMINAL TERMINAL JIS D5403 JIS D5403 BC618

4.5.5 Battery cable

BA508

CAP

LENGTH (mm)

SEIWA SLC30-R

940

FUNCTION BATTERY

MODELS

STARTER B TERMINAL Z74, Z75BU

(Code H-5) Terminal

Terminal

Corrugated tube (I.D ø10)

White taping

30 250 900

A B TERMINAL TERMINAL JIS D5403 JIS D5403 BC616

CAP

LENGTH (mm) 900

BA510

FUNCTION BATTERY

BODY GROUND

4.5.6 Engine ground (Code H-6) Terminal

A B TERMINAL TERMINAL JIS D5403 JIS D5403 BA510

23 – 1 – 50

BA510

CAP

Terminal

L (mm)

FUNCTION

280

ENGINE GROUND

CB104

180

260

1320

1820

A TERMINAL

LA312

To upper (main) harness

4.5.8 Cab harness (Code H-10) (KCMA, OCE / OPT)

4.5.9 Harness (Inside of the cab) (Code H-11) (KCMA, OCE / OPT)

23 – 1 – 51

NOTES

Book Code No.

PJ24

02E ➁

NEW HOLLAND EH45 Model Cross-reference: SK45SR-2 is NEW HOLLAND Model EH45

COMPONENTS SYSTEM TABLE OF CONTENTS I. HYDRAULIC COMPONENTS 1. Hydraulic Pump..........................................................................................I -1-1 2. Pilot Valve (Attachment).............................................................................I -2-1 3. Pilot Valve (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 1. Electrical Equipment List ..........................................................................II -1-1 2. Specifications of Electrical Equipment......................................................II -2-1

24 –0–1 ➀

PJ24

REVISION

DATE OF ISSUE

REMARKS

First Edition

October, 2001

S5PJ2402E

Second Revision

January, 2003

S5PJ2402E ➀ K·E

K·E

24 –0–2 ➀

Part I : HYDRAULIC COMPONENTS 1. HYDRAULIC PUMP 1.1 SUMMARY (1) GENERAL VIEW

DELIVERY PORT A2 (PF 1/2)

Pump for canopy spec SK40SR-2

DELIVERY PORT A1 (PF 1/2)

SK45SR-2

DELIVERY PORT A3 (PF 1/2) A3

AIR BREATHER R1

DELIVERY PORT A4 (PF 3/8) Z DRAIN PORT (PF 1/4) R1

S1 SUCTION PORT (SAE 1 1/2) Z

Fig. 1-1-1 General view of hydraulic pump (2) SPECIFICATIONS SK40SR-2

SK45SR-2

AP2D25LV1RS7-916-1

AP2D25LV1RS7-917-1

Machine Model Item

P1+P2

Delivery flow

Weight

P1+P2

35 (500)

230 (3270) 200 (2845)

35 (500)

cc / rev (cu·in/rev) 20.0(1.22) X 2 18.3 (1.12)

5.1 (0.31)

23.8(1.45) X 2 18.3 (1.12)

5.1 (0.31)

L/min (gal/min) 42.0 (11.1) X 2 38.4 (10.1) 10.7 (2.83) 52.4 (13.8) X 2 40.3 (10.6) 11.2 (2.96) Total power tilt angle control in concurrence with power shift

Control system Rated revolution

kgf/cm2 (psi) 230 (3270) 200 (2845)

Working pressure Displacement

Piston pump Gaer pump Trochoid pump Piston pump Gaer pump Trochoid pump

rpm kg (lb)

2,100 (High idle 2,290)

2,200 (High idle 2,350)

35 (77) Total power shift control by simultaneous tilt angling of swash plate.

24 –I–1–1

Pump for cab spec. with silencer DELIVERY PORT A2 (PF 1/2)

SK45SR-2

DELIVERY PORT A1 (PF 1/2)

SILENCER

DELIVERY PORT A3 A3 (PF 1/2)

AIR BREATHER R1

DELIVERY PORT A4 (PF 3/8) Z DRAIN PORT (PF 1/4)

R2 A1 A2 R3 A4 A3

S1 SUCTION PORT (SAE 1 1/2)

Fig. I-1-2 General view of hydraulic pump

(2) SPECIFICATIONS Machine

SK45SR-2 Model

Item kgf/cm2 (psi)

Working pressure

AP2D25LV1RS7-912-0 Piston pump

Gaer pump

Trochoid pump

P1+P2

230 (3270)

200 (2845)

35 (500)

Displacement

cc / rev (cu·in/rev)

23.8 (1.45) X 2

18.3 (1.12)

5.1 (0.31)

Delivery flow

L/min (gal/min)

52.4 (13.8) X 2

40.3 (10.6)

11.2 (2.96)

Total power tilt angle control in concurrence with power shift

Control system Rated revolution Weight

2200 (High idle 2350)

rpm

35 (77)

kg (lb)

24 –I–1–2

1.2 CONSTRUCTION • FUNCTION

Fig. 1-2

No.

Components

No.

Components

Shaft assy

Control piston assy

Hanger assy

Gear pump assy

Rotary group

Housing assy

Cover assy

Trochoid pump assy

Spring assy

(1) Piston pump

• This pump is a variable displacement double piston pump which delivers two equal flows with one

cylinderblock., 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.

• Control systems of this pump are two pump simultaneous tilting and constant total power shift. • The 3rd pump or pilot pump is installed on the same shaft with a coupling.

24 –I–1–3

(2) Operation 1) Pump operation

Displacement q (cm3) q = π X d2 / 4 X tan X D X Z / 2 X 10-3 S (Stroke)

(Number of piston) Piston

Hanger (Sliding surface)

Bottom dead point Cylinder block Port plate Delivery port

Outside P1 Hanger bearing

Inside P2

Top dead point De str liver ok y e Su Suction port c

tio

tro

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 port 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 angle 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 port plate.

• The oil sucked from the outside port of the cylinder block is delivered from the delivery port outside of the port plate.

24 –I–1–4

2) Control Spring A

Spring B

Hanger

Piston

Pz P3

Piston for P3 shift

Total pressure ∑P

A+B

∑Pi

A Piston

Shift control line

Air-con mode line Qmax

Section X-X

Flow rate Q

Fig. 1-4

• Delivery oil pressure P1 and P2 act on hanger through pistons that have same sectional area. • 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 A (outer), 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 A, the hanger is tilted and held tilting at the position where the hydraulic pressure balances the spring pressure. (Control line, Area A)

• After the hydraulic pressure acting on the piston rises further and the tilt angle becomes smaller, the force of spring B which has not been worked up to now starts acting on.

• The higher hydraulic pressure is required to resist this pressure of two springs,consequently the inclination of lines on the diagram will become sharp. (Drawing Area A+B)

• When the hydraulic pressure P3 acts on the shift pin, the control diagram is also shifted. • When hydraulic pressure (Pz=3.4 MPa {35 kgf/cm }) from the outside acts on Z port, the mode is changed 2

in the air-con mode.

• When the Z port is not used,it is led to the drain. 24 –I–1–5

3) Adjusting procedure of set torque

Spring seat

Adjusting screw

Total pressure ∑P (P1 + P2)

Cover

Tighten

Loosen

Q max. Hex.Nut Tighten

Flow rate Q

Loosen

Fig. 1-5

•

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

24 –I–1–6

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

2 8 10 9 6

Fig. 1-6

No. 1 2 3 6 7

Parts name Shaft Seal case Bearing Snap ring (for shaft) Snap ring (for shaft)

Parts name Q'ty No. Oil seal 1 8 1 9 O-ring 1 10 Snap ring (For hole) 1 11 Key 1

Q'ty 1 1 1 1

(2) Hanger 1 2 5

6 3 4

Fig. 1-7

Parts name No. 1 Hanger 2 Plate 3 Distance piece

Parts name Q'ty No. 1 4 Bearing 5 Socket bolt 1 6 O-ring 1

24 –I–1–7

Q'ty 2 1 1

(3) Rotary group

Fig. 1-8

No. 1 2 4 5 6

Parts name Piston Cylinder block Retainer Plate Guide

Parts name Q'ty No. 10 7 Spring 1 8 Parallel pin 1 9 Spring seat 1 10 Snap ring (for hole) 1

24 –I–1–8

Q'ty 1 3 2 1

(4) Cover 4

3 10

2 Z Z 7

Section X-X

X 1

6 7

9 7

Section Z-Z

16 Y

9 11

Section Y-Y

Fig. 1-9

No. 1 2 3 4 5

Parts name Cover Control plate Parallel pin Socket bolt O-ring

Parts name Q'ty No. 6 O-ring 1 7 Plug M6 1 9 Orifice 2 10 Bearing 3 11 Plug assy 1

24 –I–1–9

Parts name Q'ty No. 13 Socket bolt 4 16 Plug M8 4 17 Plug M5 3 1 2

Q'ty 1 2 1

(5) Control spring 34, 44, 54, 64 1

9 4

Fig. 1-10

No. 1 2 3 4 5

Parts name Q'ty No. 44 Shim 1 54 Shim 1 64 Shim 2 1 2

Parts name Q'ty No. 6 Spring 1 7 O-ring : 1A P34 1 8 Socket bolt 1 9 Nut 1 34 Shim 1

Parts name Spring seat Spring seat Cover Adjust screw Spring

Q'ty 2 2 2

(6) Control piston

X 7

Detail of X

11 Fig. 1-11

No. 1 2 3 4

Parts name Cylinder Piston Piston Parallel pin

Parts name Q'ty No. 5 Spring seat 1 6 Socket bolt 1 7 Disk spring 2 8 O-ring 1

24 –I –1–10

Parts name Q'ty No. 9 O-ring 1 11 Piston 2 3 1

Q'ty 1 1

(7) Gear pump 12

Fig. 1-12

No. 3 4 5 6 7

Parts name Housing Cover Gear Gear Side plate assy

Q'ty No. Parts name Plate 10 1 11 Guide 1 12 Coupling 1 14 O-ring 1 15 O-ring 2

24 –I–1–11

Q'ty No. Parts name Square ring 16 2 17 Square ring 2 18 O-ring : 1B P6 1 19 Socket bolt 2 1

Q'ty 1 2 1 6

(8) Trochoid pump

Fig. 1-13

No. 1 2 3 4 5

Parts name Gear Casing Side plate (A) O-ring Spring pin

Parts name Q'ty No. 6 Socket bolt (special) 1 7 Side plate (B) 1 8 Spring pin 1 9 Plate 1 1

24 –I –1–12

Q'ty 3 1 1 1

(9) Silencer

Fig. 1-14

No. 1 2 3 4

Parts name Body Bushing Plate Socket bolt : M10 X 25

Parts name Q'ty No. 5 O-ring 1 6 O-ring : 1B G25 2 7 O-ring 1 8 Plug assy 6

24 –I–1–13

Q'ty 2 2 2 2

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 ± 1.4lbf·ft)

VIEW A

T=Tightening torque

(2) Specifications SPECIFICATIONS PA30V00002F2 PV48M1032B 70 kgf / cm2 (1,000 psi) 15L/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

3.0

Secondary pressure 3.0

2.06±0.15

2.0

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.)

(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

Single operation torque

3.0

2.06±0.15

2.16

2.0

2.0 1.69

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

40.8 (2.95) 30.6 (2.21) 25.0 (1.60)

20.4 (1.48) 20.2 (1.25) 10.8 (1.25)

10.2 (0.74) 8.0 (0.58)

Operation torque kgf·cm (lbf·ft)

4.0 3.43

Operation torque (N·m)

(498) 35

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

Parts 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

Parts 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

Parts name SPRING SPRING SPRING SPRING JOINT ; M14 DISK ADJUSTING NUT ; M14 BOOTS (BELLOWS)

Q'TY 2 2 2 2 1 1 1 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 â&#x20AC;&#x201C;Iâ&#x20AC;&#x201C;2â&#x20AC;&#x201C;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 Torque

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

SPECIFICATIONS PM30V00019F1 PVD6P4001 70kgf/cm2 (1000 psi) 10L/min (2.6gal / min) 3.9kg (8.6 lb)

(580) 40.8

122.4 (885)

Operation torque

106.3 (770)

(435) 30.6

91.8 (660)

(340 ± 21) 24.0 ± 1.5

62.0 (450)

61.2 (440)

(290) 20.4

59.1 (430) 49.5 (360)

(145) 10.2 (78 ± 11) 5.5 ± 0.75

30.6 (220) Secondary pressure

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

Fig. 3-2

24 –I–3–1

Operation torque (kgf·cm)

Secondary pressure kgf/cm2(psi)

(3) Performance Characteristics

• 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.

3.0 (22)

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

Parts 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

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

Parts name Plug O-ring Socket bolt Spool Spring seat Washer Spring Spring Spring Cam shaft Bushing Cam Steel ball Set screw Boots (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

420

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 â&#x20AC;&#x201C;Iâ&#x20AC;&#x201C;3â&#x20AC;&#x201C;3

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 â&#x20AC;&#x201C;Iâ&#x20AC;&#x201C;3â&#x20AC;&#x201C;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. ( In operation in ?? direction)

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 â&#x20AC;&#x201C;Iâ&#x20AC;&#x201C;3â&#x20AC;&#x201C;5

NOTES

4. CONTROL VALVE

Pa2

Pa5

Actuator port A1~9 B1~9 18-PF1/2

Bucket

Boom

Pb9

OR1

OR3

Travel right

Travel left Pb7

MR1

Lock valve release port Pa8' 1-PF1/4 Drain port Dr1 1-PF1/4

Pb8 Pp

B6 G2

T2 A9

Manual operate

OR4

OR7

OR11

MR3

Pb6

OR8

OR9

Arm

Swing

Pb5

OR10

Pb2

Gauge port G1,G2 2-PF3/8

Nibbler & Breaker

Supply

Dozer

Slewing

Tank port T1 1-PF1

Travel straight Supply

4.1-1 GENERAL VIEW AND PORTS NO. EU , OCEANIA

Pa6

Pilot port Pa2,Pa5~9 Pb2,Pb5~9,Pp 13-PF1/4

Pa7

Pa8

Pilot operate

Pa9

Pump port P1,P2,P3 3-PF1/2

Tank port T2 1-PF1/2

Fig. 4-1-1 4.2-1 SPECIFICATIONS. EU

OCEANIA

Table. 4-1-1

ITEM

SK40SR-2

SK45SR-2

Model (Type)

BCV65-AE10

BCV65-AF10

Valve operation

Manual

Swing‚ Nibbler & Breaker‚ Dozer blade

Pilot

Travel straight‚ Travel left‚ Travel right‚ Boom‚ Arm‚ Bucket, Slewing

Flow rate Setting pressure of main relief valve P1‚ P2‚ P3

Setting pressure of over load relief valve

P1‚ P2 : 42.0 L/min‚ P3 : 36.8 L/min

P1‚ P2 : 52.4 L/min‚ P3 : 40.3 L/min

P1‚ P2···230 +50 kgf/cm2 (3270 +71 P1‚ P2···230 +50 kgf/cm2 (3270 +71 0 psi) 0 psi) at 42.0 L/min (11.1 gal/min) : MR1 at 52.4 L/min (13.8 gal/min) : MR1 P3 ········200 +50 kgf/cm2 (2840+71 0 psi) at 36.8 L/min (9.7 gal/min) : MR3

P3 ········200 +50 kgf/cm2 (2840+71 0 psi) at 40.3 L/min (10.6 gal/min) : MR3

B1‚ A3, B3, A5‚ B5‚ B9 port (OR1‚ OR7‚ OR8‚ OR9,OR10, OR11) 260 +50 kgf/cm2 (3700 +71 0 psi) at 5L/min (1.3 gal/min) B8‚ A8 port (OR3‚ OR4) 280 +50 kgf/cm2 (3980 +71 psi) at 5L/min (1.3 gal/min) 0

24 – I –4 –1 (1)

Pa2

Pa5

Actuator port A1~9 B1~9 18-PF1/2

Pilot port Pa2,Pa5~9 Pb2,Pb5~9,Pp 13-PF1/4

Bucket

Boom

Travel left

Travel straight Supply

Pb9

MR1

OR1

Travel right

OR8

Pb7

B6 G2

T2 A7

Manual operate

OR4

Lock valve release port Pa8' 1-PF1/4 Drain port Dr1 1-PF1/4

Pb8 Pp

Pb6

OR7

OR11

MR3

(Applicable machines : PJ02-00101~)

OR3

Pb5

OR9

Arm

Swing

Gauge port G1,G2 2-PF3/8

OR10

Pb2

Supply

Dozer

Slewing

Tank port T1 1-PF1

Nibbler & Breaker

4.1-2a GENERAL VIEW AND PORTS. KAI

Pa6

Pa7

Pa8

Pilot operate

Pa9

Pump port P1,P2,P3 3-PF1/2

Tank port T2 1-PF1/2

Fig. 4-1-2

4.2-2 SPECIFICATIONS. KAI

Valve operation

Table. 4-1-2

ITEM

SK45SR-2

Model (Type)

BCV65-AL10

Manual

Nibbler & Breaker‚ Dozer blade

Pilot

Travel straight‚ Travel left‚ Travel right‚ Boom‚ Arm‚ Slewing, Swing

Flow rate

Setting pressure of main relief valve P1‚ P2‚ P3

Setting pressure of over load relief valve

P1‚ P2 : 52.2 L/min‚ P3 : 40.3 L/min P1‚ P2···230 +50 kgf/cm2 (3270 +71 0 psi) at 52.4 L/min (13.8 gal/min) : MR1 P3 ········200 +50 kgf/cm2 (2840+71 0 psi) at 40.3 L/min (10.6 gal/min) :MR3 B1‚ A3, B3, A5‚ B5‚ B9 port (OR1‚ OR7‚ OR8‚ OR9,OR10, OR11) 260 +50 kgf/cm2 (3700 +71 0 psi) at 5L/min (1.3 gal/min) B8‚ A8 port (OR3‚ OR4) 280 +50 kgf/cm2 (3980 +71 psi) at 5L/min (1.3 gal/min) 0

24 – I – 4 – 1 (3)

Pa2

Pa3

Actuator port A1~9 B1~9 18-PF1/2

Pa4

Pa5

Pilot port Pa2,Pa5~9 Pb2,Pb5~9,Pp 13-PF1/4

Boom

Bucket

Travel straight Supply

Travel left

Pb9

OR1

B6 G2

T2 A7

Manual operate

OR4

Pb7

OR7

OR11

MR3

Pb8 Pp

OR8

OR9

Pb6

Lock valve release port Pa8' 1-PF1/4 Drain port Dr1 1-PF1/4

OR3

Pb5

Travel right

Arm

Swing

Pb4

(Applicable machines : PJ03-01001~)

MR1

Pb3

Gauge port G1,G2 2-PF3/8

OR10

Pb2

Supply

Dozer

Slewing

Tank port T1 1-PF1

Nibbler & Breaker

4.1-2b GENERAL VIEW AND PORTS. KCMA

Pa6

Pa7

Pa8

Pilot operate

Pa9

Pump port P1,P2,P3 3-PF1/2

Tank port T2 1-PF1/2

Fig. 4-1-3

4.2-2 SPECIFICATIONS. KCMA

Valve operation

Table. 4-1-3

ITEM

SK45SR-2

Model (Type)

BCV65-AN10

Manual

Dozer blade

Pilot

Travel straight‚ Travel left‚ Travel right‚ Boom‚ Arm‚ Slewing, Swing, Nibbler & Breaker

Flow rate

Setting pressure of main relief valve P1‚ P2‚ P3

Setting pressure of over load relief valve

24 – I –4 –1 (3)

4.3-1 CONSTRUCTION

Bucket

Boom

Travel left

Supply

Travel straight

Travel right

Arm

Swing

Nibbler & Breaker

Supply

Slewing

Dozer

(1)-2 Control Valve : Overall composition. EU , OCEANIA

19 21

Manual operate

Pilot operate

3 14

5 15

10 16

15 Fig. 4-2-1

Table. 4-2-1 No. 1 2 3 4 5 6 7

Parts name Dozer Slewing P3 supply Nibbler & Breaker Swing Arm Travel right

Q'ty No. 1 8 1 9 1 10 1 12 1 13 1 14 1 15

Q'ty No. Parts name Parts name P1‚P2 supply &Travel straight 1 16 Over load relief valve Travel left 1 17 Anti cavitation valve Boom 1 19 Tie bolt Bucket 1 20 Tie bolt P1‚P2 Main relief valve 1 21 Nut 1 P3 Main relief valve 6 Over load relief valve

24 –I – 4–2 (1)

Q'ty 2 1 4 4 8

4.3-2a CONSTRUCTION

Bucket

Boom

Supply

Travel left

(Applicable machines : PJ02-00101~)

Travel straight

Travel right

Arm

Swing

Nibbler & Breaker

Supply

Slewing

Dozer

(1)-2 Control Valve : Overall composition. KAI

19 21

Manual operate

Pilot operate

3 14

5 15

10 16

15 Fig. 4-2-2

Table. 4-2-2 No. 1 2 3 4 5 6 7

Parts name Dozer Slewing P3 supply Nibbler & Breaker Swing Arm Travel right

Q'ty No. 1 8 1 9 1 10 1 12 1 13 1 14 1 15

24 – I – 4 – 2 (2)

Q'ty 2 1 4 4 8

4.3-2b CONSTRUCTION

Bucket

Boom

Travel left

(Applicable machines : PJ03-01001~)

Supply

Travel straight

Travel right

Arm

Swing

Nibbler & Breaker

Supply

Slewing

Dozer

(1)-2 Control Valve : Overall composition. KCMA

19 21

Manual operate

Pilot operate

3 14

5 15

10 16

Fig. 4-2-3

Table. 4-2-3 No. 1 2 3 4 5 6 7

Parts name Dozer Slewing P3 supply Nibbler & Breaker Swing Arm Travel right

Q'ty No. 1 8 1 9 1 10 1 12 1 13 1 14 1 15

24 –I – 4–2 (3)

Q'ty 2 1 4 4 8

(2) Component Parts The control valve consists of the following four major groups. • Manual operation : EU , OCEANIA Swing, Dozer blade, Nibbler & breaker. KAI Dozer blade, Nibbler & breaker (Applicable machines : PJ02-00101~) Dozer blade (Applicable machines : PJ03-01001~) • Pilot operation : EU , OCEANIA Travel straight ‚ Travel right & left ‚ Boom ‚ Arm ‚ Bucket ‚ Slewing KAI Travel straight ‚ Travel right & left ‚ Boom ‚ Arm ‚ Bucket ‚ Slewing, Swing (Applicable machines : PJ02-00101~) Travel straight, Travel right & left, Boom, Arm, Bucket, Slewing, Swing, Nibbler & Breaker (Applicable machines : PJ03-01001~) • Accessory : P1 ‚ P2 supply (in common travel straight) ‚ P3 supply • Accessory(Valve) : P1 ‚ P2 ‚ P3 main relief ‚ Overload relief ‚ Anti cavitation Note) For the operating section, some typical examples are described in the below. Refer to the chapter 33 for the disassembling of control valve. Table. 4-3 1) Manual operation : Swing (No.5) EU , OCEANIA Note) Swing control of KAI is operated by hyd. pilot line. 14 15

12 11

No. 1 2a 2b 2c 2d 2e 2f 2g 3 4 5 6 7 8 9 10 11 12 13 14 15

9 10 13 7 8

6 5 4 3

2a 2b 2c 2d 2e 2f 2g

Fig. 4-3

2) Pilot operation : Slewing (No.2)

7 8

No. 1 2a 2b 2c 2d 2e 3 4 5 6 7 8 9 10 11 12 14

11,12 5

2e 2d 2c 2b

Q'ty 1 1 1 1 1 2 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1

Table. 4-4

14 10 9

Parts name Body Spool O-ring 1A P14.5 Dust wiper Oil seal retainer Spring seat Spring Spool end O-ring 1A P14.5 Dust wiper Oil seal retainer Socket bolt M6 X 12 Socket bolt M6 X 22 Cover Load check valve Spring(for check valve) Plug O-ring 1B P11 Anti cavitation valve O-ring 1B WG6 O-ring 1B P20

Fig. 4-4

24 – I – 4 – 3

Parts name Body Spool Spring seat Spring Spool end Spring seat O-ring AS 1A 119 Pilot cover Pilot cover Socket bolt M6 X 45 Load check valve Spring(for check valve) Plug O-ring 1B P11 Plug O-ring 1B P14 O-ring 1B WG6

Q'ty 1 1 1 1 1 1 2 1 1 4 1 1 1 1 1 1 1

3) P1, P2 Main relief valve (MR1)

17 11

Table. 4-5

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Fig. 4-5

4) P3 Main relief valve (MR3)

Socket Pressure regulating valve Piston Body Poppet Adjust screw Lock nut M14 Spring Spring O-ring 1A P7 Back up ring Poppet seat O-ring AS 1B 15 O-ring 1B P10 O-ring 1B P22 O-ring 1B S10 Back up ring

Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Table. 4-6

Parts name

Fig. 4-6

24 –I–4–4

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Parts name Socket Pressure regulating valve Piston Plug Body Poppet Adjust screw Lock nut M14 Spring Spring O-ring 1B P15 O-ring 1B S10 O-ring 1B P7 Back up ring O-ring 1B P14

Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1

5) Over load relief valve

Table. 4-7

Fig. 4-7

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

6) Anti cavitation valve

Parts name Socket Pressure regulating valve Piston Plug Body Poppet Adjust screw Lock nut M14 Spring Spring O-ring 1B P15 O-ring 1B S10 O-ring 1B 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

Fig. 4-8

24 –I–4–5

No. 1 2 3 4 5 6 7 8

Parts name Anti cavitaion valve Body Plug Spring Back up ring O-ring 1A P10A O-ring 1A S14 O-ring 1A P15

Q’ty 1 1 1 1 1 1 1 1

4.4-1 HYDRAULIC CIRCUIT

EU , OCEANIA

Table. 4-9-1 Dozer

1 2

12 Slewing a 3

Nibbler & Breaker

17 4

No. 1 2 3 4 5 6 7 8 9 10 11 12

Swing

14 20

14 14

Arm

23 a

Travel right a Gauge port

7 25

Supplied 11 & Travel straight

Gauge port a

19 Travel left

9 16

Boom

15 a

22 a

26 Bucket

Fig. 4-9-1

24 – I –4– 6 (1)

15 16 17 19 20 21 22 23 24 25 26

Parts name Dozer spool Slewing spool Nibbler & Breaker spool Swing spool Arm spool Travel right spool Travel straight spool Travel left spool Boom spool Bucket spool P1, P2 main relief valve P3 main relief valve B1‚ A3, B3, A5‚ B5‚ B9 Over load relief valve B8‚A8 Over load relief valve Boom lock valve Anti cavitation valve P1 by-pass circuit P2 by-pass circuit P3 by-pass circuit P1 parallel circuit P2 parallel circuit P3 parallel circuit Pp Pilot passage Tank circuit

4.4-2a HYDRAULIC CIRCUIT

KAI

(Applicable machines : PJ02-00101~)

Table. 4-9-2 Dozer

1 2

12 Slewing a 3

Nibbler & Breaker

17 4

No. 1 2 3 4 5 6 7 8 9 10 11 12

Swing

Pb4 20

Pa4

14 14

Arm

23 a

Travel right a Gauge port

7 25

Supplied 11 & Travel straight

Gauge port a

19 Travel left

9 16

Boom

15 a

22 a

26 Bucket

Fig. 4-9-2

24 – I – 4 – 6 (2)

15 16 17 19 20 21 22 23 24 25 26

4.4-2b HYDRAULIC CIRCUIT

KCMA

(Applicable machines : PJ03-01001~)

Table. 4-9-3 Dozer

1 2

12 Slewing a 3

Nibbler & Breaker

Pb3

Pa4 4

No. 1 2 3 4 5 6 7 8 9 10 11 12

Swing

Pb4 20

Pa4

14 14

Arm

23 a

Travel right a Gauge port

7 25

Supplied 11 & Travel straight

Gauge port a

19 Travel left

9 16

Boom

15 a

22 a

26 Bucket

Fig. 4-9-3

24 – I –4– 6 (3)

15 16 17 19 20 21 22 23 24 25 26

4.5 EXPLANATION OF OPERATION Following explanation is described according to the control valve of EU , OCEANIA spec. The control system of swing operation is mechanical type in EU , OCEANIA and that is hyd. pilot type in KAI . (1) Neutral position P1: The delivery oil from the hydraulic pump flows from the P1 port of the control valve (hereafter 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 nibbler & breaker. P3: The delivery oil of the hydraulic pump flows from the (C/V) P3 port into the parallel circuit of slewing 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 flows out to the tank circuit through the by-pass circuit of P3 supply section, and flows 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, don’t operate them except when working. P1 line: Left travel, Boom, Bucket P2 line: Right travel, Arm, Boom swing, Nibbler & breaker P3 line: Dozer, Slewing Pp: The delivery oil from the gear pump flows from the (C/V) Pp port into the pilot circuit through the orifice 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 nibbler & breaker 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, nibbler & breaker and boom swing in EU & OCEANIA machine 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, don’t use the control lever.

24 –I–4–7

P3 side Parallel passage

From by-pass passage of tank to tank passage

Dozer

Slewing To tank From P3 pump

P3 supplied port

By-pass passage to tank

Nibbler & Breaker P2 side Boom swing By-pass passage

Arm

Travel right From P2 pump P1,P2 supplied

From P1 pump

Travel left

Boom

Bucket

P1 side By-pass passage

Fig. 4-10 Operation at neutral position

24 –I–4–8

Orifice

(2) Pilot operating section 1) Operating boom raise With the boom raise operation, the pilot secondary pressure enters into the Pb8 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 travel operation into the parallel circuit on the boom switching section. With the movement of the spool, as the circuit from the passage leading to the boom lock valve 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 B8 port through the bridge passage and open the boom lock valve (free flow) 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 A8 port, and with the movement of the spool the oil flows out into the tank circuit. Consequently, the boom cylinder extends and raises the boom. (See page 11 and 12 for lock valve) 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

Parallel passage Bridge passage

Dr1

Pa8'

Pa8 Pb8 Pilot passage By-pass passage

P1,P2 supply Pp From P1 pump P1

To tank

Boom

Bucket Pa8

Pb8

Fig. 4-11 Operation at boom raising

24 –I–4–9

(3) Manual operation section (Swing control is oprated by hyd.line but dozer and nibbler & breaker are operated by mechanical control in KAI specification.) 1) Left swing operation With the left swing operation, the swing spool moves to the drawing out direction. With the movement of the spool, as the by-pass circuit is cut off at the swing switching section, (a portion of the oil flows out to the by-pass (tank) circuit through the notch provided on the swing spool.), the oil entered through the P2 port flows into the parallel circuit through the check valve provided on the upper part of the travel spool by-pass circuit. With the movement of the spool, as the circuit from the 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 swing cylinder rod side flows into through the A4 port, and with the movement of the spool the return oil flows out to the tank circuit that is connected by the notch of the spool. Consequently, the swing cylinder extends, and the boom swings leftward. The oil entered through Pp port passes through the orfice provided on the P1 and P2 supply section, and flows into the pilot circuit. As the oil entered in the pilot circuit flows out from the travel switching section into the tank circuit, the pilot circuit pressure becomes equal to the tank pressure, and consequently the travel spool is not switched.

Swing cylinder

Parallel passage

Bridge passage Pilot passage

A part of the oil flows out to the by-pass circuit.

By-pass passage

Nibbler & breaker

Boom swing

Arm

From P2 pump

From P2 pump From travel parallel passage

Fig. 4-12 Operation of boom swing

24 –I –4–10

Oil entered from Pp port flows into tank passage through travel switching section on the upper stream side of swing.

(4) Actuation of lock valve 1) Holding In the condition where the spool for boom is on the neutral position, pilot piston chamber (a) is connected to the drain passage through pilot port (Pa8’) used to release the lock valve, and piston chamber (b) is also connected to the drain passage through drain port (Dr1). Therefore, piston (C) must be held in the condition shown in the figure. Then the retaining pressure of the boom cylinder acts on the lock valve chamber as shown in the figure, and pushes the needle valve against the seat section and the lock valve against the seat section, preventing the leakage on the boom cylinder head side. Consequently the movement of the boom cylinder due to the leakage is also prevented.

Boom cylinder

Lock valve chamber Pilot piston Piston chamber (b) chamber (a)

Needle valve seat

Seat section

Dr1

Pa8'

Pb8 Piston A Lock valve

Drilled hole "E" Needle valve

Fig. 4-13 Operation of lock valve (Holding)

24 –I–4–11

Piston C

2) Releasing When the pilot pressure acts on pilot port (Pa8’) for releasing of lock valve, piston (C) moves leftward, and pushes and opens the needle valve through piston (A). Then, the return oil from the boom cylinder flows through the orifice of the lock valve, lock valve chamber and drilled hole, and flows into the tank passage through the notch of the spool for boom. The pressure of the lock valve chamber lowers because the needle valve opens and the return oil from the boom cylinder opens the lock valve. Consequently the return oil from the boom cylinder flows into the tank passage through the notch of the spool for boom.

Boom cylinder

Lock valve

Piston chamber (b) A8

Pilot piston chamber (a)

B8 Needle valve seat

Seat section

Dr1

Pa8'

Pb8 Piston A Lock valve

Drilled hole "E" Needle valve

Fig. 4-14 Operation of lock valve (Releasing)

24 –I –4–12

Piston C

(5) Travel straight function Switch the right and left travels and switch also any of the arm, boom, bucket, swing and nibbler & breaker operations, and the pressure oil flown into the pilot passage through the orifice from Pp port is blocked between the pilot passage and the tank passage. Therefore the pilot passage pressure becomes equal to the Pp port supply pressure. Consequently, when Pp port supply pressure acts on the travel straight spool, and the spool moves, resisting the spring force, to the position where it comes into contact with the pilot cover. When the spool is switched, the pressure oil supplied through P1 and P2 passes through respective notch provided on the spool, and flows into the right and left travel motors through respective by-pass passage, and simultaneously flows into respective parallel circuit from the passage provided on the inside of the spool. Consequently, the pressure oil flown into P1 and P2 branches out into the attachment switching sections(arm, boom, bucket, swing and nibbler &breaker) at constant rate, therefore the attachment switching section can be operated without occurrence of travel deviation. (Figure 4-15 shows the condition where the right and left travels and arm operations were switched.) To P1, P2 parallel passage

From P2 pump

Pp From P1 pump

P2 parallel passage

Travel right

Pa5

Pb5

Pa6

Pb6 Pilot passage

From P2 pump P1, P2 supplied

Pp From P1 pump Travel left

Pa7

Pb7

P2 parallel passage

Fig. 4-15 Operation of supply section

24 â&#x20AC;&#x201C;Iâ&#x20AC;&#x201C;4â&#x20AC;&#x201C;13

(6) Actuation of P1 and P2 main relief valves (MR1) 1) Actuation when released (1) The pressure oil flows through the inside of the piston placed on the pressure regulating valve (main valve) and orifice “B”, and fills “A” chamber, and consequently the pressure regulating valve and socket and pressure regulating section are securely seated. Tank passage Piston

Orifice “B”

Socket

Pressure regulating valve “A”chamber Poppet

Fig. 4-16 (2) When the oil pressure of port “P” reaches to the spring set pressure of the regulating valve, the pressure oil actuates on the regulating valve through the piston and opens it. Then, the pressure oil passes through the inside of piston, orifice “B”, “A”chamber, ring-shaped restriction “C” and passage “D” in succession, and flows into the tank passage. Tank passage

Ring-shaped restriction "C" Adjust spring

“D” passage

Fig. 4-17 (3) Since the regulating valve is open and the pressure of “A” chamber is lowered, the pressure regulating valve opens and the pressure oil of port “P” directly flows into the tank passage through the drilled hole “E”. Tank passage

Drilled hole "E"

Fig. 4-18 (4) When the pressure of port “P” lowers to the spring set pressure of the regulating valve or less, the regulating valve is pushed against the seat by the force of regulating spring of the regulating valve, and consequently the pressure of “A” chamber becomes equal to the pressure of “P” port and the pressure regulating valve is also pushed against the socket seat section, restoring to the original condition (Figure 4-16).

24 –I –4–14

(7) Actuation of P3 main relief valve (MR3) 1) Actuation when released (1) The pressure oil flows through the inside of the piston placed on the pressure regulating valve (main valve) and orifice “B”, and fills “A” chamber, and consequently the pressure regulating valve and socket and seat are securely seated. Tank passage

Orifice “B”

Piston

Adjust spring

P Seat Socket

“A”chamber Pressure regulating valve

Poppet

Fig. 4-19 (2) When the oil pressure of port “P” reaches to the spring set pressure of the regulating valve, the pressure oil actuates on the regulating valve through the piston and opens it. Then, the pressure oil passes through the inside of piston, orifice “B”, “A” chamber, ring-shaped restriction “C” and drilled hole “D” in succession, and flows around the socket and into the tank passage.

Ring-shaped restriction “C”

Drilled hole “D”

Fig. 4-20 (3) Since the regulating valve is open and the pressure of “A” chamber lowers, the pressure regulating valve opens and the pressure oil of port “P” directly flows into the tank passage through the drilled hole “E”.

Drilled hole “E”

Fig. 4-21 (4) When the pressure of port “P” lowers to the spring set pressure of the regulating valve or less, the regulating valve is pushed against the seat by the force of adjust spring of the regulating valve, consequently the pressure of “A” chamber becomes equal to the pressure of “P” port and the pressure regulating valve is also pushed against the socket seat section, restoring to the original condition (Figure 4-19).

24 –I–4–15

(8) 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 seat. Tank passage

Orifice “B”

Piston

Adjust spring

P Seat Socket

“A”chamber Pressure regulating valve

Poppet

Fig. 4-22 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 poppet valve through the piston and opens the poppet. Then, the pressure oil passes through the inside of the piston, orifice “B”, “A” chamber, ring-shaped restriction “C”, and drilled hole “D” in order, and flows out to the tank circuit around the socket.

Ring-shaped restriction “C”

Drilled hole “D”

Fig. 4-23 3. The pressure in “A” chamber drops because the poppet is open, consequently the pressure oil in the “P” port flows out to the tank circuit through the drilled hole “E”.

Drilled hole “E”

Fig. 4-24 4. When the pressure on the “P” port drops lower than the adjust spring set pressure, the poppet is pushed against the seat by the adjust spring force and the pressure in “A” chamber is equal to the pressure in the “P” port, consequently the pressure regulating valve is also pushed against the seat and returns to the original condition(Fig. 4-22).

24 –I –4–16

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 seat and the socket opens, and the oil flows from the tank passage into the “P” port and the space fills with the oil.

Tank passage

Fig. 4-25 (9) 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 anti cavitation valve opens, and the oil flows from the tank circuit into the “P” port and the space fills with the oil.

Tank passage

Seat Anti cavitation valve

Fig. 4-26

24 –I–4–17

NOTES

5. SLEWING MOTOR 5.1 GENERAL VIEW Dr

SH PG

A AIR BLEED PORT (AU)

Plug assy

SH B

PG G8

AIR BLEED PORT (AU)

A·B MU

HYDRAULIC TIMER

Code A B MU Dr PG SH G7 G8

5.2 SPECIFICATIONS

PF1/2 PF3/8 PF1/4

Gauge port

PF1/4

Table. 5-1

Model cc/rev (in /rev) 3

SK40SR-2

SK45SR-2

SG015E-501

SG015E-502A

27.2 (1.66)

38.4 (10.1) Rated flow L/min (gal/min) Hydraulic 8 (58) Parking brake torque kgf·m (lbf·ft) motor Parking brake releasing pressure kgf/m2 (psi) Cracking 6 (85) Max.50 (710) Parking brake timing Relief valve Set pressure

Size

Port Main port Main port Make up port Drain port Slewing parking brake release port Slewing parking brake pilot port

Applicable model

Displacement

VIEW Z

Rotational direction : Inlet A port : CCW Inlet B port : CW (View from shaft end)

Fig. 5-1

sec

40.3 (10.6)

6 ± 1.5

kgf/m (psi) 165 (2,350) at 38.4 L (10.1 gal) /min 180 (2,560) at 40.3 L (10.6 gal) /min 2

1/16.34

Reduction Reducing ratio Weight

PLUG ASSY

G8 Z

kg (lb)

24 –I–5–1

43 (95)

1/17.01

5.3 CONSTRUCTION (1) Motor Relief valve of A port 34 33 32 h

Make up port

35 36

30 29

Relief valve of B port 16

18 b

20 21

11 A · B port 10

8 g

5 4

4-2 4-3

Mechanical brake release chamber

4-4 4-1

Section A-A

Fig. 5-2 Table. 5-2

Parts name Q'ty No. No. Parts name 11 Brake piston 1 1 Cylinder 12 O-ring 1 2 Inner race 13 O-ring 1 3 Bearing 14 Spring 2 4 Plug assy (2) 15 Teflon ring 4-1 Plug (2) 16 Piston 4-2 Back-up ring (2) 17 Needle bearing 4-3 Cap (2) 18 Disk spring 4-4 O-ring Housing 19 Teflon ring 1 5 20 Bushing 2 6 Shockless relief valve 21 Parallel pin 2 7 Friction plate 22 Balance plate 2 8 Separator plate 23 Snap ring 1 9 O-ring 24 Piston assy 1 10 O-ring Note) Q’ty in ( ) are included within respective assemblies

24 –I–5–2

Parts name Q'ty No. 25 Return plate 1 26 Cam plate 1 27 Spring retainer 2 18 28 Collar 29 Cap 2 30 O-ring 2 31 Make-up check 1 32 Spring 4 33 O-ring 4 34 Cap 4 35 Hydraulic timer 2 36 Socket bolt 1 37 Cover 1 7

Q'ty 1 1 1 1 3 3 2 2 2 2 1 5 1

(2) Reduction gear 50 49

55 57

58 59

A chamber

Drain port

B chamber

41 40 39 38

Fig. 5-3 Table. 5-3

Parts name Q'ty No. No. Parts name 1 38 Shaft 47 Sun gear (Spur gear 4) 1 39 Collar 48 Socket bolt : M12 X 80 1 40 O-ring : 1B P115 49 Sun gear 1 41 Bearing 50 Holder 1 assy 1 42 Gear casing 51 Holder 1 1 43 Oil seal 52 Planetary gear (Spur gear 2) 1 44 Bearing 53 Shaft 1 1 45 Split collar 54 Needle Bearing Ring gear 1 46 55 Thrust plate Note) Q’ty in ( ) are included within respective assemblies

24 –I–5–3

Parts name Q'ty No. 1 56 Holder 2 assy 6 57 Shaft 2 1 58 Holder 2 1 59 Needle bearing (1) 60 Planetary gear (Spur gear 5) (3) 61 Thrust plate 1 (3) 62 Spring pin (3) 63 Pin (3)

Q'ty 1 (4) (1) (4) (4) (4) (4) 2

(3)

Relief valve 64

65 66 67

68 69 70 71 72 73

74 75 76

Fig. 5-4 Table. 5-4 No. 64 65 66 67 68

Parts name Seat Poppet Spring Sleeve Piston

(4)

Hydraulic timer

Parts name Q'ty No. 74 Nut 1 75 O-ring 1 76 Cap 1 1 1

Parts name Q'ty No. 69 Spacer 1 70 O-ring 1 71 O-ring 1 72 Sleeve 1 73 Sleeve 1

Q'ty 1 1 1

PB Port 81 P2

Dr port

PG port 87

SH port 84

Fig. 5-5 Table. 5-5 No. 77 78 79 80

Parts name O-ring Manifold Spring Poppet

Parts name Q'ty No. 81 O-ring 1 82 Cap 1 83 Spool 1 84 Plug 1

24 –I–5–4

Parts name Q'ty No. 85 Stopper 2 86 O-ring 2 87 Spring 1 2

Q'ty 1 2 1

5.4 Construction and working principle (The figures in ( ) in the statement corresponds to the symbols in Construction Drawing in Article 5.3.) (1) Hydraulic motor The rotary group is made up of a drive shaft integral cylinder (1) and seven pistons assemblies (24) housed in cylinder (1). And cylinder (1) is held onto both ends with bushings (3), (17). Piston assy (24) is guided by spring retainer (27) of return plate (25) to slide it on cam plate (26) smoothly. And balance plate (22) is pressed onto the end face of cylinder (1) by the force of disk spring (18) and hydraulic pressure acting on bushing (20). Mechanical braking parts (7) (8) (11) (14) which are used as a parking brake are placed between the periphery of cylinder (1) and housing(5). And, this is equipped with hydraulic timer (35) to hold the braking release pressure for several minutes when the brake release signal of the mechanical brake is switched from ON to OFF. And also housing (5) would contain shockless relief valve (6) for cushioning activity and make-up valve parts (31) (32) (34) to prevent generation of cavitation. (2) Explanation of hydraulic motor operation The hydraulic pressure delivered by pump through the control valve, etc. enters in A port (or B port) provided on housing (5) and is discharged from B port(or A port). And the oil leaked from each sliding section and gaps is returned into the tank through drain port “a” provided on gear case (42). The hydraulic pressure led to A port is led to the piston hole of cylinder (1) through passage “b” in cover (37), passage “c” on bushing (20) provided in cover (37), passage “d” on balance plate (22) housing a crescent port which is used to switch the supply to/from discharge by 180 degrees to a turn of motor and passage “e” on cylinder (1). The hydraulic pressure acts on piston assy (24), and piston assy (24) is pressed onto cam plate (26) with shoe. The shoe sliding surface of cam plate (26) is inclined in a constant angle, therefore the pressing force of piston assy (24) being acted on by the hydraulic pressure is transformed to the force to have the shoe slide on the swash plate. The shoe spheric section of piston assy (24) is linked like an universal joint, so the force of shoe sliding on the cam plate is transmitted to the motor output shaft as a turing effort through piston assy (24) and cylinder assy (1). This way, each piston assy (24) receives the pressure oil within the stroke from the top dead end to the bottom dead end, and transmits the hydraulic pressure to a turning force, makes cylinder assy (1) turn, and discharges the oil within the stroke from the bottom dead end to the top dead end. The discharging route is in the reverse of supply route of pressure oil described above, and discharged from B port. As above mentioned, the hydraulic motor actuates, and the output torque of the hydraulic motor is determined by hydraulic pressure and the speed is determined by the oil supply flow rate.

24 –I–5–5

(3) Construction of reduction unit and explanation of the operation The motive power transmitted by the hydraulic motor output shaft is transmitted to the 2nd stage sun gear (47) through the 1st stage sun gear (49), planetary gear (52) and holder 2 (58). Shaft (28) is held in gear case (42) with two bearings (41) (44). And oil seal (43) is placed at the center of gear to protect taper roller bearing (41) on the output shaft side in the severe load condition from the powder due to the wear of gear, the A chamber side is lubricated by motor and the equivalent hydraulic oil, and the B chamber side is lubricated with grease. (4) Explanation of mechanical brake operation The friction plate (7) is splined to the outer surface of cylinder (1). And the separator plate (8) is splined to housing (5). When the pressure inside of the mechanical brake release chamber is Zero, brake piston (11) pushes separator plate (8) and friction plate (7) with the spring (14) force, resulting in the locking of cylinder (1) (output shaft). Conversely, when the pressure of 26 to 50 kgf/cm2 (370 to 710 psi) acts on the brake release chamber, brake piston (11) resists the spring force, and strokes to the position where it strikes the end face of cover (37), and makes a space between friction plate (7) and separator plate (8), consequently the mechanical brake is released. (5) Explanation of make-up valve 1) In half braking condition (where shockless relief valve (6) is not actuated) After acceleration of the upper structure, the delivery oil flow rate from the pump to A port lowers when reducing the speed in half lever position through the control valve, but if the upper structure is slewing at relatively high speed, the “c” section shows a negative pressure due to the pumping action of motor, requiring the hydraulic oil to be fed. While the pressure at B port is lower than the hydraulic pressure of shockless relief valve (6), the full flow rate of oil to the “c” section through A port is discharged to the control valve through B port, and only the flow rate delivered through the control valve (the oil flow rate delivered by pump is restricted because the valve is placed at the half lever position) is not enough to fulfill the absolutely required oil level of the “c” section. The make-up check valve (31) is therefore required to prevent the shortage of flow rate, and the oil equivalent to the shortage is supplied to the “c” section through the makeup port. 2) When braking (where shockless relief valve (6) is actuated) When it is set to the neutral position by sudden lever operation in the condition of Par.1), the oil supply oil flow rate from the pump to A port lowers to Zero, but the upper structure keeps rotating with inertia force. At this time, shockless relief valve (6) on B side is actuated, the oil discharged by the relief valve flows through passages “g” ”h”, pushes and opens make-up check valve (31) on the A port side and led to passages “b” “c”, but make-up check valve (31) is opened through the make-up port and supply oil to passages “b” ”c”, preventing cavitation.

24 –I–5–6

(6) Explanation of relief valve operation (Relief valve sectional drawing : See Fig. 5-4) 1) When starting The pressure oil fed to A port does not start the upper structure rotating immediately because of a large inertia force, therefore a part of the oil passes through shockless relief valve (6) acting as a safety valve, pushes and opens make-up check valve (31) on the B port side through passages “g” “h”, and flows into the B port. The oil in A port opens poppet (65) resisting the spring (66) force, and flows into passage “h” from passage “g” through seat (64) to poppet (65). 2) When braking (In cushioning action) The return passage of the motor discharged oil is closed by placing the control valve to the neutral position. Immediately after this operation, the motor is rotated by large inertia force causing the pumping action, and tried to suck the oil from A port and discharge to B port, but since the return passage of the control valve is closed, consequently the pressure in B port increases. The increased pressure in B port pushes and opens poppet (65) resisting the spring (66) force, and opens make-up check valve (31) through passages “g” “h” from B port and flows into the passage “c”. In this process, the inertia energy of the upper structure is absorbed, and consequently it stops rotating. And, in the above pressure-up process, the high pressure oil entered in the front chamber of poppet (65) passes through the outer orifice of poppet (65), the outer orifice of piston (68) and the perforated small passage at the center of piston (68), and enters in the piston chamber, and then moves it to the position where it strokes to the end face of sleeve (73). Then, since poppet (65) is already open, the cushion release function is acted by low pressure first, and the pressure is raised to the specified pressure in several seconds. This smooth pressure rise reduces the shock generated when the motor is rotating or stopping. (7) Explanation of hydraulic timer operation (Hydraulic timer sectional drawing : See Fig. 5-5) The PG port always maintains a pressure higher than the mechanical brake release pressure. 1) When the mechanical brake is actuated and the output shaft is locked When the pressure is not applied to the SH port, spool (83) is pressed to the right end by the spring (87) force, and consequently the oil flow from PG port to PB port is cut off. 2) When mechanical brake is released When the signal pressure is applied to SH port, spool (83) moves leftward and PG port and PB port open, consequently the oil flows into the brake release chamber. 3) When the time delay function is ON If the supply of pressure oil to SH port is cut off in the condition shown in Par.2 ), spool (83) is pressed to the right end by the spring (87) force, consequently PG port and PB port are cut off. The pressure oil in PG port flows to the Dr port, then if the pressure difference (P1-P2) between the front chamber pressure P1 of orifice “m” and spring chamber pressure P2 becomes larger than spring (79) fitting force (F) /poppet (80) area (A), poppet (80) moves leftward, the groove shoulder blocks the passage “n” and cuts off the oil flow to the front chamber of the orifice “m”. Consequently, the spring chamber pressure P2 becomes equal to the pressure P1, and the spring (79) force moves poppet (80) rightward, consequently the oil flows out from the passage “n” to the perforation “o” again. This way, the inflow rate to Dr port is controlled by the flow control valve and the time it takes until brake piston (11) reaches the condition shown in Par.1 ) is set.

24 –I–5–7

NOTES

6. TRAVEL MOTOR 6.1 GENERAL VIEW

Fill port PF3/8 Check / Level port PF3/8

D1 A P Z B D2

Gauge port G5 Drain port PF3/8

Gauge port View Z

Fig. 6-1 6.2 HYDRAULC CIRCUIT (High speed side)

(Low speed side)

Port name & size D2 G6

D1 G5

Table. 6-2 Code A B D1 D2 G5 G6 P

A B Fig. 6-2

Port Hydraulic oil fill / drain port

˝ Drain port ˝ Pressure gauge port ˝ 1st / 2nd speed select port

Size PF1/2 PF1/4 PT1/8 PF1/8

Rotational direction (Viewed from “Z”end of reduction unit) Inlet A port,outlet B port CW Inlet B port,outlet A port CCW

24 –I–6–1

6.3 SPECIFICATIONS Table. 6-2 SK40SR-2

SK45SR-2

GM06VN-C-15/27-5

GM06VN-B-15/27-5

52.5

64.0

441 (3,190) / 242 (1,750)

538 (3,890) / 295 (2,130)

29.4 / 51.2

30.3 / 52.8

Machine model Type Reduction ratio Reduction Output torque 1st/2nd unit Revolution speed 1st/2nd Displacement 1st/2nd Working pressure Hydraulic Revolution speed 1st/2nd motor Switching pressure 1st/2nd

kgf·m (lbf·ft) rpm cc/rev

(in3/rev)

26.7 (1.63) / 15.0 (0.92)

kgf/cm2 (psi) rpm

230 (3270) 1938/3379 at 52.8 L (13.9 gal)

kgf/cm2 (psi)

35 (500)

Auto-switch pressure 1st / 2nd

kgf/cm2 (psi)

35 (500) / 185 (2630)

Drain pressure

kgf/cm2 (psi) Normal 2 (28), Max.7 (100)

Parking brake

Braking torque

kgf·m (lbf·ft)

6.6 (48)

Brake release pressure

kgf/cm2 (psi)

9.1 (129)

Lubricant

GL-4 #90

L (gal)

1.0 (0.26)

Weight

kg (lb)

56 (123)

24 –I–6–2

6.4 CONSTRUCTION (1) Composition

Reduction unit

Hydraulic motor Brake valve Parking brake Auto-2speed select mechanism

Control valve

Hydraulic pump

Fig. 6-3

24 –I–6–3

(2) Sectional view

A 35

Section F-F

F 35

Section E-E

18 29 12 E

36 34 20 22 9 25 7 24 6 102 8 19 33 36

221

236

228

227

225

230

254

237

223

226

275

Section B-B

1 190 161 162 103

17 132 149 177 167

106 105 31 2 169 115 116 151 110

108 107 104 135 139 112 243 B

266 150

224

23 4

109

273

C 263 275 264221273 201 114 145 233 299 219 220 218 222

27 275 30 113 241

Section A-O-A Fig. 6-4

24 –I–6–4

252 280 268

Section C-C

(3) Parts list Table. 6-3 No. 1

2 3 19 35 4 9 12 22 23 6 7 8 17 18 20 21 24 25 27 29 30 31 33 34 42

105 106 161 162 102 103 104 107 108 109 110 112 113 114 115

Parts name Hub Spindle kit • Spindle assy • •Spindle • •Hold flange • Reamer bolt •Capscrew RV gear assy • RV gear • Crank shaft • Spacer • Bearing (Taper roller) • Bearing (Needle) Input gear Spur gear • Spur gear Cover Pin Ring Snap ring Bearing (Ball) Snap ring Snap ring O-ring (1B P8) O-ring (1B G200) O-ring Floating seal kit • Floating seal Plug (PF 3/8) Plug (PF 3/8) Parallel pin Piston kit • Piston assy • • Piston • • Shoe • Piston assy • • Piston • • Shoe Shaft Swash plate Cylinder block Retainer plate Thrust ball Timing plate Washer Piston Spring Spring Friction plate

Q'ty 1 1 1 1 1 2 2 1 2 2 4 4 4 1 1 2 1 28 1 2 2 1 4 2 1 1 1 2 1 2 2 1 7 1 1 1 1 1 1 1 1 1 1 1 2 1 8 1 2

No. 116 132 135 139 145 149 150 151 167 169 177 190

201 223 263 264 218 219 220 221 222 224 225 226 227 228 230 233 236 237 241 243 252 254 266 268 273 275 280 299

24 –I–6–5

Parts name Separator plate Oil seal O-ring O-ring Snap ring Ball bearing Ball bearing Roller Pivot Plate Parallel pin Spring Rear flange assy • Rear flange kit • • Rear Flange • • Spool • Spool kit • • Spool • • Oil stopper • Valve seat • Valve • Spring • Plug (PF 1/4) • Ring • Plug • Stopper • Plug • Valve • Spring • Spring • O-ring (1B P7) • O-ring (1B P22) • O-ring (1B P12) • Parallel pin • Socket bolt (M8 X 20) • Socket plug (PT1/8) • Socket plug • Spring • Steel ball • O-ring (1B P11) • Orifice • Plug • Name plate

Q'ty 2 1 1 1 1 1 1 3 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 2 2 2 2 1 2 2 2 6 3 6 1 1 2 6 1 1

(4) Exploded view 1) Reduction unit

Fig. 6-5 2) Motor

Fig. 6-6

24 –I–6–6

6.5 FUNCTIONAL EXPLANATION (1) Reduction gear 1) Function The reduction gear consists of a spur gear device (hereunder called 1st reduction gear) and a differential gear device (hereunder called 2nd reduction gear) that employs a peri-cycloid gear tooth profile. The reduction gear reduces the high speed rotation from the hydraulic motor and converts it to low-speed high torque rotation of hub (1). 2) Functional explanation 2-1 : 1st reduction gear (1) The rotary motion of the hydraulic motor is trans-

SPUR GEAR (7)

CRANK SHAFT (9)

mitted to shaft (102). Rotation of shaft (102) is transmitted to input gear (6) that is linked to shaft. The input gear (6) meshes with two spur gears (7). The speed of spur gears (7) are reduced and rotate in the opposite direction.

SHAFT (102)

INPUT GEAR (6)

The reduction ratio [ i1 ] is as below : i1 = -

Zi Zs

Fig. 6-7

i1 = Reduction ratio of 1st reduction gear Zi = No.of teeth of input gear Zs = No.of teeth of spur gear

2-2 : 2nd reduction gear (1) Spur gears (7) (2 pieces) are connected to respective crankshafts (9). If spur gear (7) rotates, crankshaft (9) rotates in the same direction and at the same revolution. This causes the eccentric bodies A and B of crankshaft (9) to make eccentric motion. (revolution). The eccentric motion (revolution) is transmitted to RV gears A (4) and (B) (4) via needle roller bearing (23). RV gear A (4) and B (4) make eccentric motion in the same direction and at the same revolution as the spur gears and the crankshafts.

NEEDLE BEARING (23)

SPUR GEAR (7) ROTATION

ECCENTRIC BODIES CRANK SHAFT (9) ROTATION

ECCENTRIC MOTION

RV GEAR (4)

Fig. 6-8

24 –I–6–7

(2) The tooth face of RV gears (4) mesh constantly with pins (17) (pin number Zp). If RV gears make eccentric motion, the meshing point moves in sequence as the gears turn. In a single eccentric motion, pins (17) rotate with hub (1) by the difference between the number of teeth Zr of RV gears and the number of pins Zp i.e. the number of pins. The reduction of the 2nd reduction gear is as below : i2 =

HUB (1) PIN (17)

RV GEAR (4)

(Zp-Zr) Zp

CRANKSHAFT ECCENTRIC BODY

i2 = Reduction ratio of 2nd reduction gear Zr = No.of teeth of RV gear Zp = No.of pin

At half rotation (180°)

2-3 :Entire reduction gear The motion of the entire reduction gear equals the product that is made by multiplying the 1st reduction gear with the 2nd reduction gear. Therefore, if the hydraulic motor shaft makes one turn, the total revolution (reduction ratio i) of the reduction gear is as follows : i = i1 X i2 i=-

Zi · (Zp-Zr) Zs · Zp

i1 = Reduction ratio of 1st reduction gear i2 = Reduction ratio of 2nd reduction gear

24 –I–6–8

Fig. 6-9

At one rotation

(2) Hydraulic drive This article describes the hydraulic motor, the brake valve and parking brake driven by hydraulic pressure and the low-high 2-step select mechanism of the hydraulic motor. 1) Functions 1. Hydraulic motor The hydraulic motor is of swash-plate axial piston type and converts the force of the pressurized oil to rotary motion. 2. Brake valve (1) The brake valve controls inertia force to stop the hydraulic motor smoothly. (2) The brake valve prevents the hydraulic motor from over running by external force acting on the hydraulic motor i.e. prevents hydraulic cavitation. (3) The brake valve prevents abnormally high pressure surges that are generated as the hydarulic motor is stopped jerkily. 3. Praking brake The parking brake prevents the hydraulic motor at rest from being turned by external force. The brake is of friction plate type that is assembled integral with the hydraulic motor. 4. Low-high 2-step select mechanism The mechanism changes the hydraulic motor output in two steps : high-speed low-torque and lowspeed high-torque. 2) Functional Explanation 1. Hydraulic motor The pressurized oil supplied by the hydraulic pumps enters the rear flange (201) of the hydraulic motor. The pressurized oil passes through the brake valve and the timing plate (109) and is admitted into the cylinder block (104). The pressurized oil is admitted only to the one side of the line (Y1-Y2) that connects the top dead point with the bottom dead point of the piston (105) stroke. The pressurized oil pushes each piston (105) and generates force (F= P X A). This force acts upon the tilted surface of swash plate (103) . The force F is divided into components F2, F3, depending upon the angle of the tilted surface. Out of them the radial component F3 generates torque (T= F3 X ri) . The total force of torque of the piston (105) (T= Ý (F3 X ri ) equals the rotary force of the hydraulic motor.

24 –I–6–9

201 104

109

105

103

102

F3 F3 ri

F3 F3

F1 °

Fig. 6-10

This rotary force causes the cylinder block (104) and the shaft (102) to rotate via the pistons (105)

2-2 Brake valve Port (A) and (B) are the oil inlet and the outlet. The following is an explanation in which hydraulic oil (pressurized oil ) is supplied to port (A). When hydraulic oil is supplied to port (B), the direction of flow and motion are reversed. The rotating direction of the hydraulic motor is reversed as well. (1) If pressurized oil is supplied to port (A) by the pumps, the hydraulic motor turns. Below is a detailed explanation. If the pressurized oil is supplied by the pumps, the oil enters port (A) and opens the valve (227). The oil then passes through valve (227), enters the hydraulic motor via port (C) and gives rotating force to the hydraulic motor. In the meantime, the oil enters port (A), passes through the orifice of spool (223) and the pas-

225 223

228

227

sage a and enters chamber b . Spool (223) moves to the left from its neutral position by the hydraulic force of chamber b . In that case, a hydraulic oil passage is formed between ports (D) and (B) by the groove provided on the spool (223). The hydraulic oil discharged by the hydraulic motor flows from port (D) to port (B). Thus the hydraulic motor rotates, and the hydraulic oil returns to the oil tank. In the meantime, if spool (223) moves to the left, the pressurized oil enters port (E) and the oil flows into the parking brake and the 2-speed select valve.

24 â&#x20AC;&#x201C;I â&#x20AC;&#x201C;6â&#x20AC;&#x201C;10

A Fig. 6-11

(2) When stopping (Braking function) When the pressure oil supplied from port (A) is stopped when running, the hydraulic pressure pushing the spool disappears, spool (223) moved to the left side tries to return to the neutral position through stopper (225) with the spring (228) force. Then, the oil in the chamber b flows through passage a in the spool and tries to flow out into (A) port side, but the back pressure is produced by the effort of the restriction of passage a , and the spool return speed is controlled. At the same time, the hydraulic motor is rotated by inertia force even if the pressure oil is stopped, so the return oil of the hydraulic motor flows through the space (passage) between the spool groove and the rear flange from port (D) and returns to port (B) side. After the spool returns to the neutral position completely, the passage on the hydraulic motor return side is cut off by the spool and consequently the hydraulic motor stops rotating. During operation, this brake valve controls the sliding speed of the spool and restricts the passage on the hydraulic motor return side with the groove of the spool, consequently the hydraulic motor which is forcibly rotating with inertia force is stopped smoothly by producing back pressure. On the other hand, when the hydraulic motor is braked and stops rotating, it keeps rotating causing the pumping action with inertia force even if the pressure oil stops feeding, and consequently it tries to suck the oil. However, the passage on the suction side can not make up the oil because the passage is cut off by the spool, preventing the generation of cavitation. Then, valve (227) is actuated by slight negative pressure, and the oil passage between the circuit on port (A) side and port (C) on the motor suction section is opened and cavitation of the hydraulic motor is prevented. And, when the pressure oil is supplied from port (B), the right and left movements of respective port mentioned above are symmetrical, and the hydraulic motor stops rotating.

24 â&#x20AC;&#x201C;Iâ&#x20AC;&#x201C;6â&#x20AC;&#x201C;11

225 223

228

227

A Fig. 6-12

(3) When self-travelling It is called “Overrun” when the oil consumption of the hydraulic motor is larger than the hydraulic pump delivery oil quantity because the travel speed increased due to a steep slope when the excavator is running. When running by itself, the hydraulic power disappears similarly to that when the machine is stopping, so the brake valve actuates similarly to that when the machine is stopping, and the passage on the return side of the hydraulic motor is restricted, and the rotating speed of the hydraulic motor forcibly rotating with inertia force is reduced by generating back pressure, and is controlled to the hydraulic motor speed corresponding to the oil quantity delivered by pump.

225 223

228

227

A Fig. 6-13

24 –I –6–12

2-3 Parking brake (1) Machine is running : If the pressure from the pump is supplied to port (A) or (B), the spool (223) of the brake valve moves to the right or the left. Port (E) opens, and the pressure is led from port (E) to cylinder cham-

112 104 116 115 169

ber a . When the pressure reaches 9.1 kgf/cm2 (130 psi) or over, the spring force (113). The piston (112) moves toward rear flange (201). If the piston (112) loses its pressing force against separator plate (116) and plate (169), the friction plate (115) is let free. The friction plate (115) is engaged with cylinder block (104) of the hydraulic motor. The result is that cylinder block (104) is freed from the braking force. The hydraulic motor is freed to run.

E 113

Fig. 6-14

(2) Machine is not running : If the pressure to port (A) or (B) is suspended, the spool (223) of the brake valve moves to neutral. Port (E) is shut off, and the pressure in cylinder

112 104 116 115 169

chamber a falls. When the pressure falls below 9.1 kgf/cm2 (130 psi), the hydraulic force of piston (112) decreases below the force of spring (113). Then the action of spring (113) causes the piston (112) to be pressed against the separator plate (116), plate (169) and the friction plate (115). This pressing force creates frictional force that acts braking torque 6.6 kgf·m (48 lbf·ft). The friction plate (115) meshes with the cylinder block (104) of the hydraulic motor. The cylinder block (104) meshes with shaft (102) of the hydraulic motor. In this way, the hydraulic motor undergoes braking torque while the machine is at parking.

113

Fig. 6-15

24 –I–6–13

2-4 Explanation of auto 2-speed change mechanism (1) At low speed When the pilot pressure is not supplied from port (D), valve (263) is pushed up by the spring (266) force and the pressure oil delivered through ports (A) and (B), and the pressure oil from port (C) is cut off, consequently the oil in (P) chamber is flown out into the drain(motor area) through valve (263). Consequently, swash plate (103) inclines to the max. tilting angle 1, and the cylinder displacement of the hydraulic motor becomes the max. volume, resulting in the low speed.

Fig. 6-16

24 –I –6–14

(2) At high speed When the pilot pressure 30 kgf/cm2 (430 psi) is applied through port (D), the pressure resists the spring (266) force and the oil pressure from ports (A) and (B), consequently valve (263) is pushed down, the pressure oil in port (C) is led to (P) chamber through valve (263), piston is pushed up and held to the position where swash plate (103) reached the X surface. Consequently swash plate (103) inclines to the min. tilting angle 2, and the cylinder displacement of the hydraulic motor becomes the maximum volume, resulting in the high speed.

Fig. 6-17

24 â&#x20AC;&#x201C;Iâ&#x20AC;&#x201C;6â&#x20AC;&#x201C;15

(3) Explanation of auto change to the low speed when running at high speed It the load is raised while running at high speed, the pressure oil in ports (A) and (B) also increases. When the pressure reaches 185 kgf/cm2 (2630 psi), the oil in (P) chamber is discharged in the drain (motor case) through valve (263). Then, swash plate (103) strikes the Y surface of the spindle, inclines and is held to the max. angle 1, resulting in the low speed.

Fig. 6-18

24 –I –6–16

7. SWIVEL JOINT 7.1 GENERAL VIEW

G (P)

(F) D C (E) F

P D

E C A G

Fig. 7-1 General view

7.2 SPECIFICATIONS Table 7-1

Working Pressure

High Low High

Rated flow Low

Port size Revolution

Parts No.

24100J12703F1

A, B, C, D, E, F

210 kgf/cm2 (2990 psi)

P G A, B, C, D E, F P G A, B, C, D E, F, G P

L/min (gal/min) L/min (gal/min)

min-1 (rpm)

Height

mm (in)

Weight

kg (lb)

24 –I–7–1

35 kgf/cm2 (500 psi) 5 kgf/cm2 (70 psi) 70 (18) 40 (11) 10 (2.6) 5 (1.3) PF1/2 PF3/8 PF1/4 15 290 (11.4) 22 (49)

7.3 CONSTRUCTION F

B D

Tightening torque : kgf·m (lbf·ft) P G

P 5 E

A C 14

1 11 10 8 6

16 P

E D

D C

C B

12 15 7,17 13 4

T=4.75 (34.4)

Fig. 7-2 Construction

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

Table.7-2 No. 1 2 3 4 5 6 7 8 9

Parts name Stem Body Flange Spacer Pin Slipper seal Name Plate O-ring (1A P80) O-ring (1A G95)

24 –I–7–2

Q'ty 1 1 1 1 1 7 1 1 1

No. 10 11 12 13 14 15 16 17

Parts name Dust seal Dust seal Snap ring Capscrew (M10 X 30) Socket plug Lock washer Back-up ring Clevis

Q'ty 1 1 1 4 3 4 1 2

8. CYLINDER 8.1 SPECIFICATIONS (1) General view

Fig. 8-1 General view

Table. 8-1

SK40SR-2

Cylinder

Cylinder Bore/Rod Dia

Boom Arm Bucket Swing Dozer

ø90 / ø50 (ø3.54 / ø1.97) ø80 / ø50 (ø3.15 / ø1.97) ø75 / ø40 (ø1.97 / ø1.57) ø90 / ø50 (ø3.54 / ø1.97) ø95 / ø55 (ø3.74 / ø2.17)

Stroke

Unit : mm(ft-in) Center distance of pins Full extend B / Full retract A

Boom Arm Bucket * * Swing Dozer

Dry weight kg (lb)

696 (2´3.4˝) 1727 (5´8.0˝) / 1031 (3´4.6˝) Rod side 49.0 (108) 717 (2´4.2˝) 1825 (5´11.9˝) / 1108 (3´7.6˝) 41.0 (90) None 546 (1´9.5˝) 1378 (4´6.3˝) / 832 (2´8.8˝) 26.0 (57) None 587 (1´11.1˝) 1548 (5´0.9˝) / 961 (3´1.8˝) Both sides 48.0 (106) 26.0 (57) None 180 (7.09˝) 660 (2´2.0˝) / 480 (1´6.9˝)

SK45SR-2

Cylinder

Cushion

Unit : mm(ft-in) Cylinder Bore/Rod Dia ø100 / ø55 (ø3.93 / ø2.17) ø90 / ø50 (ø3.54 / ø1.97) ø75 / ø40 (ø1.97 / ø1.57) ø90 / ø50 (ø3.54 / ø1.97) ø95 / ø55 (ø3.74 / ø2.17)

Stroke

Center distance of pins Full extend B / Full retract A

Cushion

Dry weight kg (lb)

684 (2´2.9˝) 1742 (5´8.6˝) / 1058 (3´0.9˝) Rod side 58.0 (128) None 46.0 (101) 720 (2´4.3˝) 1840 (6´0.4˝) / 1120 (3´8.1˝) None 26.0 (57) 546 (1´9.5˝) 1378 (4´6.3˝) / 832 (2´8.8˝) 587 (1´11.1˝) 1548 (5´0.9˝) / 961 (3´1.8˝) Both sides 48.0 (106) None 27.0 (60) 175 (6.89˝) 715(2´4.2˝) / 540 (1´9.3˝) Note) Cylinders marked * are same cylinder as SK40SR-2.

24 –I–8–1

8.2 CONSTRUCTION AND FUNCTION 8.2.1 Construction (1) Boom cylinder SK40SR-2

SK45SR-2

25 24

7,8 7,13 12 11 32

15 17 16

25 24

18,19

10 6

Fig. 8-2 Construction

No. 1 2 3 4 5 6 7 8 9

Parts name Cylinder tube Piston rod Cylinder head Bushing U-ring Wiper ring O-ring Back-up ring O-ring

Parts name Q'ty No. 1 10 Holder 1 11 Cushion seal 12 Collar 1 1 13 Back-up ring 14 Cushion bearing 1 1 15 Piston 2 16 Seal ring assy 1 17 Slide ring 1 18 Setscrew

24 –I–8–2

Parts name Q'ty No. 19 Steel ball 1 1 24 Pin bushing 1 25 Wiper ring 1 27 Grease nipple 1 32 Spacer 1 1 2 1

Q'ty 1 2 4 2 1

(2) Arm & Bucket cylinder SK40SR-2

SK45SR-2

26 25 27

25 24

7,8

18,19

Fig. 8-3 Construction (This shows bucket cylinder.)

No. 1 2 3 4 5 6

Parts name Cylinder tube Piston rod Cylinder head Bushing U-ring Wiper ring

Q'ty No. Parts name 1 7 O-ring 1 8 Back-up ring 1 9 O-ring 1 15 Piston 1 16 Seal ring assy 1 17 Slide ring

24 –I–8–3

Q'ty No. Parts name 1 18 Setscrew 1 19 Steel ball 1 24 Pin bushing 1 25 Wiper ring 1 26 Pin bushing 2 27 Grease nipple

Q'ty 1 1 1 4 1 2

(3) Swing cylinder SK40SR-2

24 25

SK45SR-2

25 24

7,8 10 7,13 12

18,19

22 21

20 6

Fig. 8-4 Construction

No. 1 2 3 4 5 6 7 8 9

Parts name Cylinder tube Piston rod Cylinder head Bushing U-ring Wiper ring O-ring Back-up ring O-ring

Q'ty No. Parts name 1 10 Holder 1 11 Cushion seal 1 12 Collar 13 Back-up ring 1 1 14 Cushion bearing 15 Piston 1 2 16 Seal ring assy 2 17 Slide ring 1 18 Setscew

24 –I–8–4

Q'ty No. 1 1 1 1 1 1 1 2 1

19 20 21 22 23 24 25 27 32

Parts name Steel ball Cushion bearing Cushion seal Snap ring Stopper Pin bushing Wiper ring Grease nipple Stopper

Q'ty 1 1 1 1 2 2 4 1 1

(4) Dozer cylinder SK40SR-2

SK45SR-2

24 25

25 24

7,8

2 1

17 16 18,19

Fig. 8-5 Construction

No. 1 2 3 4 5 6

Parts name Cylinder tube Piston rod Cylinder head Bushing U-ring Wiper ring

Q'ty No. Parts name 1 7 O-ring 1 8 Back-up ring 1 9 O-ring 1 15 Piston 1 16 Seal ring assy 1 17 Slide ring

24 –I–8–5

Q'ty No. Parts name 1 18 Setscrew 1 19 Steel ball 1 24 Pin bushing 1 25 Wiper ring 1 27 Grease nipple 2 28 Grease nipple

Q'ty 1 1 2 4 1 1

8.2.2 Functions (Example of swing cylinder) Back-up ring O-ring

Back-up 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. 8-6 Cylinder head assy (1) Basic function This is a kind of hydraulic actuator, which works so that the energy of the hydraulic pressure delivered by the hydraulic pump is transformed into a large force of rectilinear motion by way of the piston, and the operating direction is changed in the extending and retracting direction by operating the valve lever for the pressure oil flowing direction change. These large force and rectilinear motion, and operating direction change are basic functions. (2) Functions of other sections The following are described with the swing cylinders. 1) Cylinder head assembly The cylinder head assembly plays a role as a bearing in piston rod (2) by press-fitting bushing(4) in the bore of the cylinder head (3). U-ring (5) is inserted in the bore of cylinder head to prevent the oil leakage to the outside. And wiper ring (6) is press-fitted in the bore of cylinder head to protect it from dust entry. The high pressure is produced in the cushion bearing at the position where the rod is almost extended to reduce the shock of the cylinder head. And it has a function to feed and discharge the high pressure oil from the cylinder tube to the port.

• Bushing (4) The bushing (4) is press-fitted in the bore of the cylinder head (3) and is in contact with the piston rod. And it shares the lateral load to the cylinder with the slide ring around the piston, moves linearly in high bearing stress to the piston rod, and reduces eccentricity which has a bad effect on the sealing capacity holding an end of the piston rod.

• Wiper ring (6) The wiper ring is fitted on the mouth where the rod cylinder telescopes from cylinder. The rod seal of U-ring (5) in the cylinder prevents the entry of dust and water and removes mud adhered on the piston rod by the movement of the piston rod.

24 –I–8–6

Cushion seal Snapring Cushion bearing (20) Ball

Slide ring (17) Piston (15)

Seal ring (16) Setscrew

Cushion bearing (14)

Stopper Cylinder Bottom

Cushion stroke Retracting side

Cushion stroke Extending side Fig. 8-7 Piston assy 2) Piston assembly The piston assembly is prevented from the pressure oil leakage to other sections from the right or left piston chamber by inserting seal ring (16) in the center of piston (15), and plays the function as a bearing for the lateral load to the cylinder. The high pressure is produced in the cushion room at the position where the rod is almost retracted to reduce the shock of the cylinder piston. And also, slide ring (17) is used to remove the contamination.

• Cushion bearing (14)

• Seal ring (16)

The cushion bearing is placed between the piston and the piston rod step section, forms annular space with the cylinder head close to the most extended rod position, restricts the oil to reduce the cylinder impact speed at the most extended position, and consequently absorbs the shock.

The seal ring is fitted at the center of the piston, seals annular space between the piston and the cylinder tube with the aid of tightness of the Oring, and forms chambers on the high and low pressure sides, bordering on the piston.

• Slide ring (17) The seal ring is fitted on both sides of the seal ring and is in contact with the inner surface of the tube. And it shares the lateral load to the cylinder with the bushing located on the bore of the cylinder head, moves linearly in high surface pressure to the inner surface of the cylinder tube, and reduces the eccentricity which has a bad effect on the sealing capacity, holding an end of the piston rod.

• Cushion bearing (20)

24 –I–8–7

The cushion bearing is placed on tip of the piston rod, forms annular space with the cylinder bottom close to the most retracted rod position, restricts the oil to reduce the cylinder impact speed at the most retracted position, and consequently absorbs the shock.

NOTES

Part Il : ELECTRICAL EQUIPMENT Applicable machines SK40SR-2 : PH03-02001~ SK45SR-2 : PJ02-00101~

2.1a ELECTRICAL EQUIPMENT LIST

Electrical Fittings

E-7 E-8 E-10 E-12 E-13 E-14 E-15 E-20

Light

L-2 L-3 L-4

M-1

STARTER MOTOR

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

Relay

YN02D01001P1

Cab accessory (2456U114) BOOM WORKING LIGHT (LH) 2456R243F2 CAB WORKING LIGHT (OPT) PY80S00002F1 CAB WORKING LIGHT (OPT)

L-1

Motor

YN02DO1001P1 2475U38

Group Code R-1 R-2 R-3 R-6 R-7 R-8 R-9 R-14 R-22 R-23

Sensor

E-3 E-4 E-6

Part No. 2475U38

Solenoid

E-1 E-2

Part Name DIODE DIODE DIODE DIODE DIODE DIODE DIODE

SV-1 SV-2 SV-3

SV-5

SW-1 SW-2 SW-3 SW-4 SW-5 SW-6

SW-7 SW-8 SW-9 SW-10 SW-11 SW-12 SW-17 SW-23 SW-24 SW-25 SW-26 SW-27

Note) This is for reference only, because the part No. might be change due to improvement. The part Nos. in [ ] are for the earlier ones before the improvement / change.

• •

24 – II – 1 – 1

Part No. PH24S00001P1 PH24S00002P1 PM24S00001P1 PH25S00002P1 PH24S00001P1 PA24E01001P1

PH52S00002P1 FUEL SENSOR ENGINE THERMO SENSOR PA24S00003P1

ROOM LAMP

E/G accessory (129400-77012) Cab accessory WIPER MOTOR (YJ76S00001P1) 2427R1350 WASHER MOTOR DECELERATION MOTOR [PM20S00001F3] PM20S00004F3 PM22P00001P1 FUEL PUMP (OPT) (AUTO AIR BLEED)

SE-1 SE-2

SV-8 SV-12

Switch

Diode

Group Code D-1 D-2 D-3 D-5 D-7 D-12 D-13

SW-28 SW-30 SW-31

Applicable machines SK40SR-2 : PH04-02801~ SK45SR-2 : PJ03-01001~

2.1b ELECTRICAL EQUIPMENT LIST

E-10

RADIO (OPT)

E-12 E-13 E-14 E-15

PM73E00004F6 E/G accessory (119836-77201) PH53S00001P1 PH73S0001P1 PM59S00002F2 PV59S00001F2 PF81S01001P1 E/G accessory (129100-77500) Cab accessory (PY54S00001P1) PM21M00005F1 PH72S00005P1 PA24S00002P3 PH73E00004F1

E-20

HEATER (OPT) BATTERY SEQUENCE BOX FUSE BOX (OPT) (FOR COOLER) TRAVEL ALARM [OCE] PM53S00001F2

L-1

ROOM LAMP

Light

Electrical Fittings

E-3 E-4 E-6

L-2

Cab accessory (2456U114) BOOM WORKING LIGHT (LH) PM80S00005F1

Sensor

E-7 E-8

FUSE BOX GENERATOR (ALTERNATOR) HORN FUSIBLE LINK GAUGE CLUSTER KCME,OCE KCMA POWER SOCKET [KCME] AIR HEATER

E-1 E-2

YN02D01001P1

Group Code SE-1 SE-2

Solenoid

Part No. YN02DO1001P1

Diode

Part Name DIODE DIODE DIODE DIODE DIODE DIODE (KCMA only) DIODE

SV-1 SV-2 SV-3 SV-5 SV-8 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

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

SW-17 SW-23 SW-24 SW-25 SW-26

M-1

Relay

Motor

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

R-1 R-2 R-3 R-6 R-7 R-8 R-9 R-14 R-22 R-23

E/G accessory (129400-77012) Cab accessory WIPER MOTOR (PM76S00001F1) PE54C00002S002 WASHER MOTOR DECELERATION MOTOR PH20S00004F1 PM22P00001P1 FUEL PUMP (OPT) (AUTO AIR BLEED) STARTER MOTOR

SW-27 SW-28 SW-30 SW-31

Part No. Part Name FUEL SENSOR PH52S00002P1 ENGINE THERMO SENSOR PA24S00003P1

PH35V00001F2 LEVER LOCK SOL. 2 SPEED SELECT SOL. E/G accessory E/G STOP SOL. (119233-77931) YJ35V00004F1 POWER SHIFT SOL. (Cooler Spec) YJ35V00004F1 TILT ANGLE SOL. PE35V00001F1 SLEW / SWING SELECT SOL. [KCMA] PH50S00007S001 KEY SWITCH WORKING LIGHT SW. PV24E01001P1 2 SPEED SELECT SW. YN03M01286S002 WIPER WASHER SW. PY50S00004P1 E/G COOLANT TEMP.SW. PM50S00006P1 E/G OIL PRESSURE SW. E/G accessory (114250-39450) HORN SW. KCME,OCE YN50E01001P1 KCMA LF03M01005F1 LEVER LOCK SW. (LH) PA50S00001P1 PY50S00003P1 HEATER SW. (OPT) DECELERATION SW. PM50S00005P1 KCME,OCE 2446U336S8 AIR FILTER CLOGGING SW. KCMA YR11P00008S005 TILT ANGLE SELECT SW. PW03M01225F1 TRAVEL ALARM SELECT SW. 2479U1190F16 GB50S00049F1 TRAVEL RIGHT (FORWARD) PRESS.SW. TRAVEL RIGHT (REVERSE) PRESS.SW. TRAVEL LEFT (FORWARD) PRESS.SW. TRAVEL LEFT (REVERSE) PRESS.SW. LF03M01005F3 SLEW / SWING SELECT SW. [KCMA] GB50S00049F1 SLEW/SWING LEVER PRESSURE SW. (LH) [KCMA] SLEW/SWING LEVER PRESSURE SW. (RH) [KCMA]

PH24S00001P1 PH24S00002P1 PM24S00001P1 PH25S00002P1 PH24S00001P1 PA24E01001P1 PA24E01001P1

PM24S00001P1 PA24E01001P1

Note) This is for reference only, because the part No. might be change due to improvement.

•

24 –II–1–2

2.2 SPECIFICATIONS OF ELECTRICAL EQUIPMENT Code No. Parts Name Parts No. Use Applicable Machine D-1‚2‚3‚7‚12

Specifications

PM210-02031

Model

1.1A or less

Rated current Diode

Description

800V or more

Breakdown

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

PM05-05001~, PV08-20001~ PW08-20001~,PX09-08001~ PH03-02001~,PJ02-00101~

A : D-5,13 B : D-1,2,3,4,12,13,14 Max rated

Current

Breakdown

400V J4

Diode

7321-9822-30

Type

YN02D01001P1 Travel 1‚ 2speed Maker

Housing

Terminal

2poles

YAZAKI SUMITOMO

7123-7729-40 6098-0017

7116-1181P

4poles

YAZAKI

7123-7144

7116-1181P

24 – II – 2 – 1

3Y15

Mating connector

PM05-05001~ PV08-20001~ PB02-00101~ PH03-02001~ PJ02-00101~ PH04-02801~ PJ03-01001~

Code No. Parts Name Parts No. Use Applicable Machine E-1 Fuse box

Specifications

Spare fuse

10A‚ 30A‚ one each

2YG

2RB

119836-77201

20PAM SUMITOMO Connector Housing : 6950-0982 Terminal : 1500-0166 8230-4282

10A

30A

Generator (Alternator)

CN1

10A

5E 2W

Circuit protection

E-2

1A 8A WY

30A

10A

Pin arrangement

PM73E00004F3 PM73E00004F6

PW08-20001~ PX09-08001~ PH03-02001~ PJ02-00101~ PH04-02801~ PJ03-01001~

Description

30A

10A 10A

Wiper Tuner Relay Solenoid Working light Deceleration motor Horn Dome light Timer Relay Gauge cluster Battery relay

Note) “PM73E00004F3” has the harness YANMAR Part No.

119836-77201

Voltage

L terminal

12V

Rated rpm

5.000 r.p.m

Output curret

40A (13.5V)

Weight

IC terminal

M5 BAT terminal

Rotating direction

3.5Kg

Generator PW08-20001~ PX09-08001~ PH03-02001~ PJ02-00101~ PH04-02801~ PJ03-01001~

Terminal (Female) YAZAKI 7115-1050-02 BAT

Condenser 0.5 F

Charge lamp Diode

Diode

Auxiliary diode

Battery

Key SW. Rotor coil

Stator coil

IC regulator

Alternator

Connection E-3 Horn PH53S00001P1 Warning sound

Maker's Part No.

BG62-66-790A

Rated Voltage

DC 12V

Rated current

Max 3.5A

Basic frequency

390 ± 20Hz

Sound level

110 ± 5dB

Insulation resistance 1MΩ or more/500VMegger

PM05-05001~, PV08-20001~ PW08-20001~, PX09-08001~ PH03-02001~, PJ02-00101~ PH04-02801~, PJ03-01001~

Drain 2 holes

24 – II – 2 – 2 1

Code No. Parts Name Parts No. Use Applicable Machine E-4

Specifications

Description

Allowable current

45A

Operating voltage

12V

Fusible link PH73S00001P1 Fuse PM05-05001~, PV08-20001~ PW08-20001~, PX09-08001~ PH03-02001~, PJ02-00101~ PH04-02801~, PJ03-01001~

E-6 Gauge Cluster

EU OCE

[PM59S00002F1] PM59S00002F2 Monitor Panel PM05-05001~, PV08-20001~ PW08-20001~, PX09-08001~ PH03-02001~, PJ02-00101~ PH04-02801~, PJ03-01001~

CONNECTOR TABLE No. 1 2 3 4 5 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 Gauge Cluster

Specifications

Operating voltage KAI

[PV59S00001F1] PV59S00001F2 Monitor Panel PM05-05001~ PV08-20001~ PJ02-00101~ PJ03-01001~

Description

45A

CONNECTOR TABLE No. 1 2 3 4 5 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

Reverse side

Connector

Hour meter (-)

18 19 20

Front side

11 12 13 14 15 16 17 18 19 20

Water temp, sensor

Housing : 174977-2 Terminal : 173682-1

20MA-040MLI E-7 Power socket

Operating voltage

DC 12V

Opeating current

15A (MAX.)

YN81S00001P1 12V power source YW06501~ LP11001~,YP02301~ YN08001~,YQ02301~ LQ03301~,LL02301~ PV08-20001~ PJ02-00101~ E-7 Power socket KCME

PF81S01001P1 12V Power source PH04-02801~ PJ03-01001~ Maker : NILES CO.,LTD. 12V Power (Water-proof type)

24 – II – 2 – 4 1

VIEW I

2MA-JMII+ HOUSING TERMINAL SEAL RETAINER

: : : :

174354-2 171661-1 172888-2 1-174355-1

Code No. Parts Name Parts No. Use Applicable Machine E-8 Air-heater 129120-77501

Specifications

Description

M6 terminal torque 0.35~0.5 kgf·m (2.5~3.6 lbf·ft)

129100-77500

YANMAR Part No. Rated voltage

DC 11V

Rated current

36.5A

Rated output

400W

Insulation resistance 3MΩ or more / 500 V Megger For E/G start PH03-02001~ PJ02-00101~ PH04-02801~ PJ03-01001~ Ground E-10

Maker Voltage

Clarion 12V

Display button

Tuner

Display

PY54S00001P1 Radio (OPT) PM05-05001~ PV08-20001~ PJ02-00101~ PJ03-01001~

Speaker

Preset button Power / Volume 1~6 Tune / time adjust

E-12 3PM Heater PM21M00005F1

Vinyl tube

Electric circuit LR

Heating PM05-05001~ PV08-20001~ PJ02-00101~ PJ03-01001~

DC12V

10A Fuse LW

Machine side

24 – II – 2 – 5

Code No. Parts Name Parts No. Use Applicable Machine E-13 Battery [PH72S00004P1] PH72S00005P1

Specifications

Description

P. No.

PH72S00004P1

Type

95D31L

Rated voltage

DC 12V

Capacity

64Ah / 5HR

Amount of electrolyte

5.2L

Power source

P. No.

PH72S00005P1

PH03-02001~ PJ02-00101~ PH04-02801~ PJ03-01001~

Type

105D31L

Rated voltage

DC12V

Capacity

64Ah/5HR

Amount of electrolyte E-14

5.3L

Rated voltage

DV12V

Relay [PA24S00002P2] PA24S00002P3 Sequence box (Holding circuit unit)

Input/output operation

PM05-05001~, PV08-20001~ PW08-20001~, PX09-08001~ PH03-02001~, PJ02-00101~ PH04-02801~, PJ03-01001~

GND Decel.relay solenoid

Decel.SW

Travel1,2speed solenoid

Electric circuit

E-15

Maker’s part No. Fuse

Travel1,2 speed SW

1406-2000

AMP : 0-1757831 Mating connector : 0-1749231 Terminal : 175027-1

Pin arrangement

20A blade X 2

Fuse box (For cooler) PH73E00004F1 Fuse (OPT) PW08-20001~ PX09-08001~ PJ02-00101~ PJ03-01001~

E-20 Travel alarm [PM53S00001F1] PM53S00001F2

Reted votage

12V DC

Rated current

50mA or less

Sound pressure Frequency Intermittency

90 ± 6dB 2400 ± 300Hz 80 ± 10 cycle/min

Alarm sound PM05-05001~, PV08-20001~ PW08-20001~, PX09-08001~ PH03-02001~, PJ02-00101~ PH04-02801~, PJ03-01001~

24 – II – 2 – 6 1

POWER SOURE PLUS (PINK)

SUMITOMO HOUSING : 6187-2311 : 1500-0105 POWER SOURE MINUS TERMINAL HARNESS SEAL : 7160-8234 (BLACK)

Code No. Parts Name Parts No. Use Applicable Machine L-1

Specifications

Model Rated voltage

Light

Description

17030-01700 12V

Bulb

12V10W

Maker’s P/No.

DS U023

2456U114 Dome light (Cab only) PM05-05001~, PV08-20001~ PW08-20001~, PX09-08001~ PH03-02001~, PJ02-00101~ PH04-02801~, PJ03-01001~

L-2

Effective area of lens Light

Bulb

102cm2 Halogen 12V-55W

2456R243F2 Boom working light (L.H.) PM05-05001~ PV08-20001~ PW08-20001~ PX09-08001~ PH03-02001~ PJ02-00101~ L-2

M12 Bolt

Maker’s P/No. Effective area of lens

Light

Bulb

BL84-150 82cm2 Halogen 12V-55W

PM80S00005F1 Boom working light (L.H.) PM06-05601~ PV09-22001~ PH04-02801~ PJ03-01001~

L-3, 4

M12 Bolt

Bulb

12V-55W

Light PY80S00002F1 Working light (OPT) (Cab spec.) PV10001~ PW07001~ PX05001~ PW08-20001~ PX09-08001~ PJ02-00101~

24 – II – 2 – 7

CA104

Code No. Parts Name Parts No. Use Applicable Machine M-1

Specifications

M4 S terminal

Description

M8 B terminal

Motor 129400-77012

E/G starter PM03-02001~ PJ02-00101~ PH04-02801~ PJ03-01001~

YANMAR P /No.

129400-77012

Rated voltage

DC 12V

Output

2.0 KW

Rated time Rotating direction Weight

Rotating dinection

30 seconds CW viewed from pinion gear 5.2 Kg View Z

M-2

Maker’s P/No. Rated voltage

Motor

S16WMT10165 12V 106˚ ± 3˚

YJ76S00001P1 Wiper (Cab only) PM05-05001~ PV08-20001~ PW08-20001~ PX09-08001~ PH03-02001~ PJ02-00101~ M-2

YAZAKI 7122-2045

Maker Maker’s P/No.

DENSO 849100-5120 (12V spec.)

Motor PM76S00001F1 Wiper motor (Cab only) YH04-02801~ YJ03-01001~

24 – II – 2 – 8 1

Code No. Parts Name Parts No. Use Applicable Machine M-3

Specifications

Maker’s P/No.

Description

EW-4B

Motor 2427R1350 Window washer (Cab only) M05-05001~ PV08-20001~ PW08-20001~ PX09-08001~ PH03-02001~ PJ02-00101~ M-3

Motor Type

DC Ferrite magnet Type Motor

Rated voltage

DC12V

Motor (Pump) PE54C00002S002 Window washer (Cab only) YH04-02801~ YJ03-01001~

M-4

Motor A : [PM20S00001F3] B : PM20S00004F3 Deceleration side

A : PJ02-00101~00600 B : PJ02-00600~

side (at shipping) Stroke

Plug Rated voltage

12V

Working force

15kg or more

Spring tension

Setting16 ± 2kg

Working time

1or less

Stroke

35 +1.0 —0.4 mm

24 – I I – 2 – 8 A

BS YAZAKI Connector Pin arrangement

Code No. Parts Name Parts No. Use Applicable Machine

Specifications

Description

M-4 10 Motor

Ø6

PH20S00004F1 42

P1 P2 36

Deceleration Stroke YH04-02801~ YJ03-01001~

AMP Connector Type : 174264-2 Dummy

Switch OFF : P2 ON : P1 Common (-)

Rated voltage Stroke

11 kg {24 lb}

Working time

1S or less

Rated voltage Max.working current

Fuel pump

Delivery rate

PM22P00001P1 Auto air bleed (OPT) PM05-05001~ PV08-20001~ PH03-02001~ PJ02-00101~ PH04-02801~ PJ03-01001~

36 ± 2 mm

Working force Working current

M-6

DC12V

(-)

Relay

PTC thermistor

8.5A or less

Circuit Diagram

DC 12V 1.5A or less At open condition 400cc /min or more YAZAKI water proof connector BS-2M 7118-3320-30 (Black)

Mating connector YAZAKI No.7319-3320

AEX 0.5B (Black) AEX 0.85R (Red) Vinyl tube (Blue)

INLET

24 – I I – 2 – 9

OUTLET

Code No. Parts Name Parts No. Use Applicable Machine R-1‚ 7 Relay PH24S00001P1 Battery relay E/G stop relay Opt.work light relay

Specifications

Maker’s P/No.

VF7-41F11

Rated voltage

DC 12V

Coil resistance

72Ω ± 10%

Insulation resistance Applicable connector Applicable terminal

PM05-05001~, PV08-20001~ PW08-20001~, PX09-08001~ PH03-02001~, PJ02-00101~ PH04-02801~, PJ03-01001~

R-2

Description

20MΩ (500V) VCF7-1000(P&B) AMP280756-4 AMP280755-4 AMP42281-1

Circuit diagram YANMAR P/No.

129136-77101

Rated voltage

DC 12V

Relay

M6 B terminal

PH24S00002P1 M6 S terminal Safety relay PH03-02001~ PJ02-00101~ PH04-02801~ PJ03-01001~ Circuit diagram R3‚ 8, 9,14, 22, 23 Relay

Maker’s P/No.

RC-5103

Rated voltage

DC 12V

Insulation resistance 1Ω or more/20A,20˚C

R3 : PM24S00001P1 R8,R9,R14,R22,R23: PA24E01001P1 Deceleration relay Charge indicator relay

PM05-05001~ PV08-20001~ PJ02-00101~ PH04-02801~ PJ03-01001~ R-6 Relay PH25S00002P1

5 3

4 Circuit diagram YANMAR Part No.

129211-77920

Rated voltage

12V

Exciting current

Timer

Without bracket : R3 With bracket : R8,R9,R14,R22 R23

Connector YAZAKI 7122-2446

1sec

Red (Acc)

Timer Unit PM05-05001~, PV08-20001~ PW08-20001~, PX09-08001~ PH03-02001~, PJ02-00101~ PH04-02801~, PJ03-01001~

Black (GND)

24 – I I – 2 – 10

Red / White (Relay)

VIEW Z

Yellow (Relay)

Code No. Parts Name Parts No. Use Applicable Machine SE-1 Sensor PH52S00002P1

Specifications

Rated voltage

Description

12V

Float position

FULL

1/2

EMPTY

Allowable (Ω)

10 0 -4

90 +10 0

Rasistance (Ω)

—

Fuel sensor PW08-20001~ PX09-08001~ PH03-02001~ PJ02-00101~ PH04-02801~ PJ03-01001~

SE-2

Rated voltage

DC 12V

Type

Thermistor type

Sensor PA24S00003P1 E/G thermo sensor PM05-05001~, PV08-20001~, PW08-20001~,PX09-08001~, PH03-02001~, PJ02-00101~, PH04-02801~, PJ03-01001~,

Temperature (˚C)

(50)

100 (120)

Resistance value (Ω) (153.9) 51.9 27.4 (16.1) The figures in parentheses are reference values

24 – I I – 2 – 11

Code No. Parts Name Parts No. Use Applicable Machine SV-1‚2

Specifications

DC12V

Rated voltage Relief valve set pressure

Solenoid

Description

Flow rate

2-speed select A1

35 kgf/cm2

Lever lock A2

15 L/min (P port)

PH35V00001F1 Safety lock lever Travel 2-speed select PM05-05001~ PV08-20001~ PW08-20001~ PX09-08001~ PH03-02001~ PJ02-00101~

PH35V00001F1 PH04-02801~ PJ03-01001~

T1 T=Tightening torque T=4.5 ± 0.5 kgf·m (33 ± 4 lbf·ft)

P1 P2

T=0.8 ± 0.1 kgf·m (5.8 ± 0.7 lbf·ft)

T=4.5 ± 0.5 kgf·m (33 ± 4 lbf·ft)

SUMITOMO Connector HW090, 2PM Housing : 6181-0070 Terminal : 1500-0105 A1, A2 P2

SV-3

YANMAR P/No.

119233-77931 Stroke7.4mm

12V DC

Rated voltage Solenoid

Pull coil : 36.5Amps

Rated current

GND(Black)

Hold coil : 98Amps

119233-77931 E/G stop

Connector YAZAKI 7222-6234-40

PM05-05001~, PV08-20001~, PW08-20001~,PX09-08001~, PH03-02001~, PJ02-00101~, PH04-02801~, PJ03-01001~,

Pull coil (White) Hold coil (Red)

SV-5

Rated voltage Power consumption

Solenoid YJ35V00004F1

SUMITOMO 090 TYPE 2PM

12V DC

Working pressure

12W 50 kgf/cm2

3-PF 1/4 A

Hydraulic diagram

Power shift (Air-con spec) PM05-05001~, PV08-20001~, PW08-20001~,PX09-08001~, PH03-02001~, PJ02-00101~, PH04-02801~, PJ03-01001~,

O-ring (1A P10)

24 –I I–2 –12

Body

O-ring (1A P10)

Solenoid

Code No. Parts Name Parts No. Use Applicable Machine SV-12

Specifications

Rated voltage Consumption power

Solenoid

Rated pressure

Description

DC 12V 12W 50 kgf/cm2 SUMITOMO Connector HW090 (2P) Housing : 6181-0070 Terminal : 1500-0105

PE35V00001F1 KAI Slew/Swing select PV08-20001~ PJ02-00101~ PJ03-01001~ HYDRAULIC CIRCUIT

24 – I I – 2 – 13

Code No. Parts Name Parts No. Use Applicable Machine

Specifications

SW-1

4MY -312

Description

4MY -CNA

CONNECTION TABLE

Switch A : [PM50E00001F1] B : PH50S00007S001

TO N AU TUR RE

TO AU RN U T RE

Key switch

A B

PM05-05001~ PV08-20001~ PW08-20001~ PX09-08001~ PH03-02001~ PJ02-00101~ PH04-02801~ PJ03-01001~

Ø5 DRAIN HOLE

C Note) “PH50S00007S001” has not the harness

SW-2

M Switch PV24E01001P1

OFF

Connection table L

(E)

OFF ON

L:70WX2 lamps L

Working light

(Unconnected)

PM05-05001~, PV08-20001~ PW08-20001~, PX09-08001~ PH03-02001~, PJ02-00101~ PH04-02801~, PJ03-01001~

M SW-3

Type

Buried in right travel lever

Type

0850-00596

(E)

Switch & Marks

Switch YN03M01286S002 (Right travel lever) Trvel 1‚ 2speed PM05-05001~, PV08-20001~ PW08-20001~, PX09-08001~ PH03-02001~, PJ02-00101~ PH04-02801~, PJ03-01001~

SW-4

Auto returm

Insulation resistance 1MΩ or more (DC500V Megger) Switch

Auto returm

Connection table Load

PY50S00004P1

2A 3A (Peak10A)

Wiper Washer (Cab only) PM05-05001~, PV08-20001~ PW08-20001~, PX09-08001~ PH03-02001~, PJ02-00101~ PH04-02801~, PJ03-01001~

3A (Peak10A) 5A (Peak10A) Wiper motor

Connector YAZAKI 7323-2446

Cam switch Wiper Washer Motor

24 –I I– 2–14

Code No. Parts Name Parts No. Use Applicable Machine

Specifications

SW-5

YANMAR Part No.

Switch

Operating temperature

PM50S00006P1

Description

121250-44901 ON : 110 ± 3˚C, OFF : 100˚C or less

Electric capacity Insulation resistance

DC12V 1A 100MΩ or more/ 500V Megger

E/G water temperature Tightening torque

2.8 kgf·m (20 lbf·ft)

PM05-05001~, PV08-20001~ PW08-20001~, PX09-08001~ PH03-02001~, PJ02-00101~ PH04-02801~, PJ03-01001~

SW-6 YANMAR Part No. Switch A : [124160-39450] B : 114250-39450

Rated voltage Rated load Operating pressure

E/G oil pressure A B

[124160-39450] 114250-39450 DC6V, 12V, 24V 5W (Lamp load) 0.5 ± 0.1kgf/cm2 (7.1 ± 1.4 psi)

PH03-02001~02470 PJ02-00101~00431 PH03-02471~ PJ02-00432~ PH04-02801~ PJ03-01001~ SW-7 Type Switch YN50E01001P1 KCME, OCN

Rated Insulation resistance

MIYAMA DS-257 OFF-(ON) momentary 125V 3A (AC) 100MΩ or more / DC 500V Megger

Horn switch SUMITOMO Housing : 6090-1031 Terminal : 8230-4282

PM05-05001~, PV08-20001~ PW08-20001~, PX09-08001~ PH03-02001~, PJ02-00101~ PH04-02801~, PJ03-01001~

SW-8 SW-9

Rated voltage Rated current

Switch PA50S00001P1

Insulation resistance Stroke

DC12V 15A 1MΩ or more Switch ON : 2 ± 1mm Full stroke : 10 ± 2mm

Lever lock sw (RH,LH) PM05-05001~, PV08-20001~ PW08-20001~, PX09-08001~ PH03-02001~, PJ02-00101~ PH04-02801~, PJ03-01001~

24 – I I – 2 – 15

Code No. Parts Name Parts No. Use Applicable Machine SW-10

Specifications

Maker’s P/No.

Description

0850-00595

Switch PY50S00003P1 Heater switch (OPT) PM05-05001~, PV08-20001~ PW08-20001~, PX09-08001~ PH03-02001~, PJ02-00101~ PH04-02801~, PJ03-01001~

Connector YAZAKI 7323-2446

SW-11

DC 12V

Rated voltage Switch

(MAX : DC 16V)

Insulation resistance 1MΩ or more (500VMegger)

PM50S00005P1 Deceleration switch (OPT) PM05-05001~, PV08-20001~ PW08-20001~, PX09-08001~ PH03-02001~, PJ02-00101~ PH04-02801~, PJ03-01001~

SW-12

[93R00-8003]

Maker's Part/No. Switch

REX801001

KCMA

[LE11P01015S001] YR11P00008S005 Air filter clogging switch

1A / 30V (DC)

Over load current

2A / 125V (AC)

Voltage

600V

Insulation resistance

1MΩ

YY00101~ YH00101~ PV08-20001~ PJ02-00101~

SW-12

Type

DC12V

Switch KCME, OCN 2446U336S8 Air filter clogging switch PW10-22001~ PX11-08901~ PH04-02801~ PJ03-01001~

24 –I I– 2–16

6242-1061(SUMITOMO) Mating connector 6242-5061(SUMITOMO)

Code No. Parts Name Parts No. Use Applicable Machine

Specifications

SW-23

Single-pole single-throw

Type Switch

(Altrenate)

Rated voltage

2479U1190F16

Description

DC24V

Insulation resistance

More than 1MΩ / DC 500V Megger

Travel alarm YF01-00101~ YU01-00101~ YV08-20001~ PH04-02801~ PJ03-01001~ SW-24,25,26,27,30,31

Voltage : 18~30V

Contact rating

Current : 10mA~3.5A

Switch Insulation resistance GB50S00049F1

100MΩ more/ DC 500V Megger

Slew/swing lever,Travel pressure switch

PT 1/8

PV08-20001~ PJ02-00101~ PJ03-01001~

SW-7, 28

KAI

Left

Right Grip assy PV03M01133F2 Handle assy (with switch) LF03M01005F3 SW-28

Grip & Switch KAI

SUMITOMO 090 Type water proof connector Housing : 6187-2311 equivalent

Grip assy PV03M01133F1 Handle assy (with switch) LF03M01005F1 SW-7

Control lever LF01-00501~ PJ02-00101~ PJ03-01001~ TAPING

SUMITOMO TERMINAL : HM090

24 – I I – 2 – 17

SUMITOMO TERMINAL : HM090

Book Code No.

PJ31

02E ➀

NEW HOLLAND EH45 Model Cross-reference: SK45SR-2 is NEW HOLLAND Model EH45

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

PJ31

31 –0–1 ➀

REVISION

DATE OF ISSUE

REMARKS

First Edition

October, 2001

S5PJ3102E

Second Revision

January, 2003

S5PJ3102E ➀ K·E

K·E

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) ATTACHMENTS .............................................................................................................. Code No. ; PJ32 Part I ; Removing and Installing Part II ; Disassembling and Assembling 1) Cylinder (2) UPPER SLEWING STRUCTURE .................................................................................... Code No. ; PJ33 Part I ; Removing and Installing Part II ; Disassembling and Assembling 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. ; PJ34 Part I ; Removing and Installing Part II ; Disassembling and Assembling 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. PJ11 TOOLS for standard tightening torque.

31–1–1

NOTES

Book Code No.

PJ32

02E ➀

NEW HOLLAND EH45 Model Cross-reference: SK45SR-2 is NEW HOLLAND Model EH45

ATTACHMENTS TABLE OF CONTENTS PART I - REMOVING AND INSTALLING 1.ASSEMBLY AND LOCATION ..........................................................................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 1. CYLINDER ................................................................................................II-1-1

PJ32

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.

REVISION

DATE OF ISSUE

REMARKS

First Edition

October, 2001

S5PJ3202E

Second Revision

January, 2003

S5PJ3202E ➀ K·E

K·E

32 –0–2 ➀

Part I : REMOVING AND INSTALLING 1. ASSY AND LOCATION

(N) SWING CYLINDER HEAD PIN

(M) SWING CYLINDER ROD PIN

(L1) (UPPER) (L2) (LOWER) SWING CENTER PIN

(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

(R) (K) DOZER CYLINDER BUCKET HEAD PIN ATTACHING PIN

(H) BUCKET CYLINDER ROD PIN

(J) BUCKET DRIVE PIN

Fig. 1-1 Parts and location (Typical example)

32 –I–1–1

(P)DOZER PIN

(Q) 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.

A J

(2) Move the O-rings (3)toward the bucket bosses using a spatula.

K GL

(3) In order to remove pin (K) which links arm and bucket, remove the ring (2) and the pin (1) by means of minus screwdriver, and draw out pin (K).

Fig. 2-2 To place bucket on ground

• If the pin does not come off easily, the pin is

loaded. Take off the load by manipulating the operating lever.

•

Take care so the dust seal between the arm and the bucket bosses is not damaged.

(4) Adjust the bucket by manipulating the operating lever so the pin (J) between the bucket link and the bucket is not loaded. (5) Remove the ring (2) and pin (1) then pull out the pin (J).

2 B

PIN FOR BUCKET LINK

DUST SEAL

1 SECTION B-B

(6) Remove bucket assy. Weight : 100 kg (205 lb) ................... SK40SR-2

DUST SEAL

: 104 kg (230 lb) .................... SK45SR-2 2.2 INSTALLATION OF BUCKET Installation is performed in the reverse order of removal, including the following workings :

PIN FOR ARM

Fig. 2-3 Assembly of pin (SECTION A-A)

• When aligning the pin holes, 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 Article 2.3. (4) Replace the worn pins and bushings according to the Chapter "ATTACHMENT DIMENSIONS" of "SPECIFICATIONS". (5) When inserting the pin, coat the shaft with grease.

• The bucket can be attached easily if the bucket link is installed in the beginning.

32 –I–1–2

Fig. 2-4 Installation of bucket

2.3 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 1.0mm (0.04 in). (4) Adjust clearance (B) where it is more than 1.0mm (0.04 in). (5) Several shims (10) of 0.5mm (0.02 in) thickness are set in each of the three capscrews (8). The clearance can be decreased by removing 0.5mm (0.02 in) 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 1.0mm (0.04 in). : 17 mm T=6.7 kgf·m (48 lbf·ft)

• Specified clearance is required between bushing (A) and arm.

(7) Operate the bucket and confirm that the total of both clearances are within 1.0mm (0.04 in). (8) Reinstall O-ring (3) to its original position and apply grease to there.

32 –I–1–3

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, place the arm tip to 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.

Fig. 2-5 Arm removing posture

: 27 mm (4) Lift up the arm cylinder body with a nylon sling in order not to exert any load to the pin (E). (5) Remove the capscrew and nuts that are preventing the pin (E) from coming out. Then remove the pin (E) and shims. : 19 mm (6) Placing wood block 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 exert any load to the pin (F). (8) Remove the capscrew that is preventing the pin (F) connecting the arm and boom, from coming out. Then pull off the pin (F). : 36 mm

PIN (F) PORTION

PIN (E) PORTION

Fig. 2-6 Sectional view of Installation pin

BUCKET CYLINDER

(9) Remove the arm assy paying attention to the stability of arm. Weight of arm assy: approx.

130 kg (290 lb) ................................... SK40SR-2 140 kg (310 lb) ................................... SK45SR-2 (10) Removal of bucket cylinder

1) Remove the capscrew that is preventing the rod pin (H) from coming out, then pull off the pin (H). : 24 mm

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). : 19 mm 3) Apply a nylon sling to the tube of bucket cylinder, and remove the cylinder. Weight ; 26 kg (57 lb)

32 –I–1–4

Fig. 2-8 Sectional view of Installation pin

3.2 INSTALLATION OF ARM Installation is performed in the reverse order of removal, including the following work.

BOSS

• At the alignment of pin bore, never insert your finger into the bore.

• Make sure to align them with visual check.

DUST SEAL

(1) Make the welded area clean to inspect any cracks there. (2) Check the dust seal for damages, and replace the faulty dust seal to new one (referring to Fig. 2-9 for the installing procedures).

BUSHING

Fig. 2-9 Dust seal installation

(3) Referring to the Chapter "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. : 17 mm

(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 plastic shim first, then adjust the clearance with steel shims.

G H

F The sum of both clearances to 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

SHIM The sum of both clearances : less than0.5mm (0.020in) after shim adjustment

SHIM

The sum of both clearances: To be within 0.5mm (0.020in) after shim adjustment

SHIM

1.0~1.5

SHIM

1.0~1.5 3.0

3.5

SHIM The clearance to be from 0.1mm (0.004in) to 0.5mm (0.02in) after shim adjustment

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 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 arm cylinder and boom cylinder, and apply a plug to all the openings. :27 mm

A 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 pin installing

5) Remove the boom cylinder. Weight : 49 kg (110 lb) ...................... SK40SR-2 : 58 kg (130 lb) ..................... SK45SR-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 : approx. 190 kg (420 lb) ...... SK40SR-2 220 kg (485 lb) ...... SK45SR-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). : 19 mm 2) Applying a nylon sling to the tube of arm cylinder, remove the arm cylinder. Weight : 41 kg (90 lb) ....................... SK40SR-2 : 46 kg (100 lb) ..................... SK45SR-2

PIN (D) PORTION

32 –I–1–6

PIN (A) PORTION

Fig. 2-14 Sectional view of pin installing

4.2 INSTALLATION OF BOOM Installation is performed in the reverse order of removal, including the following.

BOSS

• At the alignment of pin bore, never insert your finger into the bore.

• Make sure to align them with visual check.

DUST SEAL

(1) Make clean the welded area on each of structure to inspect any cracks there. (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).

BUSHING

Fig. 2-15 Dust seal installation

(3) Referring to the Article "ATTACHMENT DIMENSIONS" of Specifications, replace the worn-out pin and bushing 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. : 19 mm

(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 plastic shim first, then adjust the clearance with steel shims.

The sum of both clearances: To be from 0.5mm (0.020in) to 0.9mm (0.035in) after shim adjustment SHIM

PIN (A) PORTION

The sum of both clearances to be within 0.1mm (0.004in) to 0.5 (0.02in) SHIM

1.0~1.5

3.5

2.5

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 (1) Preparation for Removal

(4) Remove the swing bracket (A9). Weight : 99 kg (218 lb)

1) To make the removing work easy, swing by around 30° for leftward.

5.1.2 Removal of swing cylinder (C11) (1) Disconnect two connecting hoses for the swing cylinder.

2) Remove cover (A1) then disconnect the hoses of bucket cylinder,arm cylinder and boom cylinder,and apply plugs to all the openings. : 27 mm

: 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) (1) Removing the capscrew (C4) that is preventing the rod side pin (M) of swing cylinder (C11) from coming out, remove the pin (M). : 19 mm

(3) Take out the swing cylinder (C11) from the front side. Weight : 48 kg (106 lb)

(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 pin (L1) (L2) from coming out, remove the pin (L1) (L2).

: 19 mm

C11 A A9

C4 L2

Fig. 2-18 Removal of swing bracket

B8 A B8

B9 Fig. 2-17 Swing portion (Typical example)

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.

(5) Refer to Fig. 2-19 for the shim adjustment at pin installing portion.

(1) Check the dust seal for damages, and replace the faulty dust seal to new one.

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

(2) Referring to the Article "ATTACHMENT DIMENSIONS" of Specifications, replace the worn-out pin and bushing to new ones. (3) Before inserting the pin, apply grease to the shaft area. (4) Reffering to Fig.2-19,install the capscrews and nuts to prevent the pin from coming out. Before tightening them, apply Loctite #242 to threaded area.

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

4.3mm (0.17in)

The sum of both clearances to be within 0.1mm (0.004in) to 0.5mm (0.02in) SHIM

1.0~1.5mm (0.039~0.059in)

SECTION D-D SECTION A-A

SECTION B-B

Fig. 2-19 Sectional view of pin installing

32 –I–1–9

NOTES

Part II : DISASSEMBLING AND ASSEMBLING 1. CYLINDER 1.1 TOOLS NEEDED 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

Tool/Jig

1. Steel hammer 2. Wooden or plastic mallet

Gimlet

2~3 kinds of minus screwdriver Flat chisel

Jig

Capable to hold outer dia. of cylinder head and tube installing pin portion Measuring Device

1. Special wrench 2. Extension pipe for wrench

Remarks A sharp-point tool may be used in place of gimlet 1. For pressing head bushing (A) 2. For pressing pin bushing (B) 3. For installing seal ring (C) 4. For pushing seal ring into groove (D) 5. For reforming seal ring (E) 1. Slide calipers 2. Micrometer 3. Cylinder gauge 4. V-block

• For the details of special jigs, refer to Article 1.7 of this section.

1.2 GENERAL PRECAUTIONS

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

•Prior to disassembly, thoroughly clean the cylinder externally.

•

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

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

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

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

•This manual describes mainly for the boom cyl-

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

32 –II–1–1

inder as an typical example.

Confirm referring to the construction drawings in the [24-I-8]

1.3 CYLINDER CONSTRUCTION (EXAMPLE OF BOOM CYLINDER)

•See [24-I-8] CYLINDER for the others.

25 24

7,8

7,13 12 11 32

15 17 16

25 24

18,19

10 6

No. 1 2 3 4 5 6 7 8

Parts name Cylinder tube assy Piston rod assy Cylinder head Bushing U-ring Wiper ring O-ring Back-up ring

Q'ty No. Parts name 1 9 O-ring 1 10 Holder 1 11 Cushion seal 1 12 Collar 1 13 Buck-up ring 1 14 Cushion bearing 2 15 Piston 1 16 Seal ring assy

Q'ty No. Parts name 1 17 Slide ring 1 18 Setscrew 1 19 Steel ball 1 24 Pin bushing 1 25 Dust seal 1 27 Grease nipple 1 32 Spacer 1

Fig. 1-1 Construction of cylinder

1.4 DISASSEMBLY

• The numbers in ( ) following to each part name

are the numbers corresponding to those in Fig. 1-1 "Boom cylinder" except for notes. (1) Disassembly of cylinder assy 1) Fix the clevis portion of tube with a vise, 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 2 1 1 2 4 2 1

3) Make straight the locking fin for the cylinder head (3) .

• Use cautions bending / straightening of locking

fin, because locking fin and cylinder tube are made with one-piece.

3 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 a rag to prevent it from un-

expected strike. 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.

Fig. 1-4 Disassembling cylinder head

(2) Disassembly of piston rod assy 1) Fix the piston rod assy in level.

Fig. 1-5 Disassembling piston rod 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).

14 15

18 19

Fig. 1-6 Removing piston assy

32 –II–1–3

3) Disassembling of cushion bearing on retract side (Only swing cylinder) a. Remove piston nut. b. Remove snap ring by tapping with plastic mallet. c. Slide cushion bearing toward thread of piston rod, and remove stopper (Divide into 2 portions.) d. Remove cushion bearing. e. Expand the slit of cushion seal, and remove it.

Snap ring Cushion seal (Split one place)

Thread

Piston rod

Flattening Stopper Cushion Bearing (Dividable)

Fig. 1-7 Disassembling of cushion bearing 4) Remove the cylinder head assy.

Fig. 1-8 Removing cylinder head assy (3) Disassembly of piston assy: 1) Remove the slide ring (17) from the piston (15).

• Expand the split on the slide ring (17) as mini-

mum as required to pull it off for axial direction (2 places).

2) Remove the seal ring assy (16).

• Cut off the seal ring (16) or remove it using a minus screwdriver.

Fig. 1-9 Disassembling piston assy

9 (4) Disassembly of cylinder head assy: 1) Remove the O-rings (7) and back-up ring (8) from the outer periphery of cylinder head (3). Then remove the O-ring (9).

3 7

Fig. 1-10 Disassembling cylinder head assy

32 –II–1–4

2) Disassembly of holder (Boom and swing cylinder) a. Remove collar (12). b. Remove cushion seal (11). c. Remove spacer (32). d. Remove O-ring (7) and back-up ring (13).

Removing direction Holder (10) Back-up ring (13) Cushion seal (11) Collar (12) Spacer (32)

Removing direction

Fig. 1-11 Disassembling holder

5 3) Remove the U-ring (5).

SECTION A-A

Fig. 1-12 Removing U-ring 4 6 4) Remove the wiper ring (6).

•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 cylinder head.

Fig. 1-13 Removing wiper ring

Jig 5) Remove the bushing (4) using a removal jig.

Fig. 1-14 Removing bushing

32 –II–1–5

O-ring (7)

(5) Disassembly of clevis portion: 1) Remove the dust seal (25) from the clevis portion of tube (1) and piston rod (2).

25 Fig. 1-15 Removing dust seal

2) Remove the pin bushing (24).

• Using a metal block, push it out with a press

METAL BLOCK

machine.

Fig. 1-16 Removing pin bushing

32 –II–1–6

1.5 ASSEMBLY (1) Assembling clevis portion 1) With the installing jig (B) shown Article 1.7, press the bushing (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. 1-17 Installing pin bushing

SETTING TOOL

2) With the setting tool, install the dust seal (25).

Fig. 1-18 Installing dust seal (2) Assembling cylinder head 1) With installing jig (A) shown Article 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. 1-19 Assembling cylinder head

2) Installing U-Ring

• Install the U-ring (5) paying attention for its intalling direction.

SECTION A-A

Fig. 1-20 Installing U-Ring

32 –II–1–7

3) Assembly of holder (10). a. Install spacer (32) b. Install cushion seal (11) c. Install collar (12) d. Install back-up ring and O-ring (7).

Installing direction Holder (10) Back-up ring (13) Cushion seal (11) Collar (12) Spacer (32)

Installing direction

Fig. 1-21 Assembling holder

4) Using the setting tool, install the wiper ring (6). SETTING TOOL

6 Fig. 1-22 Installing wiper ring

32 –II–1–8

O-ring (7)

5) Install the back-up ring (8) and O-rings (7). Then install the O-ring (9). 9

Fig. 1-23 Installing back-up ring and O-ring (O-RING) (3) Assembly of piston portion : 1) Install the O-ring for the seal ring assy (16).

Fig. 1-24 Installing O-ring Seal ring (16) 15

2) Set the sliding jig (C) shown Article 1-7 on the piston (15), then quickly push the seal ring (16) onto the piston (15) with the pushing jig (D).

Fig. 1-25 Assembling seal ring

(O-RING)

3) Since the seal ring (16) is stretched at the installation, reform it with the reforming jig (E) shown Article 1-7.

Seal ring (16) E

Fig. 1-26 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 (2places).

16 15 Fig. 1-27Installing slide ring

(4) Installation of piston rod assy : 1) Fix the piston rod (2) in level, and install the cylinder head assy onto it. 2

Fig. 1-28 Installing head assy 2) Assembling of cushion bearing on retract side (Only swing cylinder) a. Before tightening of piston nut, install cushion bearing. b. Direct the slits of cushion seal toward the thread, and install it into groove. c. Install cushion bearing directing the flattening portion as shown in Fig.1-29. Install stopper into groove. d. Push cushion bearing fully toward stopper, and

Snap ring

Slit

Thread

Cushion seal (Split one place)

Piston rod

Flattening Stopper Cushion Bearing (Dividable)

drive snap ring. 3) Install the piston assy. a. Install the cushion bearings (14) (for Boom, and Swing cylinder ) and piston (15) on the piston rod (2), and tighten them up.

Fig. 1-29 Assembling of cushion bearing

• Torque for piston : Refer to Table 1-4

b. Put the steel ball (19) into the threaded bore, and securely tighten it with the setscrew (18). And caulk the setscrew (18) with a punch at two points.

15 18 19

• Torque for setscrew : Refer to Table 1-4 Fig. 1-30 Installing piston assy

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. 1-31

2) Install the cylinder head (3).

• Apply hydraulic oil on the packings (seals) prior to install.

• Torque for cylinder head : Refer to Table 1-4

Fig. 1-32

3) Bend the locking fin on the tube to lock the cylinder head.

Fig. 1-33

32 –II–1–11

1.6 MAINTENANCE STANDARDS (1) Inspection after disassembly 1) Inspection item Table 1-2 Parts Name

Inspecting Portion 1. Neck of rod

Replace

Presence of crack

Replace

3. Threads

Presence of scores, etc.

Recondition or replace

4. Bend

Measure amount of bend

Refer to Rod Bend

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

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

piston is attached

Piston rod 5. Plated surface

Rod cover (Cylinder head)

Remedy

Presence of crack

2. Stepped part to which

Cylinder tube

Inspection Item

1. Bushing

1) Wear of inside 2) Defect of inside

Replace

(2) Repair procedure Replace sliding parts and seal parts according to the followings. (i) Bushing ································· Where 1/4 of circumference from end to end is worn in copper color. (i i) 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 limit This service limit shows the limit of wear in the case where there is no flaw on the sliding surface of the cylinder tube, piston rod, etc. to such a degree that the sealing performance has failed. 0

1) Clearance between piston rod and bushing Replace the bushing when the clearance between piston rod and the rod bushing is over 0.25mm(0.01in).

1/ 2

Fig. 1-34 Measuring method

2) Bend of piston rod The limit bend of the rod is 0.5mm(0.02 in)/m. Support both ends of the parallel section of the piston rod with V-block, set a dial gauge at the center point of two blocks, and read and measure the max. value and min. value of the movement of dial gauge while turning the piston rod.

• The piston rod may not slide smoothly due to the partial bend even if the limit value of the bend is within the above limit values. Pay special attention to that at the operation test after the assembly. When the piston rod moves with creaking or is unsmooth, replace the piston rod.

(4) Tightening torque A : Cylinder head B : Piston assy C : Setscrew

Table. 1-3 Example of Measurement

Interval of V-blocks (m) 1 2

Movement value of Corrective action dial gauge (mm) 1 2

Replace Replace

(Table 1-3 Shows the example of measurement.)

Fig. 1-35

Table 1-4 Location

SK40SR-2

SK45SR-2

Boom Arm Bucket Swing Dozer Boom Arm Bucket Swing Dozer

Unit:kgf·m (lbf·ft)

Cylinder head A 54 (390) 46 (330) 43 (310) 54 (390) 58 (420) 66 (480) 54 (390) 43 (310) 54 (390) 58 (420)

32 – I I – 1 – 13

Piston nut B 170 (1230) 135 (980) 73 (530) 170 (1230) 142 (1030) 211 (1530) 170 (1230) 73 (530) 170 (1230) 142 (1030)

Setscrew C

1.7 (12)

3.2 (23) 3.2 (23) 1.7 (12) 3.2 (23)

(5) Inspection after assembly Pump

ldling test 1) Place the cylinder level in idling condition. 2) Pressurize it through alternate ports on both sides softly, and operate the piston rod 5 or 6 times. 3) Be sure that the piston rod moves smoothly without abnormalities.

Directional valve

Tank

Cylinder

Leak test Outside leaking 1) Apply test pressure on the extension and retraction sides for 3 minutes. 2) Check on the rod seal section, cylinder head clamping section, every weld zone for possible failures like leaking and permanent set.

•

Fig. 1-36 Idling test

Pump Directional valve

•

Inside leaking 1) Remove the hose on the extension side. 2) Apply test pressure for 3 minutes on the retraction side alternately. 3) Measure oil leakage on the extension side.

Inside leaking

• Leaking should be 1cc/3min. or less.

Tank

Cylinder

(6) Bleeding air of hydraulic cylinder When removing cylinder and hydraulic piping, etc. bleed them of air simultaneously. 1) Start the engine and idle it for approx. 5 minutes. 2) Repeat the extension and retraction of the cylinder 4 or 5 times at engine low idling.

• Stop the piston rod 100mm short of the stroke end in order not to relieve.

3) Operate the cylinder extension and retraction at the engine high idling as shown in Par.2), then stroke the piston rod to the stroke end at low idling to relieve it.

32 –II–1–14

fig. 1-37 Leak test

1.7 JIG LIST 1) Installing Jig (A) for press fitting of head bushing (4).

2) Installing Jig (B) for press fitting of pin bushing (24) (26). 0 0 -0.25 (-0.010 )

øF

øA

øB

0 ( øB-0.1 -0.004)

øA ± 0.2 (± 0.008)

Material : Steel Material : Steel

Unit:mm (in) Applicable cylinder SK40SR-2 SK45SR-2 (Rod dia ø 40) Bucket

Bucket

(Rod dia ø 50) Boom Arm Swing

Arm Swing

(Rod dia ø 55) Dozer

Boom Dozer

Dimension A B C D

49.5 (1.95) 39.5 (1.56) 25.0 (0.98) 67.0 (2.64)

A B C D

59.5 (2.34) 49.5 (1.95) 25.0 (0.98) 67.0 (2.64)

A B C D

64.5 (2.54) 54.5 (2.15) 25.0 (0.98) 67.0 (2.64)

Unit:mm (in) Applicable cylinder SK45SR-2 SK40SR-2 (Rod dia ø 45)

32 – I I – 1 – 15

Arm Bucket

(Rod dia ø 50) Boom Swing

Boom Swing

(Rod dia ø 55) Dozer

Dozer

Dimension A B C D E F A B C D E F A B C D E F

54.0 (2.13) 44.5 (1.75) 10.0 (0.39) 5.0 (0.20) 30.0 (1.18) 65.0 (2.56) 59.0 (2.32) 49.5 (1.95) 10.0 (0.39) 5.0 (0.20) 30.0 (1.18) 70.0 (2.76) 64.0 (2.52) 54.5 (2.15) 10.0 (0.39) 5.0 (0.20) 30.0 (1.18) 75.0 (2.95)

3) Sliding Jig (C) for seal ring (16)

4) Pushing Jig (D) for seal ring (16)

øC

øA

øB 5

15°

R 5

øB ± 0.05

øD

øC +0.2 +0.1

8°

A -0.1 -0.3

Material : Nylon or Acrylic

Material : Steel

Unit : mm (in) Applicable cylinder SK45SR-2 SK40SR-2 (Tube ID:ø 75) Bucket

Bucket

Dimension A øB øC øD

16.4 (0.65) 75.5 (2.97) 73.8 (2.91) 62.0 (2.44)

A øB øC øD

16.4 (0.65) 80.5 (3.17) 78.8 (3.10) 66.0 (2.60)

Unit : mm (in) Applicable cylinder SK45SR-2 SK40SR-2 (Tube ID:ø 75) Bucket

(Tube ID:ø 80) Arm

Bucket

(Tube ID:ø 90) Arm Boom Swing Swing (Tube ID:ø 95)

(Tube ID:ø 90) Boom Swing

Arm Swing

(Tube ID:ø 95) Dozer

Dozer

(Tube ID:ø 100) _

Boom

A øB øC øD

16.4 (0.65) 90.5 (3.56) 88.8 (3.50) 66.6 (2.62)

A øB øC øD

19.9 (0.78) 95.5 (3.76) 93.8 (3.69) 78.0 (3.07)

A øB øC øD

19.9 (0.78) 100.5 (3.96) 98.8 (3.89) 78.0 (3.07)

Dozer

(Tube ID:ø 100) _

32 –II–1–16

Boom

Dimension øA øB øC øA øB øC øA øB øC øA øB øC øA øB øC

80.0 (3.15) 78.0 (3.07) 70.0 (2.76) 85.0 (3.35) 83.0 (3.27) 75.0 (2.95) 95.0 (3.74) 93.0 (3.66) 85.0 (3.35) 100.0 (3.94) 98.0 (3.86) 90.0 (3.54) 105.0 (4.13) 103.0 (4.06) 95.0 (3.74)

5) Reforming Jig (E) for seal ring (16) Unit : mm(in)

(0.79)

50 (1.97)

Material : Steel

Dimension A

90.0 (3.54)

Bucket

75.5 (2.95)

(Tube ID:ø 80) _ Arm

95.0 (3.74)

80.0 (3.15)

(Tube ID:ø 90) Boom Arm Swing Swing (Tube ID:ø 95)

105.0 (4.13)

90.0 (3.54)

110.0 (4.33)

Dozer

95.0 (3.74)

(Tube ID:ø 100) _ Boom

115.0 (4.53)

100.0 (3.94)

Bucket øA

R3 (0.12)

+0.004) øB +0.1 0 ( 0

R (0.1 3 2

)

Applicable cylinder SK40SR-2 SK45SR-2 (Tube ID:ø 75)

1.8 POSSIBLE CAUSES FOR TROUBLE AND REMEDY Trouble conditions Oil leakage from sliding face of piston rod. (A ring shape oil is formed on piston rod and enlarged resulting dripping down of oil)

Major possible causes • Foreign material is caught by U-ring or wiper ring at its inside periphery. • Scores or fault on U-ring or wiper ring at its inside periphery.

• Remove foreign material.

• Scores on sliding face of piston rod.

• 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. to new ones. • If leakage is not stopped by replacing seals, replace piston rod. • Re-plating of hard chrome on piston rod.

• Peeling off of hard chrome plating. Oil leakage from outer periphery of cylinder head.

Remedy

• Damages on O-ring. • Damages on back-up ring.

• Replace each part to new one.

• Replace the part. • Replace the part.

Oil leakage from welded portion. • Damages on welded portion on tube.

• Replace the part.

Piston movement due to leakage. (For the case when static load that is equivalent to value of multiplication of max. working pressure and cylinder area, is applied to rod, max. movement of piston is larger than 0.5mm (0.02 in)) per 10 minutes.

• Foreign material is caught by sliding face of slide ring.

• Remove foreign material.

• Scores or faulty condition on sliding face of slide ring.

• Replace the part.

• Scores on sliding face of seal ring assy.

• Replace the part.

• Damages on O-ring.

• Replace the part.

32 –II–1–17

6. DOZER (BLADE) 6.1 REMOVAL (1) Put a support of appropriate height under the attaching side of dozer body, and make the dozer at a stable condition not to exert any load to the pin (P).

B2, B3

Q C3, C4 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. (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 wood block. : 19 mm (5) Remove the capscrew (B2) and nuts (B3) that are preventing the dozer body fixing pin (P) from coming out, and remove the two pins (P). : 17 mm

SUPPORT

Fig. 2-20 Removing/installing dozer blade

(6) Gradually move the machine to backward to remove the dozer. Weight SK40SR-2 SK45SR-2

Standard 175kg (390 lb) 186kg (410 lb)

With cutting edge 188kg (415 lb) 199kg (440 lb)

(7) If necessary, remove the dozer cylinder by means of removing the pin (R) of head side. Weight : 26 kg (57 lb) ....................... SK40SR-2 : 27 kg (60 lb) ....................... SK45SR-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 Article "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) Referring to Fig. 2-21, install the nuts for capscrew to prevent the pin from coming out. : 17 mm

32 –I–1–10

NUT 0.5~1.0mm (0.02~0.04in) STOPPER CAPSCREW

Fig. 2-21 Tightening procedures for nuts

Book Code No.

PJ33

02E ➁

NEW HOLLAND EH45 Model Cross-reference: SK45SR-2 is NEW HOLLAND Model EH45

UPPER SLEWING STRUCTURE TABLE OF CONTENTS PART I - REMOVING AND INSTALLING ........................................................... I-1-1 1. CANOPY OR CAB..................................................................................... I-1-1 2. GUARD (COVER AND SUPPORT) .......................................................... I-1-3 3. FLOOR PLATE ASSY ............................................................................... I-1-6 4. BATTERY .................................................................................................. I-1-8 5. SEAT STAND ............................................................................................. I-1-9 6. COUNTERWEIGHT .................................................................................I-1-12 7. FUEL TANK...............................................................................................I-1-13 8. HYDRAULIC OIL TANK ...........................................................................I-1-14 9. AIR CLEANER .........................................................................................I-1-17 10. GENERATOR (DYNAMO) ........................................................................I-1-17 11. STARTER .................................................................................................I-1-18 12. MUFFLER ................................................................................................I-1-19 13. PUMP ......................................................................................................I-1-20 14. RADIATOR ...............................................................................................I-1-22 15. ENGINE ...................................................................................................I-1-24 16. CONTROL VALVE ....................................................................................I-1-26 17. SOLENOID VALVE....................................................................................I-1-29 18. PILOT VALVE ...........................................................................................I-1-30 19. SLEWING MOTOR ..................................................................................I-1-31 20. SWIVEL JOINT ........................................................................................I-1-33 21. UPPER FRAME .......................................................................................I-1-35 PART II - DISASSEMBLING AND ASSEMBLING ............................................II-1-1 1. HYDRAULIC PUMP ..................................................................................II-1-1 2. CONTROL VALVE .....................................................................................II-2-1 3. PILOT VALVE (ATTACHMENT)..................................................................II-3-1 4. PILOT VALVE (TRAVEL)............................................................................II-4-1 5. SLEWING MOTOR ...................................................................................II-5-1 6. SWIVEL JOINT .........................................................................................II-6-1

33 –0–1 ➀

PJ33

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.

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. (Note) In the descriptions in this chapter, the distinction of applicable machine numbers between before / after the change (brush-up) is indicated as (before BU) or (after BU). Applicable Machine Nos.

• Before BU • After BU

SK40SR-2 : PH03-02001~ SK45SR-2 : PJ02-00101~ SK40SR-2 : PH04-02801~ SK45SR-2 : PJ03-01001~

REVISION

DATE OF ISSUE

REMARKS

First Edition

October, 2001

S5PJ3302E

Second Revision

January, 2003

S5PJ3302E ➀ K·E

K·E

33 –0–2 ➀

Part I : REMOVING AND INSTALLING 1. REMOVAL&INSTALLATION CANOPY OR CAB

A15

[A] before BU SK40SR-2 : PH03-02001~ SK45SR-2 : PJ02-00101~ A.1.1 REMOVAL OF CANOPY (1) Remove floor mat (A15).

(2) Removing cover (A7). Loosen sems bolt (A6) M8 X 20 and (A10) M8 X 25 one each and remove the cover. However, the removal of the cover (A7) is required only when the handrail shown in Par.(4) is removed.

A10 A7

Fig. 1-1 Removing floor mat Removing cover (A7)

: 13 mm

(3) Removing canopy assy Loosen two capscrews (19) M16X60 and 2 capscrews (9) M20 X100, and remove support (2,7) and canopy (1) together. : 24 mm Canopy weight: 79 kg (174 lb) (4) Removing handrail (11) Loosen one sems bolt (4) M10 X 40 and 2 sems bolts (16) M10 X 25, and remove the handrail (11). : 19 mm

2 7 9

19 19

11 16

(5) Install it by the procedure reverse of the removal. A.1.2 REMOVAL OF CAB (OPT) A.1.2.1 Removing cab (1) Remove floor mat(A13). (2) Removing cab harness connector.

Fig.1-2 Removing canopy assy Removing hand rail (11)

1) Remove the cab harness and 12P connector for the harness connecting to the cab at the control stand on the right rear side. (For details, refer to the chapter “Electric System”.) 2) Remove coupler 3P for radio at the control stand on the left rear side.(OPT)

33 – I – 1 – 1

A13

Fig. 1-3 Removing floor mat (A13)

A1.2.2 Removing cab (1) Removing cover on the rear side of cab Loosen 3 sems bolts (20) M6 and remove the cover (19). : Screwdriver (Plus) 19

(2) Removing bolts attaching the rear side of the cab Loosen a capscrew (2) M16 for the bracket of the guard, and remove shims (8) 1.6, 2.3, 3.2 (thickness choise).

•

B (5)

B 24

: 24 mm In case of KAI , shim (8) are not equipped. 2 19

SECTION B-B

VIEW I

Fig. 1-4 Outside of cab

2 (3) Removing attaching bolts in the cab 2

1) Loosen and remove capscrew (3) M10 X 30 installing the floor plate and the cab. : 17 mm

2) Loosen and remove 3 capscrews (2) M16 X 50.

Fig. 1-5 Installing point of cab

: 24 mm

(4) Hanging cab Sling the wire to the hanging hook on the ceiling of the cab. Cab weight : 180 kg (400 lb) EU : 220 kg (485 lb) KAI (5) Installing cab Install the cab by the procedure reverse of the removal. Tighten every bolt to the following torques. M6 ; T = 0.45 kgf·m (3.25 lbf·ft) M10 ; T = 4.7 kgf·m (34 lbf·ft) M16 ; T = 19.5 kgf·m (141 lbf·ft) Fig. 1-6 Hanging cab

33 – I – 1 – 2

1. CANOPY / CAB [B] after BU SK40SR-2 : PH04-02801~ SK45SR-2 : PJ03-01001~ B1.1 CANOPY REMOVAL (1) Remove the floor mat (6). (2) Removing handrail (11) Unscrew two M10 X 45 SEMS bolt (4) to remove the handrail (11). : 17 mm (3) Removing handrail (12) Unscrew two M12 X 35 capscrew (17) to remove the handrail (12). : 19 mm

Fig. 1-7 Floor mat and cover removal

(4) Removing canopy assembly Unscrew two M16 X 60 capscrew (19), and two M20 X 70 capscrew (9) to remove the support (2), (4) and the canopy (1) in one piece. : 24 mm : 30 mm Canopy weight : 70 kg (154 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) For M20 : T=38 kgf·m (275 lbf·ft)

B.1.2 CAB REMOVAL (Option) B.1.2.1 Removal preparation (1) Remove the floor mat (6). (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 –2 A

B.1.2.2 Cab removal (1) Removing cover installed on rear of cab Unscrew three M6 SEMS bolts (19) to remove the cover (16). : 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

(3) Removing mounting screws inside cab 1) Unscrew M10 X 30 capscrew (3) fastening the cab to the floor plate.

Fig. 1-10 Outside of cab

: 17 mm 2) Unscrew three M16 X 50 capscrews (2) fastening the cab to the upper frame. : 24 mm Note) Shim (25) and (26) are placed at marked position. thikness of shim (25) is 1.2 mm and that of (26) is 2.0 mm

Fig. 1-11 Cab assembly fastening positions

(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 – 1–2 B

2. GUARD (COVER AND SUPPORT) 2.1 REMOVAL (1) Removing cover assy (1) Unlock and open cover assy (1), and loosen 4 sems bolts (50) M8 X 20 (yellow), and remove cover (1).

: 13 mm

Fig. 2-1 Removing cover assy (1) 50

(2) Removing panel assy (2) Loosen and remove 3 sems bolts (22) M8X20 (green), one sems bolt (50) M8 X 20 (yellow) and remove panel assy (2).

: 13 mm

Fig. 2-2 Removing panel assy (2)

(3) Removing panel assy (3) Loosen and remove one capscrew (25) M8 X 20, and 3 sems bolts (50) M8 X 20 (green). : 13 mm Weight : 15 kg (33 lb)

Fig. 2-3 Removing panel assy (3)

33 – I – 1 – 3

(4) Removing bonnet assy (4) Loosen and remove 2 sems bolts (24) M10 X 25 (yellow), unlock and open bonnet assy (4), and remove bonnet (4) from the hinge section.

20 50

: 17 mm

(5) Removing bonnet assy (5) Remove 3 grommets (20), and loosen and remove 3 sems bolts (50) M8 X 20 (yellow). : 13 mm

24 Fig. 2-4 Removing bonnet assy (4) (5)

(6) Removing cover assy (6) Loosen and remove 4 capscrews (23) M10 X 35 and 3 sems bolts (24) M10 X 25 (yellow).

7 24 6

: 17 mm

(7) Removing cover assy (7) Loosen and remove 3 capscrews (23) M10 X 35 and 3 sems bolts (24) M10 X 25 (yellow). : 17 mm

23 23 24

Fig. 2-5 Removing cover assy (6) (7)

33 –I–1–4

(8) Removing cover assy (8) Loosen and remove 4 sems bolts (22) M8 X 20 (green).

: 13 mm 23 (9) Removing cover (36) Loosen and remove 5 sems bolts (22) M8 X 20 (green).

: 13 mm 36

(10) Removing bracket assy (9) Loosen and remove 3 sems bolts (22) M8 X 20 (green), 1 capscrew (23) and 1 sems bolt (24) M10 X 25 (yellow).

Fig. 2-6 Removing cover assy (8), cover (36) and bracket assy (9)

: 13, 17 mm Weight : 16 kg (35 lb)

(11) Removing cover assy (17) Loosen and remove 3 sems bolts (50) M8 X 20 (yellow). : 13 mm

50 50

17 Fig. 2-7 Removing cover assy (17)

(12) Removing support (10) Loosen and remove 4 capscrews (21) M12 X 45.

: 19 mm Weight : 47 kg (104 lb)

• Removing seat stand and counterweight is required to disassemble this support (10). (See par. 5 and 6.)

2.2 INSTALLATION Install the cover by the procedure reverse of the removal.

Fig. 2-8 Removing support (10)

33 –I–1–5

3. FLOOR PLATE ASSY The floor plate is equipped with travel pilot valve assy, swing pedal and nibbler & breaker pedal therefore remove them simultaneously.

6 2

3.1 REMOVAL OF FLOOR PLATE ASSY (1) Remove floor mat. (2) Remove floor cover (A7). (3) Remove canopy. (4) Remove cover assy (2).

(See Section 1.)

FLOOR PLATE

: 13 mm (5) Remove cover assy (7) of the deck under the floor. (See Article 2.1-(7).) (6) Disconnect the electric wiring for the travel 1, 2 speed change switch at the connector section. Disconnect the cable of the negative side of the battery to prevent the short-circuit, etc.

• The figure shows the before BU.

(7) Removing travel pilot pipe (Carry out after releasing the circuit pressure.) Remove the hose for travel pilot valve(A10) at the mark position on the pilot valve side and plug up the hole.. Attach a tag on which the connecting position to the pilot valve is indicated to the removed hose. The tightening torque is as follows.

•

Fig. 3-1 Removing cover assy (2)

A10 2 4

* Pb7

C/V

S/V

Pb6

Tightening torque kgf·m (lbf·ft) Thread size Spanner in use (PF) (mm) 1/4

Note)

O-ring type joint

30˚flare type

2.7 (20)

3.0 (22)

C/V

S/V

Pa7

C/V Pa6

Take care of the torque for pilot valve because this valve is made of alminum.

Fig. 3-2 Removing pilot piping SWING PEDAL EU , OCEANIA N & B PEDAL KAI

(8) Removing cable of EU , OCEANIA swing pedal and KAI N & B pedal

22 36

1) Loosen 2 sems bolts (36) M8 X 20, and draw bracket (24) out upward. 2) Pull pin (11) out, loosen the adjusting nut, and disconnect cable (22).

(122) ADJUSTING NUT 11 Fig. 3-3 Removing cable from pedal

33 – I – 1 – 6

(9) EU , OCEANIA Removing N & B pedal rod 1) Loosen 2 nuts (14) and remove rod (4).

T=1.1 kgf·m (7.9 lbf·ft)

14 Fig. 3-4 Removing pedal rod

(10) Removing cover assy (18) in front of stand Loosen 2 sems bolts (24) M8 X 16 and remove cover assy (18).

• SEMS bolts : 2 (before BU) : 4 (after BU)

(11) Remove cover assy (17) on the left rear side. (See Article 2.1- (11).)

• The figure shows before BU.

Fig. 3-5 Removing cover assy (18)

before BU

3.2 REMOVAL OF FLOOR PLATE (1) Remove plate(3).

: 13 mm 45

(2) Remove the cable and grommet (4A) for the governor motor from plate (3) (OPT).

4A 6

(3) Remove the cable and grommet (4B) for the dozer lever from floor plate (1). (4) Remove cover (36). (See Article 2.1-(9).)

(5) Loosen sems bolt (43) M12 X 55 and capscrew (45) M16 X 40 which are tightened together with the stand one each.

after BU

: 19 mm , 24 mm

4A 3

(6) Pull floor plate (1) out forward.

6 3.3 INSTALLATION OF FLOOR PLATE

(1) Install the floor plate by the procedure reverse of the removal.

33 – I – 1 – 7

Fig. 3-6 Removing floor plate (1)

4. BATTERY 4.1 PREPARATION FOR REMOVAL (1) Push down the seat forward and remove cover (27).

PUSH DOWN THE SEAT

SEAT

Fig.4-1 Push down the seat

4.2 REMOVAL (1) Disconnect the cable terminal on the negative side. (2) Next, disconnect the cable terminal on the positive side. : 12 mm

A3 A1 A2

Follow the specified battery cable disconnecting procedure. The disconnection of the battery cable should be carried out starting from the grounding side, and the connection should be carried out finally the grounding side. STRAP

(3) Loosen nut (A3) and remove bracket (A1) and rod (A2). (4) Take out the battery holding the strap auxiliary attached to the battery. 4.3 INSTALLATION Install the battery by the procedure reverse of the removal.

33 – I – 1 – 8

Fig. 4-2 Removing battery

5. SEAT STAND 5.1 PREPARATION FOR REMOVAL (1) Remove the canopy and the handrail. (See Section 1.) (2) Remove bracket assy (9) for the guard, cover (36) and cover assy (17). (See Section 2.) (3) Remove cover assy (18) in front of the seat stand. (See Article 3.1- (9).) (4) Remove plate (3) in the rear of the floor plate. (See Article 3.2- (1).) (5) Disconnect (negative) terminal of the battery. (See Section 4.)

• The figure shows before BU. 9 38

5.2 REMOVAL (1) Removing dozer lever assy (9) Loosen and remove 2 sems bolts (38) M8 X 16, and keep the dozer cable moved leaving it connecting.

Fig.5-1 Removing dozer lever assy (9) and cover assy(19)

: 13 mm (2) Removing cover assy (19) Loosen and remove 2 sems bolts (38) M8 X 16. : 13 mm 10

• SEMS bolts : (M8 X 20, after BU)

(3) Push the seat down forward, and disconnect 2 connectors (CN-4 and CN-5) for the main harness and the instrument panel harness in the relay box. (For details, See Chapter “Electric System”.)

(4) Disconnect 2 connectors(CN-60 and CN61) for the instrument panel harness and the engine harness. (For details, See Chapter “Electric System”.)

(5) Remove fire prevention cover (25). 1) Remove cover assy (8) (See 2.1- (8)) 2) Loosen 2 capscrews (10) M8 X 20, and separate fire prevention cover (25) and seat stand.

Fig. 5-2 Removing fire prevention cover (25)

33 – I – 1 – 9

(6) Removing air cleaner hose (2) Remove air cleaner hose (2). (See 9.2-(1)) (7) Removing throttle cable (B2) Loosen adjusting nut of throttle cable, and separate throttle lever (1-8) from cable (B2).

13 1-8

THROTTLE CABLE ADJUSTING NUT

Apply MoS2 grease to these places at assembling.

: 17 mm

• Be sure the condition that bracket (18) for throttle cable is separated from seat stand when removing air cleaner hose (2) in work of par. (6)

2 18

Fig. 5-3 Removing throttle cable and air cleaner hose (8) Remove the covers on both right and left sides and disconnect the connectors for the left switch panel and the right gauge cluster, and then disconnect the plug of lever lock limit switch circuit. (See Section “Electric System”.)

• The figure shows before BU.

(9) Moving right and left control box Loosen 3 left sems bolts (37) M8 X 20 and 4 right sems bolts (37) and remove the control box, and then move the control box forward to the position where it does not interfere with hanging the seat stand, leaving the pipe of the control valve connected.

MOVE CONTROL BOX FORWARD

: 13 mm

Fig. 5-4 Moving right and left control box

33 – I – 1 – 10

(10) Removing battery cable Remove the cable on the battery (positive) side at B terminal section. (See Article 11.2.)

11 (M8X25, 2 PCS.) 3 (before BU)

(11) Removing deceleration motor Loosen and remove 2 sems bolts (10) M8 X 25. 11 (M8X20, 3 PCS.)

: 13 mm,T = 1.1 kgf·m (8.0 lbf·ft)

3 (after BU)

(12) Disconnecting heater hose (OPT) Disconnect 2 heater hoses on the engine side.

Fig. 5-5 Removing deceleration motor

before BU

43 44

(13) Removing seat stand Loosen and remove one sems bolt (43) M12 X 55, 2 sems bolts (44) M12 X 40 and one capscrew (45) M16 X 40. : 19 mm , 24 mm

Removed seat stand weight: Approx. 55 kg (121 lb) (including seat)

after BU

5.3 INSTALLATION Install the seat stand by the procedure reverse of the removal.

Fig. 5-6 Removing seat stand

33 – I – 1 – 11

6. COUNTERWEIGHT 6.1 PREPARATION FOR REMOVAL (1) Remove panel assy (3), bonnet assy (4) and cover assy (17). (See Section 2.) (2) Preparing for slinging Counterweight slinging Jig (See Chapter “Tools”.) Bolt (A) M20 X 50, 2 pieces Wire rope (nylon sling)

• • •

BOLT (A) WIRE ROPE A

COUNTERWEIGHT SLINGING JIG

B9 6.2 REMOVAL (1) Remove plate (B9) and attach the counterweight slinging jig. (2) Attach the wire rope and stretch the wire to the degree not having slack. Counterweight : 550 kg (1210 lb) (3) Remove one capscrew (B1) M16 X 50 and 2 capscrews (B2) M16 X 45.

B5 B6 B7

B6 B7

: 24 mm (4) Remove counterweight (1). (5) Remove shims (B5) (B6) (B7).

B1 B2 Fig. 6-1 Removing counterweight

6.3 INSTALLATION (1) Install the counterweight by the procedure reverse of the removal. (2) Install shims (B5) (B6) (B7) as they were. (3) Hanging and attaching the counterweight Check that 3 attaching bolts can be screwed in by hand.

B5, B6, B7

(4) Apply Loctite #262 on capscrews (B1) and (B2),and tighten them with washers (B3) and (B4). : 24 mm Tightening torque : 28.5 kgf·m (206 lbf·ft) (5) Remove the slinging Jig.

B1, B2

B3, B4

Fig. 6-2 Installing counterweight

33 –I –1–12

7. FUEL TANK before BU 7.1 PREPARATION FOR REMOVAL (1) Remove cover assy (1), panel assy (2) and cover (36), bracket assy (9) and cover assy (6).

(See Section 2.) B8

7.2 REMOVAL (1) Open cap (A3) and loosen drain plug (B13) to drain fuel. Tank capacity : 50 L (13.2 gal)

(2) Disconnect the hoses at the fuel inlet and outlet. (before BU) (3) Loosen 3 capscrews (B1) M10 X 25.

: 17 mm

B13

(4) Disconnect the connector for level sensor (B8). (5) Remove the fuel tank (A1). Weight : 23 kg (51 lb) (after BU) (3) Loosen two Sems-bolts (B4) M10 X 20, and remove boss (B6) and drain hose together. : 17 mm (4) Disconnect the connector for level sensor (B8).

after BU

(5) Loosen 3 capscrews (B1) M10 X 25. : 17 mm (6) Remove the fuel tank (A1). Weight : 23 kg (51 lb)

B7 A1

7.3 INSTALLATION Install the fuel tank by the procedure reverse of the removal following theTightening Torque Table.

Code B1

Parts Capscrew (M10)

Tools (mm)

Torque kgf·m (lbf·ft)

4.7 (34)

B1 DRAIN HOSE B4 B5 CLIP

CLIP B6 DRAIN HOSE

• Apply Loctite #262 to capscrew (B1).

Fig. 7-1 Removing fuel tank

33 – I – 1 – 13

8. HYDRAULIC TANK 8.1 PREPARATION FOR REMOVAL (1) Slew the upperstructure right about 90 degrees to make the work easy.

A10

(2) Remove the fuel tank according to the procedure in section 7 “Fuel Tank”. (3) Remove panel assy (3). (See Article 2.1-(3).) A16 A9 8.2 REMOVAL (1) Releasing internal pressure of tank Release internal pressure by pressing the cap boots of breather assy (A10). Keep the cap boots pressed until the hissing sound dies out.

A1 B1 A4

A15

(2) Remove plug (A15) and drain hydraulic oil. : 22 mm Tank capacity : Approx. 48 L (13 gal) (3) Loosen clip (A9), and disconnect hose (A4) of reserve tank.

Fig. 8-1 Releasing internal press. Draining hyd.oil Separate reserve tank hose

(4) Disconnecting suction hose From the hole under the hydraulic tank, 1) Remove clip (11). Screwdriver (-) 2) Disconnect hose (7). Screwdriver (-)

11 7 Place white dot mark to tank side

Fig. 8-2 Removing suction hose

33 –I –1–14

(5) Disconnecting return oil hose Disconnect every hose at the marked position. : 22, 27, 36 mm

S/M Dr

S/M Mu

O/C (OUT)

* Fig. 8-3 Disconnection of return oil hose

* P/V T

S/V

Fig. 8-4 Disconnection of return oil hose (6) Removing hydraulic tank Loosen 3 capscrews (B1) M 10 X 25 and remove hydraulic tank (A1).

: 17 mm Weight : Approx.36 kg (80 lb)

B1 B1

Fig. 8-5 Removing hydraulic tank

33 –I–1–15

8.3 INSTALLATION (1) Clean the hydraulic tank, hose and equipment. (2) Install the hydraulic tank by the procedure reverse of the removal. The tightening torque is shown below. Code

Parts

Tools (mm)

Torque kgf·m (lbf·ft)

Capscrew (M10)

4.7 (34)

A15

Plug (PF3/8)

7.5 (54)

Clip

Screwdriver

0.55 (4.0)

• B1 and B3 are required an application of Loctite #262. Torque Thread Spanner in size (PF) use (mm) 1/4 3/8 3/4

19 22 36

kgf·m (lbf·ft)

O-ring type joint

30˚flare type

3.7 (27) 7.5 (54) 16.5 (120)

3.0 (22) 5.0 (36) 12.0 (87)

(3) After installation, supply the specified hydraulic oil, and check oil level with level gauge (A16). (See Figure 8-1.) Oil quantity: Approx.48 L (13 gal) (4) Air bleeding 1) Start engine. 2) After operating the engine for 2 or 3 minutes at low idling, telescope respective cylinder several times to bleed the air in circuit. (5) Reconfirmation of oil level Stop the engine in the position shown in Fig. 8-7, and confirm the hydraulic oil level again. And at the same time check that every section is free from oil leakage. Fig. 8-7 Oil checking position (Engine stops)

33 –I –1–16

9. AIR CLEANER

16-7

9.1 PREPARATION FOR REMOVAL Open bonnet assy.in the rear of machine.

EU , OCEANIA KAI

9.2 REMOVAL (1) Loosen 3 clips (5) and one capscrew (8), and disconnect air hoses (2) (3). : Screwdriver (-)

Air cleaner

8 5

(2) In case of KAI , disconnect 2 plugs of indicator (16-7) from engine harness.

5 3

(3) Loosen 2 capscrews (9) and remove the air cleaner assy. : 13 mm

9.3 INSTALLATION Install the air cleaner by the procedure reverse of the removal. Fig. 9-1 Removing air cleaner

10. GENERATOR (DYNAMO) 10.1 PREPARATION FOR REMOVAL 2

(1) Remove cover assy (8). (See Section 2.)

(2) Disconnect the negative terminal of the battery. 10.2 REMOVAL

(1) Remove connector (CN-302), terminal of battery and eyelet terminal P. (See Chapter 23. Electric System)

(2) Loosen capscrews (1) (2) (3). : 13mm

Fig. 10-1 Removing generator GENERATOR

(3) Remove V-belt and then remove generator (4). 10.3 INSTALLATION (1) Install the generator by the procedure reverse of the removal. (2) Tension of V-belt Adjust the tension within the following range by pushing the center of V-belt by thumb. Tension (Deflection) :8 to10 mm (0.3 to 0.4 in)

CRANK PULLEY

Fig. 10-2 Tension of V-belt

33 –I–1–17

11. STARTER 11.1 PREPARATION FOR REMOVAL (1) Remove cover assy (18) in front of the seat stand. (See Article 3-1- (10).)

(2) Remove plate (3) in the rear of the floor plate. (See Article 3-2- (1).)

SEAT STAND

(3) Loosen 2 sems bolts (38) M8 X 16 and remove cover assy (19). : 13 mm (4) Push down seat, and remove battery cover. Disconnect the connector on the negative terminal side of the battery. (5) Push down relay box toward front. Remove canopy to make the work easier.

•

Fig. 11-1 Removing cover assy (19) 11.2 REMOVAL (1) Remove the starter B terminal. : 13 mm (2) Remove the connector of the starter S terminal. : 7 mm or screw driver (-) (3) Loosen 2 attaching bolts (1) and remove the starter. : 19 mm ENGINE HARNESS

S TERMINAL T=0.2 kgf·m (1.4 lbf·m)

TO BATTERY B TERMINAL T=0.88 kgf·m (6.4 lbf·m)

Fig. 11-2 Removing startrer

Detail of terminal 11.3 INSTALLATION Install the starter by the procedure reverse of the removal.

33 –I –1–18

12. MUFFLER 12.1 PREPARATION FOR REMOVAL (1) Slew the upperstructure right about 30 degrees. (2) Remove under cover (3) under the muffler. : 17 mm Torque : 5.3 kgf·m (38 lbf·ft) (3) Remove cover assy (8). (See 2.1-(8)) 3

Fig. 12-1 Removing under cover 7

12.2 REMOVAL (1) Loosen capscrew (12) from outside of counterweight, and remove exhaust tube (3). : 17 mm

After BU, the shape of this parts are different

1 13 14

(2) Loosen and take out one nut (14) and 2 nuts (15) through the under cover section. : 13 mm

A 7

(3) Loosen 2 capscrews (13) and remove 2 clamps (7). : 13 mm B

(4) Take out muffler (1) drawing it downward.

• The figure shows before BU.

Fig. 12-2 Removing muffler 15

12.3 INSTALLATION Install the muffler by the procedure reverse of the removal following the Tightening Torque Table.

Code

Parts

Tools (mm)

Torque kgf·m (lbf·ft)

Capscrew

2.4 (17)

Capscrew

2.4 (17)

50°

14 (A) 14 (B) Nut

Bead of shell welding

2.4 (17)

• The figure shows before BU.

Assemble the clamps should not be contacted with bead portion.

Fig. 12-3 Installing muffler

33 – I – 1 – 19

13. PUMP 13.1 PREPARATION FOR REMOVAL (1) Remove cover assy (17). (See Section 2.) (2) Remove the counterweight. (See Section 6.) (3) Bleed the internal pressure of hydraulic tank and drain hydraulic oil. (See Section 8.)

C/V

C/V P1

C1 C2

13.2 REMOVAL (1) Removing the hose and the joint connecting the pump Tag the hose to identify.

C/V P3

A1 A3

•

1) Add pilot delivery oil hose (B16). : 22 mm 2) Disconnect drain hose (B2). : 19 mm

S/V T Z

B2 A4

S/V

3) Remove clip (11) and disconnect suction hose (5). : Screwdriver (-)

B16

4) Loosen 4 capscrews (14) M12x35 and remove tube (12).

11 12

: 10 mm

5) Disconnect main pump delivery oil hoses (2) (3) (4). : 27 mm

Fig. 13-1 Removing pump

(2) Loosen 2 capscrews (C2) M12 X 35 and remove pump (C1). : Ball joint type : 10mm Pump weight: 36 kg (80 lb)

13.3 INSTALLATION Install the pump by the procedure reverse of the removal following the indication.

T=8.9 kgf·m (64 lbf·ft) Do not use Loctite because of this bolt is applied coating. Apply grease

(1) Apply grease on the spline section of the pump input shaft. Grease: SHELL Retinax AM grease (or equivalent) (Molybdenum disulfide extreme pressure multipurpose grease) : MoS 2 grease (2) Insert the pump spline section in the coupling.

C2 T=14.6 kgf·m (106 lbf·ft) T=6.7 kgf·m (48 lbf·ft) Apply Loctite #262

(3) Install the pump with capscrew (C2). : Ball joint type : 10mm

Fig. 13-2 Installing pump

33 –I –1–20

(4) Connect main pump delivery oil hoses (2) (3) (4), pilot delivery oil hose (B16) and drain hose (B2). (See Fig. 13-1.) Tightening torque kgf·m (lbf·ft) Thread size Spanner in use (PF) (mm)

O-ring type joint

30˚flare type

1/4

3.7 (27)

3.0 (22)

3/8

7.5 (54)

5.0 (36)

1/2

11.0 (80)

8.0 (58)

(5) Tighten capscrew (14) and connect suction tube (12). : 10 mm T=11.0 kgf·m (80 lbf·ft) (6) Apply sealant to the tube on the suction hose (5) inserting section and fix clip (11). : Screwdriver (-) T=0.55 kgf·m (4.0 lbf·ft) (7) Return all equipment removed during the preparation. (8) After supply of hydraulic oil {approx.48 L (13 gal)}, bleed the air in circuit. (See section 8.3)

33 –I–1–21

14. RADIATOR after BU

14.1 PREPARATION FOR REMOVAL (1) Remove panel assy (3). (See Section 2.)

(A13)

• Remove the relating cover, equipment, etc. to make the work easier, if necessary.

CLIP (A14)

14.2 REMOVAL (1) Bleeding the water of radiator. 1) Remove the radiator cap. 2) Loosen drain cock (A6) to drain.

•

A4 A9

(After BU) Remove drain plug (A14) to drain.

Capacity : Approx.1.8 L (0.5 gal)

B1 A

(2) Disconnecting oil cooler piping. 1) Release the pressure of the hydraulic circuit. 2) Disconnect hoses (1) (3) of the oil cooler, and plug the inlet and outlet of the oil cooler and the hoses. (3) Remove clip (A9) and disconnect hose (A4) of reserve tank (A5).

A8 B2-1 A2 B2-2 A8 A1

A8 A12

(4) Disconnect radiator hoses (A1) (A2) clipped with (A7) (A8).

B4 A10

Tools : Cutting plier, Minus screwdriver

A A6

(5) Loosen capscrew (B2-1) and remove stay (B1). : 17 mm

• The figure shows before BU.

Fig. 14-1 Removing radiator

(6) Loosen capscrew (A12) and disconnect hose (A3) and boss (A10) together. : 17 mm

•

(After BU) Remove hose (A13) and plug (14) from frame.

(7) Loosen 2 capscrews (B2-2) and remove radiator assy (C1).

: 17 mm Weight : 19 kg (42 lb) ............. SK40SR-2 : 20 kg (44 lb) ............. SK45SR-2 (8) Remove shims (B4) and (B5).

Fig. 14-2 Disconnecting oil cooler piping

33 – I – 1 – 22

14.3 INSTALLATION (1) Install the radiator by the procedure reverse of the removal. Adjust the space between the fan and the radiator shroud to be 28.5mm(1.1in).

(2) Before installation, apply sealant:Loctite #262 to capscrew (B2-2) for installation of the radiator.

SHROUD

28.5

(3) The fan and shroud should be installed adjusting the spacing according to Fig.14-3.

Relating Parts Tightening Torque Code

Parts

A12 B2-1 Capscrew (M10) B2-2

Tools (mm)

Torque kgf·m (lbf·ft)

4.7 (34)

Adjust the space between the fan and the radiator shroud to be 15mm (0.6in) around the fan.

(4) Making up coolant (LLC : Long Life Coolant). For the mixing ratio of LLC, refer to the Chapter 4 MAINTENANCE in Operator’s Manual.

33 –I–1–23

FAN

Fig. 14-3 Installation of radiator

15. ENGINE 15.1 PREPARATION FOR REMOVAL (1) Remove the canopy. (See Section 1.) (2) Remove the seat stand. (See Section 5.) (3) Remove the counterweight. (See Section 6.) (4) Remove the radiator. (See Section 14.) (5) Remove the pump or disconnect the hose. (See Section 13.) (6) Remove the battery grounding.(See Section 4).

* * 24

Fig. 15-1 Removing fuel hose, Removing fuel pump 15.2 REMOVAL (1) Disconnecting fuel hose Disconnect every hose at

16-7

marks position.

(2) Removing fuel pump (24) (OPT) 1) Pull out connector (2FY-BS) of the harness for auto air bleeding. (For details, refer to the chapter 23 “Electric System”.) 2) Loosen 2 capscrews (25) M6 X 12, and remove fuel pump (24) from engine bracket. : 10 mm

2 5

Air cleaner (1)

8 5 5

(3) Separating air cleaner (1) Loosen clamp (5), disconnect hose (3) from engine. And pull out the connector for indicator ( KAI only) (16-7). : Screwdriver (-)

Fig. 15-2 Separating air cleaner (1)

14 2 15

(4) Removing exhaust tube (2) Loosen 5 nuts (14) and 2 nuts (15), and remove exhaust tube (2). : 13 mm

After BU, the shape of this parts are different.

• The figure shows before BU.

A B

Fig. 15-3 Removing exhaust tube (2)

33 – I – 1 – 24

(5) Removing support (10) Loosen 4 capscrews (21) M12 X 45, and remove support (10) and the air cleaner together.

B 10

: 19 mm (6) Disconnecting harness·cable. (For details, Refer to the Chapter 23 “Electric System”.) 1 Disconnect B terminal of starter motor (M-1) of the battery cable on the positive side. (See section 11.) 2) Remove the engine grounding cable.

21 21

Fig. 15-4 Removing support (10)

Prepare the stand on which the engine assembly can be placed. (7) Removing engine 1) Removing engine attaching capscrew (9), (15) Loosen 2 capscrews (9) M12 X 115 and 2 capscrews (15) M12 X 120 that the capscrews fix the engine to 3 rubber mounts (5) and to one rubber mount (6). 2) Hanging engine Sling and hang the engine from 2 hooks on the top of the engine. Weight : Approx.180 kg (400 lb)

After BU, the shape of the brackets (1) (2) are different. 9 15 8

5 6

A 8

3) Place the engine on the stand in the stable condition.

15.3 INSTALLATION (1) Install the engine by the procedure reverse of the removal. For the tightening torque and Loctite, refer to figure below.

Code

Parts

Tool (mm)

Torque (lbf·m)

Capscrew (M10)

4.7 (34) Apply Loctite #262

9,15

Capscrew (M12)

8.1 (59) Apply Loctite #262

8 5 3 9

8 14

• Use mount rubber marked [A] to identify with mount rubber (5). (3 places)

• Use mount rubber marked [C] to identify with mount rubber (6). (1 place)

5 4

• The figure shows before BU.

33 – I – 1 – 25

Fig. 15-5 Removing engine

16. CONTROL VALVE 16.1 PREPARATION FOR REMOVAL (1) Remove the canopy. (See Section 1.)

16.2 REMOVAL (1) Disconnecting hose Disconnect all hoses connecting to the control valve, and tag for identity and plug for prevention for entry of dust.

(2) Remove the floor plate assy. (See Section 3.) (3) Remove cover assy (7). (See Article 2.1-(7).)

• Fig. 16-1 and 16-2 show the

(4) Bleed the internal pressure of hydraulic tank.

EU , OCEANIA

specification. In KAI case,the operation of boom swing (and Nibbler & Breaker [after BU]) are actuated by hydraulic pilot line in place of EU , OCEANIA direct drive cable of swing pedal. However, the hose replacement is a same procedure. S/M

A10

A14

ARM (H)

BOOM S/J (R)

S/ J : SWIVEL JOINT S/M : SLEWING MOTOR

S/J F

S/J

A13

SWING A6

A15 S/J

A4 BOOM

(H)

A11 S/M B

B8 B1

BUCKET A8 (R)

ARM (R)

BUCKET (H)

A6 SWING H

A12 S/J

S/J

A28

PUMP PUMP A2

S/M

6 P1

G G1

S/J

Dr1

PUMP A1

The figure shows before BU.

5 A3 B3

•

SELECTOR N&B

O/C (IN)

Fig. 16-1 Removing main hose

33 – I – 1 – 26

P/V : PILOT VALVE C/B : CONTROL BLOCK SHUT/V C

B28

SHUT/V

B30

P/V

C/B

Pa2

P/V

Pa2

Pa5

Pa6

A6 Pa6 C5

Pb2

Pa7

Pa8

Pa7 Pb2 Pb5

C/B

Pb6

SHUT/V Pb7

B29

Pb6

Pa9

Pb7

Pa8'

Pb9

P/V A2

P/V 2

S/V

C/B 16

B18

C/B C/B 9

•

The figure shows before BU. Fig. 16-2 Removing pilot hoses DOZER CABLE

(2) Removing cable Disconnect cables (21) and (22) from the control valve while turning rod end (35).

EU, OCEANIA : SWING CABLE KAI : N & B CABLE

KAI specification is equipped the cable for N & B in place of the swing cable (22). Remove N & B cable in the same way. by hydraulic pilot line, then N & B cable is not equipped. (after BU)

• The operation of Nibbler & Breaker is actuated

22 35

• The figure shows before BU.

Fig. 16-3 Removing cable

(3) Removing N & B rod ( EU only) Loosen nut (13) and (15), remove rod (17) from control valve.

13 17 15 Fig. 16-4 Removing rod

33 – I – 1 – 27

(4) Removing control valve 1) Loosen 3 capscrews (2) M10 X50 and remove control valve (A1) and bracket (1) together.

DOZER SLEWING SUPPLY NIBBLER & BREAKER

: 17 mm Weight : Approx. 46 kg (101 lb)

BOOM SWING ARM TRAVEL (Right) SUPPLY & TRAVEL STRAIGHT TRAVEL (Left) BOOM BUCKET

2) Loosen 2 capscrews (4) M10 X 25 and one capscrew (10) M8 X 90, and remove control valve (A1).

: 13, 17 mm Weight : 35 kg (77 lb)

•

The figure shows before BU. Fig. 16-5 Removing control valve

16.3 INSTALLATION (1) Install the control valve by the procedure reverse of the removal. (2) Tighten capscrew (4). Clean the mating surface and pay attention in order not to deform the valve. : 17 mm (3) The tightening torque on hose, etc. as shown below. Tightening torque kgf·m (lbf·ft) Thread size Spanner in use (PF) (mm) 1/4 3/8 1/2 3/4 1

19 22 27 36 41

O-ring type joint

30˚flare type

2.7 (20) 7.5 (54) 11.0 (80) 16.5 (120) 26.0 (188)

3.0 (22) 5.0 (36) 8.0 (58) 12.0 (87) –

Note)

Take care of the torque for pilot port (PF 1/4) because this control valve is made of alminum. (4) Check hydraulic oil level, if the level is low, replenish the specified oil. (See Section 8.3) (5) Check the operation while operating the attachment. (6) Check the oil level and that it is free from oil leakage.

33 – I – 1 – 28

17. SOLENOID VALVE 17.1 PREPARATION FOR REMOVAL (1) Remove left deck cover assy (7). (See 2.1-(7)) 17.2 REMOVAL (1) Disconnecting hose Disconnect all hoses connecting with the solenoid valve, and tag for identity and plug for prevention for entry of dust.

B26

(2) Disconnect the connector from main harness. (3) Loosen 2 sems bolts (B23) M8 X 25, and remove solenoid valve (B26). : 13 mm T=3.0 kgf·m (22 lbf·ft)

B23 B26

17.3 INSTALLATION (1) Install the solenoid valve by the procedure reverse of the removal. Thread size Spanner in use (mm) (PF) 1/4 3/8

Note)

19 22

O-ring type joint kgf·m (lbf·ft) 2.7 (20) 7.5 (54)

Take care of the torque for solenoide valve because this valve is made of alumi-

num.

33 –I–1–29

Fig. 17-1 Removing solenoid valve

18. PILOT VALVE 18.1 PREPARATION FOR REMOVAL The procedure is the same on both sides, so explain the procedure for the right side.

34 34-1 34-2 34-3

(1) Disconnect negative terminal of the battery.

BOOTS

(2) Bleed the internal pressure of hydraulic tank.

(3) Remove the control box and monitor panel on both right and left sides. (4) Remove sems bolts (55) (56) and remove cover assy (33) (34). (See Figure 18-1.) : Screwdriver (+)

55 56

• The figure shows before BU.

Fig. 18-1 Removing cover (RH control box) B5 T=1.1 kgf·m (8.1 lbf·ft)

18.2 REMOVAL mark position and * plug all holes, and tag all hoses in order to iden-

1) Remove every hose at the

tify when assembling. 2) Shift the boots and remove 4 capscrews (B5).

P 3 4

: 10 mm

2 1

3) Remove pilot valve (A1).

18.3 INSTALLATION (1) Install the pilot valve by the procedure reverse of the removal following the tightening torque shown below. 1) Attaching sems bolts (9) (10). : Screwdriver (+) T=0.27 kgf·m (2.0 lbf·ft) 2) Installing hoses, etc.

* *

C/B S/V

C/B

* C/B

C/B

S/V A2

Fig. 18-2 Removing hoses

Tightening torque kgf·m (lbf·ft) Thread size Spanner in use (mm) (PF) 1/4 3/8

19 22

O-ring type joint

30˚flare type

2.7 (20) ––––

3.0 (22) 5.0 (36)

Note) Take care of the torque for pilot valve because this valve is made of aluminum. (2) Check the function while operating the attachment. (3) Check the oil level and that it is free from oil leakage. Fig. 18-3 Port position of pilot valve

33 – I – 1 – 30

19. SLEWING MOTOR 19.1 PREPARATION FOR REMOVAL (1) Remove cover (36) of guard and bracket assy (9). (See 2.1-(9) (10)) (2) Remove the floor plate assy. (See Section 3.) (3) Release the internal pressure of pipe line and hyd. tank.

A11 C/V B2

C/V A2

A10 Fig. 19-1 Removing main hoses

19.2 REMOVAL (1) Disconnect 5 hoses connecting to the slewing motor. (See Figure 19-1 & 19-2) : 22 mm, 27 mm

TANK

2 TANK

4 C/V

S/J

Fig. 19-2 Removig main hoses

(2) Disconnect 2 pilot hoses (B20) (B47) connecting to the slewing motor. : 19 mm

SH PG

B20

B47 Fig. 19-3 Removing pilot hoses

33 –I–1–31

(3) Loosen 8 capscrews (1) M16 X 45 and remove the slewing motor. : 24 mm (Approx.350 mm (14 in) Long type Weight : Approx.43 kg (95 lb)

Slewing motor

Fig. 19-4 Removing slewing motor 19.3 INSTALLATION (1) Install the slewing motor by the procedure reverse of the removal following the tightening torque shown below. 1) Apply Loctite #515 all around the attaching surface of the slewing motor. 2) Attach capscrew (1) for mounting the motor. : 24 mm T=28.5 kgf·m (206 lbf·ft) Apply Loctite #262 3) Installing hoses Tightening torque kgf·m (lbf·ft) Thread size Spanner in use (PF) (mm) 1/4 3/8 1/2

19 22 27

O-ring type joint

30˚flare type

3.7 (27) 7.5 (54) 11.0 (80)

3.0 (22) 5.0 (36) 8.0 (58)

(2) Check hydraulic oil level, if the level is low, replenish the specified oil. (See Section 8.3) (3) Check the function while operating the slewing motion. (4) Check the oil level and that it is free from oil leakage.

33 –I –1–32

20. SWIVEL JOINT 20.1 PREPARATION FOR REMOVAL (1) Raise the machine about 30cm (1ft) from the ground. Raise the machine and place 4 supports on the front and rear, and the right and left sides of the crawler shoe.

Fig. 20-1 Raise the machine

(2) Remove bracket assy (9) of guard and cover (36). (See Article 2.1-(9) and (10).) (3) Remove cover assy (2) of the floor plate. (See Article 3.1-(4).) (4) Loosen 4 sems bolts (2) M10 X 25 and remove under cover (1). : 17 mm (5) Release the internal pressure of pipe line and hyd. tank. (6) Disconnect the hose for the slewing motor. (See Section 19.)

1 2

• Remove the canopy to make the work easier.

Fig. 20-2 Removing under cover before BU

C/V A7

C/V B1

20.2 REMOVAL (1) Disconnect all remaining hoses from the upper side. : 19 mm

A13

A12 A28

A15

C/V C/V

C/V

A14

after BU

C/V B7

C/V C/V A13 B6 A7 A12 C/V B1

C/V

A28

Fig. 20-3 Removing upper side hoses

A15

A10

D A C/V E A6 A9

A3 A4

C/V A14 A1

(2) Disconnect all remaining hoses and tubes connecting to the swivel joint.

• Plug the connection and tag the hoses and

A G

A1 A2

tubes.

Fig. 20-4 Removing lower side hoses

33 – I – 1 – 33

(3) Removing stopper Loosen 2 capscrews (10) M12 X 40 and remove stopper (2). : 19 mm (Long size of 300mm (12 in) is required.)

Fig. 20-5 Removing stopper C2

(4) Removing swivel joint Loosen 4 capscrews (C2) M14 X 35 from the lower side and remove swivel joint (C1) from the lower side. : 22 mm Weight : 22 kg (49 lb)

20.3 INSTALLATION (1) Install the swivel joint by the procedure reverse of the removal following the tightening torque shown below.

20-6 Romoving swivel joint

1) Attaching capscrew (C2) DOZER(H)

: 22 mm T=18.5 kgf·m (134 lbf·ft) Apply Loctite #262

DOZER(R)

F E P P D

2) Attaching capscrew (10)

A (above) FORWARD

: 19 mm T=11.7 kgf·m (85 lbf·ft)

Tightening torque kgf·m (lbf·ft)

1/4 3/8 1/2

19 22 27

B (below) REVERSE

3) Installing hoses. Thread size Spanner in use (PF) (mm)

B A

O-ring type joint

30˚flare type

3.7 (27) 7.5 (54) 11.0 (80)

3.0 (22) 5.0 (36) 8.0 (58)

TRAVEL MOTOR (LH)

P B(above) FORWARD A (below) REVERSE D2 TRAVEL MOTOR (RH)

Fig. 20-7 Location of ports

4) Installing tubes Tightening torque kgf·m (lbf·ft) Tube dia. Spanner in use (PF) (mm) ø 10 ø 15 ø 18

19 27 32

Flareless type (Nut-Sleeve) 5.0 (36) 12.0 (87) 15.0 (108)

(2) Install all equipment removed during preparation as they were before. (3) Check hydraulic oil level, if the level is low, replenish the specified oil. (See Section 8.3) (4) Check the function.

33 –I –1–34

21. UPPER FRAME 21.1 PREPARATION FOR REMOVAL (1) Remove the floor plate assy. (See Section 3.) (2) Remove the guard, etc. (See Section 2) (3) Remove the counterweight. (See Section 6.) (4) Drain oil from the hydraulic tank. (See Article 8-2.) (5) Disconnect the hose on the upper side of the swivel joint. (See Article 20-2.) (6) Remove the stopper for the swivel joint. (See Fig. 20-5.) (7) Remove the attachment. (See Section “Boom” of Chapter “ATTACHMENT”.) (8) Remove the swing bracket. (See Section “Swing” of Chapter “ATTACHMENT”.)

UPPER FRAME SLEWING BEARING OUTER RACE

21.2 REMOVAL (1) Putting a match mark on the slewing bearing Put a match mark on the upper frame and the slewing bearing outer race.

5, 6

Fig. 21-1 Slewing bearing and upper frame

(2) Hanging upper frame temporarily. Sling the upper frame at three points, a swing bracket attaching hole position on the front side and two positions on the support (10) of rear side of the upper frame. (3) Removing upper frame installing bolt Remove 19 capscrews (7) for securing the slewing bearing and the outer race and one reamer bolt (8). : 22 mm (4) Removing upper frame Raise the upper frame slightly, and remove and place it on the stand after being sure that it is safe. Weight : Approx.1150 kg (2540 lb) .... SK40SR-2 1600 kg (3530 lb) ... SK45SR-2

Fig. 21-2 Hanging upper frame temporarily

33 –I–1–35

21.3 INSTALLATION (1) Install the upper frame by the procedure reverse of the removal. (2) Cleaning connecting surface. Clean the lower surface of the upper frame and the upper surface of the slewing bearing. (3) Apply Loctite #515 to mating surface between upper frame and outer rece.

Apply Loctite #515 to all hatched areas only. (Coat the race inside of the capscrews)

(4) Slinging procedure 1) Sling the upper frame and hang it horizontally. 2) Check the match mark put on it when disassembling. 3) Fit the match mark and lower the upper frame checking the engagement of the slewing pinion gear and the internal gear of the slewing bearing inner race.

Fig. 21-3 Installing slewing bearing

(5) Installing slewing bearing and upper frame 1) Apply Loctite #262 to one reamer bolt and 19 capscrews (7) and tighten them temporarily.

Apply Loctite #515 to hatched portion

2) Tighten the reamer bolt and capscrews to the specified torque spacing at 180°interval on the back and forth and the right and left. : 22 mm T=18.5 kgf·m (134 lbf·ft) Apply Loctite #262

Outer “S”zone

Reamer bolt

(6) Install all equipment removed during working as they were before and be sure it functions correctly.

Fig. 21-4 Position of reamer bolt

33 –I –1–36

Part II : DISASSEMBLING AND ASSEMBLING 1. HYDRAULIC PUMP 1.1 CONSTRUCTION

No.

Parts name

No.

Parts name

DRIVE SHAFT

CONTROL PISTON

HANGER

GEAR PUMP

ROTARY GROUP

HOUSING

COVER

TROCHOID PUMP

CONTROL SPRING

Note) Refer to section 1.HYDRAULIC PUMP in COMPONENTS SYSTEM PJ 24 for detail.

33 –II–1–1

1.2 DISASSEMBLY AND ASSEMBLY Refer to Article PJ24 for internal construction of this pump. (1) Tools and Jig 1) Tools

•

Tools Allen wrench

Q'ty

Size (Nominal)

Tools Torque wrench

One each 4.5.6.8.10

Plastic mallet

Medium type

Socket wrench

Snap ring plier

For hole(for snap ring 72)

Grease

Snap ring plier

For shaft(for snap ring 28,30)

Adhesive agent

Q'ty

Size (Nominal)

For the specified torque

10 1 Small amount Small amount Loctite #270

2 Jig 1. Working bench Plate which is used to set the pump shaft facing downward. If the shaft end does not contact with the work bench, the wood block is available instead of it.

Working bench (Plate)

2. Jig for bearing

Jig for bearing

(2) General precautions 1) Carry out the disassembly and assembly in a clean area, and prepare clean containers to put the removed parts in.

5) Replace all seals with new ones by disassembly and apply grease to them.

2) Before disassembling, clean around the ports, and remove the coating on every connection with wire brush.

7) Don’t tamper with adjusting screw unnecessarily.

6) Check that every part is free from wear and seizure, and remove burr, etc. with emery paper.

3) Clean the removed parts with cleaning solvent. 4) Put a matchmark on every part and assemble it meeting the matchmark.

33 –II–1–2

1.3 DISASSEMBLY 1) Removing gear pump 1. Remove 2 socket bolts (M10 X 25). : 8 mm

2. Remove the coupling.

2) Removing trochoid pump 1. Remove three socket bolts (M5 X 12). : 4 mm

2. Remove the cover using two socket bolts (M5 X 50).

33 –II–1–3

3. Take the gear out of the casing.

4. Remove side plate (A) from the casing.

5. Remove side plate (B) from the casing.

6. Remove the key from the shaft

33 –II–1–4

3) Disassembling main pump 1. Removing cover Since the control spring is strong, remove three socket bolts (M12 X 30) and one (M12 X 55). : 10 mm

2. Remove cover Pay attention not to drop the control plate attached on the back side.

•

• If it is hard to remove cover, tap cover with plastic mallet lighty.

3. Removing the control spring section Remove two springs (inside and outside).

4. Remove the spring seat.

33 –II–1–5

5. Place the pump laterally and remove the rotary group from the shaft.

6. Remove plate.

7. Remove shaft. Remove snap ring with plier. Snap ring plier (for hole : ø 72)

8. Remove oil seal casing using two minus screwdriver.

33 –II–1–6

9. Remove O-ring

10. Tap lightly rear end of shaft with plastic mallet, and remove shaft.

11. Removing hanger. Remove four socket bolts (M6 X 16) and plate. : 5 mm

12. Remove distance piece.

33 –II–1–7

13. Remove bearing.

14. Remove hanger.

15. Removing cover. Remove control plate.

16. Removing control piston. Remove two socket bolts (M8 X 25). : 6 mm

• Loctite #270 is applied on the threaded part of socket bolt, so remove it only when required.

33 –II–1–8

17. Remove cylinder and parallel pin.

• Take care not miss those O-ring fitted on cylinder section. (2 pcs)

18. If equipped, remove piston for air-conditioner mode.

19. Remove piston.

20. Remove disk springs and spring seats. SK40SR-2 : 4 pcs. SK45SR-2 : 3 pcs.

33 –II–1–9

21. Removing control spring seat. Remove two socket bolts (M8 X 30) and remove cover. : 6 mm

22. Remove spring seat.

23. Removing shaft. Removing bearing. Remove snap ring from shaft, using snap ring plier. Snap ring plier (for shaft : ø28, ø30)

24. Place bearing in the vise, and lightly tap rear end of shaft with plastic mallet then remove bearing from shaft.

Protector

33 –II–1–10

4). Disassembling gear pump 1. Loosen four socket bolts (M10 X 20). : 8 mm

2. Remove the cover.

3. Remove the square ring.

4. Remove the plate, guide and O-ring.

33 –II–1–11

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

33 –II–1–12

1.3 MAINTENANCE STANDARD (1) Parts replacement standard Item

Replacement criterion

Remedy

inspection • Visual •Replace To be free from flaw, scuffing and PISTON ASSY

CYLINDER BLOCK

Piston assy and cylinder block

wear. (Especially the sliding section) clearance between the piston • Check outer diameter and inner diameter of the cylinder block. To be D-d 0.05mm

PISTON

SHOE

• Replace • Piston shoe and piston the play in the axial direction • Check of the piston and shoe. To be

Piston shoe and piston

OIL SEAL INSTALLING RANGE

0.2mm

• Shaft • Replace the wear of the oil seal insta• Check lling range. To be Wear

Shaft

0.025mm.

that the sliding surface is free • Replace it when • Check from flaw. the flaw is severe.

Control plate

that it is free from gall and it in set • Check • Replace step wear. if it is impossible

GUIDE

to correct.

Guide and retainer

that it is free from slight gall • After correction • Check with lapping, and flaw.

clean it to remove the lapping compound.

RETAINER

33 –II–1–13

(4) Installing 1) Assembling of main pump 1. Installing hanger assy. Install hanger in housing.

2. Install bearing.

3. Install distance piece and check the preload of bearing is 0.1 ± 0.02mm confirming the distance by means of micrometer and depth micrometer.

4. Install the plate with four socket bolts (M6 X16). : 5 mm Torque : 1.35 kgf·m (9.8 lbf·ft)

33 –II–1–14

5-1.Assembling shaft assy. Place bearing on the pedestal, and press-fit shaft with jig. When there is no press, drive the shaft with jig and plastic mallet in the same manner as the above. JIG

SHAFT

5-2. Fix snap rings and bearing. Snap ring plier (for shaft : ø28, ø30)

5-3. Install shaft in housing and tap the spline end with a plastic mallet lightly to fit outer race of bearing into the hole of housing completely.

6. Apply grease on O-ring and fit it.

33 –II–1–15

7. Install seal casing with oil seal in housing straight along axis.

• Apply grease on oil seal lip.

8. Fix snap ring to housing and fix shaft.

9. Assembling rotary group. Install ten pistons in retainer of rotary group.

10. Apply grease on three parallel pins, fit it in the cylinder block.

33 –II–1–16

11. Apply grease on sphere portion of guide.

12. Install guide between retainer and cylinder block and insert pistons in the holes of cylinder block.

13. Installing rotary group. Install plate in hanger. In this case, apply grease on the rear surface of plate to prevent dropping. Rear

Apply grease to this side

Front

Ground side

14. Align rotary group with spline of shaft, and install it to inside of housing.

• Apply grease on sliding surface of piston shoe

and sliding surface to the control plate of cylinder block.

33 –II–1–17

15. Apply grease on the sphere portion of spring seat and install it to hanger in housing.

16. Fit two springs, inner and outer.

17. Fit spring seat and disk springs to cover assy. SK40SR-2 : 4 pcs. SK45SR-2 : 3 pcs. DIRECTION OF FITTING

DISK SPRING SPRING SEAT

18. Install control piston.

33 –II–1–18

19. If equipped, install piston for air-conditioner mode.

20. Apply grease on O-rings, and fit them to cylinder.

21. Apply grease on two parallel pins (ø10) and one parallel pin (ø7.5) and install them to cylinder.

22. Install cylinder with two socket bolts (M8 X 25).

• Apply Loctite #270 to thread portion. : 6 mm Torque : 3.25 kgf·m (23.5 lbf·ft)

33 –II–1–19

23. Install spring seat in control spring section.

24. Install cover with two socket bolts (M8 X 30). : 6 mm Torque : 3.25 kgf·m (23.5 lbf·ft)

25. Apply grease to rear surface of control plate and install it on the cover to align the hole with parallel pins.

26. Fit five O-rings (2 kinds), on mating face of cover. O-ring

O-ring

33 –II–1–20

O-ring

27. Install cover parallel to the attaching surface of housing.

28. Install cover with three socket bolts (M12 X 30) and one socket bolt (M12 X 55). : 10 mm Torque : 11.3 kgf·m (81.4 lbf·ft)

2) Assembling trochoid pump 1. Insert the key in the shaft. TROCHOID PUMP SIDE

ROUND SIDE

KEY

COVER SIDE

Insert the key directing the round side to the trochoid pump side.

2. Install side plate (B) on the cover.

33 –II–1–21

3. Install side plate (A) and the plate on the casing.

4. Place the gear in the casing.

• Install directing the match mark face to side plate (B) side.

MATCH MARK

INNER ROTOR OUTER ROTOR

5. Install casing to cover.

6. Install casing with three socket bolts (M5 X 12). : 4 mm Torque : 0.75 kgf·m (5.4 lbf·ft)

33 –II–1–22

3) Assembling gear pump 1. Fit the square ring to the plate on the assembling side of gear pump.

• Then pay attention to the suction and delivery direction.

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.

4. Insert the O-ring in the guide and then insert it in the plate. LARGE CHAMFERED SIDE

GUIDE

O-ring

O-ring PLATE

33 –II–1–23

5. Place the plate, guide and O-ring in the housing.

• Then pay attention to the suction and delivery direction.

SUCTION SIDE

DELIVERY SIDE

6. Fit the square ring.

7. Place the cover on the housing.

8. Fix the housing and the cover with 4 socket bolts (M10 X 25). : 8 mm Torque : 5.6~7.0 kgf·m (41~51 lbf·ft)

33 –II–1–24

9. Install O-ring on attaching surface of gear pump.

4) Installing gear pump 1. Fit the coupling to the shaft end on the main pump side.

2. Connect the gear pump to the main pump. Fix the gear pump with 2 socket bolts (M10 X 25). : 8mm Torque : 6.3 kgf·m (46 lbf·ft)

33 –II–1–25

NOTES

2. CONTROL VALVE 2.1 ASSEMBLY DRAWING

Bucket

Boom

Travel left

Supply

Travel straight

Travel right

Arm

Swing

Nibbler & Breaker

Supply

Slewing

Dozer

(1)-1 General view EU , OCEANIA

19 21

Manual operate

Pilot operate

3 14

5 15

10 16

Fig. 2-1-(1)

Table. 2-1-(1) No. 1 2 3 4 5 6 7

Parts name Dozer Slewing P3 supply Nibbler & Breaker Swing Arm Travel right

Q'ty No. Q'ty No. Parts name Parts name 1 8 P1‚P2 supply &Travel straight 1 16 Over load relief valve 1 1 9 Travel left 17 Anti cavitation valve 1 1 10 Boom 19 Tie bolt Bucket 1 1 12 20 Tie bolt 1 1 13 P1‚P2 Main relief valve 21 Nut 1 1 14 P3 Main relief valve 6 1 15 Over load relief valve

33 – I I– 2– 1 (1)

Q'ty 2 1 4 4 8

Bucket

Boom

Travel left

Supply

Travel straight

Travel right

Arm

Swing

(Applicable machines : PJ02-00101~)

Nibbler & Breaker

Supply

Slewing

Dozer

(1)-2a General view KAI

19 21

Manual operate

Pilot operate

3 14

5 15

10 16

Fig. 2-1-(2)

Table. 2-1-(2) No. 1 2 3 4 5 6 7

Parts name Dozer Slewing P3 supply Nibbler & Breaker Swing Arm Travel right

Q'ty No. Q'ty No. Parts name Parts name 1 8 P1‚P2 supply &Travel straight 1 16 Over load relief valve 1 1 9 Travel left 17 Anti cavitation valve 1 1 10 Boom 19 Tie bolt 1 1 12 Bucket 20 Tie bolt 1 1 13 P1‚P2 Main relief valve 21 Nut 1 1 14 P3 Main relief valve 6 1 15 Over load relief valve

33 – I I– 2 – 1 (3)

Q'ty 2 1 4 4 8

Bucket

Boom

Travel left

Supply

Travel straight

Travel right

Arm

(Applicable machines : PJ03-01001~)

Swing

Nibbler & Breaker

Supply

Slewing

Dozer

(1)-2b General view KCMA

19 21

Manual operate

Pilot operate

3 14

5 15

10 16

Fig. 2-1-(3)

Table. 2-1-(3) No. 1 2 3 4 5 6 7

Parts name Dozer Slewing P3 supply Nibbler & Breaker Swing Arm Travel right

33 – I I– 2– 1 (3)

Q'ty 2 1 4 4 8

(2) Component Parts The control valve consists of the following four major groups. • Manual operation : EU , OCEANIA Swing, Dozer blade, Nibbler & breaker. KAI Dozer blade, Nibbler & breaker (Applicable machines : PJ02-00101~) Dozer blade (Applicable machines : PJ03-01001~) • Pilot operation : EU , OCEANIA Travel straight ‚ Travel right & left ‚ Boom ‚ Arm ‚ Bucket ‚ Slewing KAI Travel straight ‚ Travel right & left ‚ Boom ‚ Arm ‚ Bucket ‚ Slewing, Swing (Applicable machines : PJ02-00101~) Travel straight, Travel right & left, Boom, Arm, Bucket, Slewing, Swing, Nibbler & Breaker (Applicable machines : PJ03-01001~) • Accessory : P1 ‚ P2 supply (in common travel straight) ‚ P3 supply • Accessory(Valve) : P1 ‚ P2 ‚ P3 main relief ‚ Overload relief ‚ Anti cavitation Note) For the operating section, some typical examples are described in the below. Refer to the chapter 33 for the disassembling of control valve. Table. 2-2 1) Manual operation : Swing (No.5) EU , OCEANIA Note) Swing control of KAI is operated by hyd. pilot line. 14 15

12 11

No. 1 2a 2b 2c 2d 2e 2f 2g 3 4 5 6 7 8 9 10 11 12 13 14 15

9 10 13 7 8

6 5 4 3

2a 2b 2c 2d 2e 2f 2g

Fig. 2-2

2) Pilot operation : Slewing (No.2)

7 8

No. 1 2a 2b 2c 2d 2e 3 4 5 6 7 8 9 10 11 12 14

11,12 5

2e 2d 2c 2b

Q'ty 1 1 1 1 1 2 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1

Table. 2-3

14 10 9

Fig. 2-3

33 – I I – 2 – 2

Q'ty 1 1 1 1 1 1 2 1 1 4 1 1 1 1 1 1 1

3) P1, P2 Main relief valve (MR1)

17 11

Table. 2-4

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Fig. 2-4

4) P3 Main relief valve (MR3)

Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Table. 2-5

Parts name

Fig. 2-5

33 –II–2–3

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Parts name Socket Pressure regulating valve Piston Plug Body Poppet Adjust screw Lock nut M14 Spring Spring O-ring 1B P15 O-ring 1B S10 O-ring 1B P7 Back up ring O-ring 1B P14

Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1

5) Over load relief valve (ORV)

Table. 2-6

Fig. 2-6

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

6) Anti cavitation valve (ACV)

Parts name Socket Pressure regulating valve Piston Plug Body Poppet Adjust screw Lock nut M14 Spring Spring O-ring 1B P15 O-ring 1B S10 O-ring 1B 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. 2-7

Fig. 2-7

33 –II–2–4

No. 1 2 3 4 5 6 7 8

Parts name Anti cavitaion valve Body Plug Spring Back up ring O-ring 1A P10A O-ring 1A S14 O-ring 1A 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, dirt 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 port is capped and clean the outer surface of the assy. The work should be carried out on the appropriate work bench which is covered by clean paper or rubber mat. (4) When it is required to leave it in the removed condition, apply rust inhibiter 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. 2-8 Tools

Q'ty

Remarks

Allen wrench

One each

4 , 5 , 6 , 8, 10 mm

Spanner

One each

13 , 19 , 21 , 22 , 30 mm

Socket wrench

One each

13 , 19 , 22 mm

Torque wrench

0.2 kgf·m ~ 2.0 kgf·m (1.4 ~ 14 lbf·ft)

Torque wrench

2.0 kgf·m ~ 12.0 kgf·m (14 ~88 lbf·ft)

Magnet

Pliers

Screw driver (-)

Tweezer

Hook wrench

Prepare cleaning solvent, hydraulic oil, grease, Loctite #242,tag and marker (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. 2-3 and 2-8.) First, loosen and remove 2 socket bolts (6) with allen wrench of 5mm. Then, remove pilot cover (4). 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 (3) 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 swing spool is as follows. (In KAI ,swing is controlled by hyd.pilot system) (Refer to Figures 2-2 and 2-9.) First, loosen and remove 2 socket bolts (7) with allen wrench of 5mm. Then, remove end cover (8). The spring section of the swing spool is exposed, 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. 12 11

10 9

9 10

7 8 11,12 6

6 6 5 4 3

2e 2d 2c 2b

2b 2c 2d 2e 2f 2g

Fig. 2-9 Manual switching type

Fig. 2-8 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. 2-10.) First, loosen and remove 2 socket bolts (8) with allen wrench of 5mm. Then, remove pilot cover (11). Spring (10) and spring seat (9) are exposed, so remove them. Draw out and take out spool assy (2a~2b) 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 (8) on the opposite side with allen wrench of 4mm, and pilot cover (7) can be removed and also filter case assy (4~6).

(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 allen wrench of 8mm. It may be difficult to loosen the plug because Oring (10) 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 (8), load check valve (7) through the hole used to remove the plug with tweezers or magnet. The numbers in Fig. 2-11 corresponds to the number of the slewing section in Fig. 2-3. The form of the travel, section differ, but they can be disassembled by the same procedure.

17 1

8 7

2a 2b 3 5 4

Fig. 2-10 P1 and P2 supply and travel straight section

(2) P1, P2 main relief valve (Code : MR1) P3 main relief valve (Code : MR3) 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 30) of MR1 and MR3, ORV with spanner of 22mm. At that time, don’t remove the valves applying spanner to the opposing flat 19. The set pressure of the MR1, and MR3, ORV differs at the position, so tag every valve with respective attaching position. And handle the removed MR1, MR3, and ORV paying attention not to damage the seat section. The MR1, MR3, and ORV are essential for the performance and safety, but don’t disassemble the MR1, MR3, and ORV because it is very difficult to reset the pressure. When there is a failure, replace the assy.

33 –II–2–7

Fig. 2-11 Load check valve Dozer, Slewing, Nibbler & Breaker, Swing, Arm, Boom, Bucket

PLUG O-RING

SPRING LOAD CHECK VALVE

Fig. 2-12 Load check valve (Travel right and left)

(4) Disassembling lock valve The disassembling method to check the abnormality is shown below for reference. (Refer to Figure 2-13,2-14) First, loosen and remove three socket bolts (27) with allen wrench of 5mm. And, remove pilot cover (14).

Fix the pilot cover with vise, and loosen and remove plug (18) with allen wrench of 8mm.

Pay attention to piston guide (12) projecting from the bottom of the pilot cover so as not to cause damage. Remove lock valves (6~10) and needle valve (11) which are exposed.

Put marks on piston C and piston A so that the installing directions can be seen easily. Don’t disassemble piston guide (12), but store it as a set with the pilot cover. When malfunction occurs, replace it with one set (12~14). Loosen ball retainer (21) with allen wrench of 4mm. Take out steel ball ø7 (20) from the hole where the ball retainer was removed with magnet.

Fix it with vise at the sides other than the port faces. Take out piston C (17), lock valve spring (16) and piston A (15) from the hole where the plug was removed by tweezer or magnet.

Remove and store the needle valve first because it drops out easily. Don’t disassemble the lock valve, but store it as one set (6~10). When malfunction occurs, replace it with one set (6~11).

Lock valve (6~10) 5

11 13

22,21

20 12 15 16

18,19

Fig. 2-13

22,21

Fig. 2-14

33 –II–2–8

18,19

(5) Disassembling other parts Remove the parts which are not removed yet by the procedures (1) to (4). 1) Pilot cover on hydraulic pilot switching section (Refer to Figure 2-8.) Loosen and remove two socket bolts and washer (6) with allen wrench of 5mm. Pull out pilot cover (5) horizontally. Then check that O-ring (3) on the bottom of the pilot cover installing flange on the main body side has not dropped out.

(7) Precautions when disassembling The parts removed during respective work shall be carried and stored, paying special attention to them so as not to damage them or make them dirty. And when other works, storage and carry are necessary in the state where the parts are removed, fill up the holes the parts are removed from with cap, tape, etc. to prevent the entry of dust, etc.

2) Spool seal on the manual switching section (Refer to Figure 2-9.) Loosen and remove two socket bolts (6) with allen wrench of 5mm. Concurrently oil seal retainer (5) is removed.Remove spool seal [ “O-ring (3), dust wiper (4) ] out of the spool hole on the side face of the main body with (-) driver, paying attention to spool seal and the switching section so as not to damage. Don’t reuse the removed O-ring, but replace it with new one. When reuse is unavoidable, check that it is free from damage, deformation, foreign matters adhered, etc. before attaching. (6) Disassembling switching section The numbers in ( ) just after the part name in the descriptions shows the symbol in the sketch drawing. (Figure 2-1) Loosen and remove four M8 nuts (21) on both sides, which are used to assemble the switching section on both sides of the valve, with spanner of 13mm (or socket wrench). Pull four tie-bolts (19,20) out of the side face, and respective switching section can be removed. Then, pay attention to various O-rings attached on the mating face of the respective switching section so as not to miss them. The switching section is equipped with several plugs screwed in. These plugs are used for spare holes, so disassemble them as required.

33 –II–2–9

(8) Disassembling anticavitation valve (ACV) The ACV is an essential part for performance. Therefore when the malfunction occurs, replace it with new one. The disassembling method to check the cause of the malfunction, etc. is shown below for reference. The numbers in ( ) just after part name in the descriptions shows the symbols in the sectional view. (Figure 2-7) First, fix the main body with vise lightly at the hexagonal sections of the opposing flat 22. Loosen and remove plug (3) with allen wrench of 8mm. After removal of spring (4), push anticavitation valve (1) in from the seat side, paying attention to the seat section so as not to damage, and pull O-ring (6) and back-up ring (5) out of the side from where plug (3) was removed carefully, paying attention to the inside of threaded section of body (2) so as not to damage. (9) Disassembling P1, P2 main relief valves (MR1) The MR1 is an essential part for performance and safety, and it is very difficult to reset it, so when the malfunction occurs, please replace it with new assy. The disassembling method to check the cause of the malfunction, etc. is shown below for reference. The numbers in ( ) just after part name in the descriptions show the symbols in the sectional view. (Figure 2-4) First, fix the main body with vise lightly at the hexagonal sections of the opposing flat 30. Loosen and remove lock nut M14 (7) with spanner of 19mm. Loosen and remove adjusting screw (6) with allen wrench of 4mm, and spring (8) and regulating valve (5) can be taken out with tweezer, etc. Then, fit the hook spanner to the hole of socket (1), and loosen and remove it. Consequently the remaining parts can be pulled out concurrently. And then, pull out regulating valve seat (12), piston (3), spring (9) and pressure regulating valve (2) in turn.

(10) Disassembling P3 main relief valve (MR3) The MR3 is an essential part for performance and safety, and it is very difficult to reset it, so when the malfunction occurs, please replace it with new assy. The disassembling method to check the cause of the malfunction, etc. is shown below for reference. The numbers in ( ) just after part name in the descriptions show the symbols in the sectional view. (Figure 2-5) First, fix the main body with vise lightly at the hexagonal sections of the opposing flat 22. Loosen and remove lock nut M14 (8) with spanner of 19mm. Loosen and remove adjusting screw (7) with allen wrench of 4mm, and spring (9) and regulating valve (6) can be taken out with tweezer, etc. Then, loosen and remove plug (4) with spanner of 19mm, and the remaining parts can be pulled out concurrently. And, pull out socket (1), piston (3), spring (10) and pressure regulating valve (2) in turn. (11) Disassembling overload relief valve (ORV) The ORV is an essential part for performance and safety, and it is very difficult to reset it, so when the malfunction occurs, please replace it with new assy. The disassembling method to check the cause of the malfunction, etc. is shown below for reference. The numbers in ( ) just after part name in the descriptions show the symbols in the sectional view. (Figure 2-6) First, fix the main body with vise lightly at the hexagonal sections of the opposing flat 30. Loosen and remove lock nut M14 (8) with spanner of 19mm. Loosen and remove adjusting screw (7) with allen wrench of 4mm, and spring (9) and regulating valve (16) can be taken out with pincet, etc. Then, loosen and remove plug (4) with spanner of 19mm., and the remaining parts can be pulled out concurrently. And, pull out socket (1), piston (3), spring (10) and pressure regulating valve (2) in turn.

33 –II–2–10

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 quantity 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) Don’t stretch the seals until it will be deformed 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–2–11

2.7 ASSEMBLY WORK 1. The assembling method is merely explained, so for figures refer to Section“Disassembly”. 2. Assembling procedure (1) Assembling the switching section (Refer to Fig. 2-1-1 (1) or 2-1-1 (2).) Put all sections in order as shown in Table directing the actuator port downward. Table. 2-7 MARK SK40SR-2, SK45SR-2 Dozer SA Slewing AN P3 supply NA Nibbler & Breaker BS Boom swing BT Arm BU Travel left DF P1,P2 supply FD Travel right OA Boom QA Bucket AO End cover HB SECTION (Block)

Note: The symbols are marked on the upper surface of the switching section (Actuator port face)

Then, check that the mating surface of the each switching section is free from dust, etc. and the O-ring is securely fitted in the groove. And, insert 4 tie bolts (19, 20) through the switching section from the side, and tighten 4 lock nuts M8 (21) to the specified torque with socket wrench of 13mm. T=2.0 kgf·m (14.5 lbf·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 mallet, etc. following the Fig.2-1, or make them uniform with press machine, etc. after tightening. (2) Assembling load check valve Put the load check valve of the valve on the work bench directing the actuator port upward. 1) Section other than travel (Refer to Fig. 2-11.) Place load check valve (7) in the hole at the cen-

ter of the valve in normal condition (direct the bevel section downward.), and check that it is placed in at the center. Fit spring (8) on the guide of the load check valve. Tighten the plug by hand so that the guide of the load check valve can be fitted on the guide of plug (9), and the spring can be in place. Then, check that O-ring (10) is fitted on the plug. Screw in with a certain amount, and tighten it to the specified torque with allen wrench of 8mm T=4 kgf·m (29 lbf·ft) 2) Travel section (Refer to Fig. 2-12.) Place the load check valve in the hole at the center of the valve in normal direction (direct the bevel 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 switching section can be fitted on the guide of the plug after checking that the check valve spring does not drop even when the plug is reversed up and down in this condition. Screw in with a certain amount, and tighten it to the specified torque with allen wrench of 8mm. T=4 kgf·m (29 lbf·ft) Assemble it paying attention to the position where two types of the load check valve are installed in proper position. (3) Assembling MR1, MR3, ORV and ACV Install the valves to respective ports for installation with the specified torque. MR1 : 6.5 kgf·m (47 lbf·ft) MR3,ORV and ACV : 4 kgf·m (29 lbf·ft) Observe the specified torque. When the respective valves are 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 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.

33 –II–2–12

(4) Assembling spool assy 1) In case of hydraulic pilot switching type, (Refer to Fig. 2-8.) Insert respective spool assy in the spool holes 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 switching section are free from dust, etc. and also O-ring (3) is securely fitted on the bottom of the flange of the switching section (2 places before and after the switching section.) Then, apply a slight hydraulic oil to the spool before insertion. And, don’t force the insertion of the spool due to the difficulty to getting in, or it may cause malfunction,etc. Next, check that the spool moves smoothly by getting it in and out several times by hand, and be sure that there are no unsmooth movements or catching. Where there is above feeling of the physical disorder, replace the set of the spool assy and the switching section. And, install pilot cover (4) on the flange section of the switching section from the spring side of the spool assy securely, and install it on the switching section by tightening socket bolt (6) with allen wrench of 5mm. T=1.05 kgf·m (7.6 lbf·ft) Fit the flange section on the opposite end of the switching section so that pilot cover (5) fits into the flange section of the switching section after checking that O-ring (3) is placed in, and then install it the switching section with socket bolt (10) tightening with allen wrench of 5mm to the specified torque. T=1.05 kgf.m (7.6 lbf·ft) 2) In case of manual switching type, (Refer to Fig. 2-9.) Insert respective spools in the spool holes of the switching section paying attention to the position and direction after checking that respective spool assy and the spool holes of the switching section are free from dust, etc.

getting it in and out several times by hand, and be sure that there are no unsmooth movements or catching. And, install end cover (8) on the switching section from the spring side of the spool assy with socket bolt (7) tightening with allen wrench of 5mm. T=1.05 kgf·m (7.6 lbf·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 switching section, and tighten socket bolt (6) with allen wrench of 5mm. T=1.05 kgf·m (7.6 lbf·ft) 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 retainer is inserted in parallel. 3) In case of travel straight section (Refer to Fig. 2-10.) Install the filter case assy on the flange section of the switching section paying attention to the direction after checking that the travel spool and spool holes of the switching section are free from dust, etc. and O-ring (3) is securely fitted on the flange bottom of the P1 and P2 supply section (2 places before and after the 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 (6) is placed in filter case (4). And, don’t force the insertion of the spool. Install spring seat (9) and spring (10). And fit pilot cover (11) on the flange section securely, tightening socket bolt (8) to the specified torque with allen wrench of 5mm. T=1.05 kgf·m (7.6 lbf·ft)

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

33 –II–2–13

(5) Assembling lock valve The assembling method is shown below when it was disassembled to check the cause of the malfunction for reference. (Refer to Figures 2-13,2-14) First, fix pilot cover (14) with vise at the side faces other than the port face. After fixing the pilot cover, insert piston A (15) in the hole on piston guide (12), paying particular attention to direction. After inserting piston A, and then after inserting lock valve spring A (16) and piston C (17) in the hole on the pilot cover paying particular attention to the direction, tighten plug (18) to the specified torque with allen wrench of 8mm. T=4.5 kgf·m (32.5 lbf·ft) At this time, check that O-ring (19) is fitted in the plug. When it is hard for pistons (A,C) to be inserted, don’t insert them by force because it may cause malfunction, etc. So special attention must be paid. And check that pistons (A,C) are inserted smoothly and there is no creak, getting them in and out by hand. When there is a sense of abnormality as mentioned above, replace pistons (A,C) and the piston cover with new ones as one set. After setting steel balls ø7 (20) on the setting seat surface of the pilot cover upper surface, tighten ball retainer (21) to the specified torque with allen wrench of 5mm. T=0.9 kgf·m (6.5 lbf·ft)

all at once, but tighten three bolts by turns gradually so that the lock valve cover is placed in parallel. (6) Assembling MR1 The MR1 is an essential part for performance and safety, and it is very difficult to reset it, so when the malfunction occurs, please replace it with new assy. The assembling method to check the cause of the malfunction, etc. is shown below for reference. The numbers in ( ) just after part name in the descriptions shows the symbols in the construction drawing. (Figure 2-4) First, place spring (9) and piston (3) in pressure regulating valve (2), and house it in socket (1). Then place regulating valve seat (12) in. Then, tighten socket (1) in body (4) lightly, fix it with vise at the hexagon section of opposing flat 30 of the body, and apply hook spanner to the socket hole and tighten it to the specified torque. T=2 kgf·m (15 lbf·ft)

At this time, check that O-ring (22) is attached on the ball retainer. After making sure that O-rings (3~5) are housed in the insert section of the lock valve, set lock valve sections (6~10) and needle valve (11) and insert it in the lock valve hole. And place pilot cover (14) in the body slowly, matching piston guide (12) projected from the bottom surface to the hole on the body side. At this time, be sure to fit needle valve (11) on the seat section inside of the lock valve cover. And tighten socket bolt (27) to the specified torque with allen wrench of 5mm. T=1.05 kgf·m (7.6 lbf·ft) At this time, don’t tighten it to the specified torque

33 – I I – 2 – 14

And Fix it again directing the socket side downward. After making sure that regulating valve (5) is placed in the hole of regulating valve seat, insert spring (8) and tighten adjusting screw (6) and nut(7) lightly. And adjust the pressure by adjusting screw (6) turning with allen wrench of 4mm, and tighten lock nut M14 (7) to the specified torque. T=2 kgf·m (15 lbf·ft) Assemble it by the reverse procedure of the disassembly, paying attention to the direction and the sequence and following the specified torque. Be sure to tighten them to the specified torque because the torque other than the specified torque may cause the oil leakage and breakage. Here the assembling procedure is shown below for reference when it is disassembled to check on it for abnormalities. The figures in ( ) following the part names in the explanation show signs marked in the construction drawing (Figure 2-4). First, install regulating valve (6)and spring (9) on plug (4), and tighten it slightly with adjusting screw.

At the same time, tighten nut (M4) lightly. And set spring (10) and piston (3) on pressure regulating valve, and insert it in socket (1). After checking that piston (3) is completely inserted in the hole on the top end of plug (4),tighten body (5) and plug (4) to the specified torque. T=6 kgf·m (43 lbf·ft) And adjust the pressure by adjusting screw (6) turning with allen wrench of 4mm, and tighten lock nut M14 (7) to the specified torque. T=2 kgf·m (15 lbf·ft) Assemble it by the reverse procedure of the disassembly, paying attention to the direction and the sequence and following the specified torque. Be sure to tighten them to the specified torque because the torque other than the specified torque may cause the oil leakage and breakage. (7) Assembling MR3 The MR3 is an essential part for performance and safety, and it is very difficult to reset it, so when the malfunction occurs, please replace it with new assy. (8) Assembling ORV (overload relief valve) The ORV 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 numbers in ( ) after part name in the description shows the symbol in cross section (Fig. 2-6). 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 pressure regulating valve (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=6 kgf·m (43 lbf·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=2 kgf·m (14 lbf·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. (9) Assembling ACV (anticavitation valve) 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 assembly is shown below. The numbers in ( ) after the part name in the description show the symbol in cross section(Fig. 2-7). First, place anticavitation valve (1) in body (2), and place spring (4) in it. Then tighten the plug to the specified torque. T=6 kgf·m (43 lbf·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.

33 –II–2–15

2.8 MAINTENANCE STANDARD Parts inspection Parts name

Inspection item

Criterion and corrective action

Switching section 1) Existence of scratch, rust and corrosion

1) Replace it when there is flaw on the following section. • Sliding section against the spool, especially land section where the hold pressure is borne. • 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 overload relief valve • Failure it may cause malfunction, etc.

Spool

1) Replace it when there is scratch on the peripheral sliding surface 2) In case the spool is not smooth, repair or replace it.

1) Existence of scratch, rust and corrosion 2) Insert spool in the hole of the switching section, stroke it while rotating.

Load check valve 1) Damage of load check valve and spring 2) Insert load check valve in plug and experimentally operate it.

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

Main 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 dent, replace it. 3) Replace 4) Replace all parts, as a general rule.

(MR) Overload relief valve (ORV)

33 –II–2–16

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) Measure the pressure of relief valve 1. Each attachment 1) Malfunction of relief valve does not function, • Dust caught between press. regulating • Replace the assy. or the actuation is valve and seat slow. • Dust caught between poppet and seat • Replace the assy. (Poor power) • Press. regulating valve is stuck. • Replace the assy. Or there is no • Breakage or permanent set in fatigue of • Replace the assy. response. spring

• Loose of adjusting screw • Readjust it, and tighten the lock nut to the specified torque. • Disassemble and clean it. In case of severe flaw, replace the

2) Dust caught between the switching section and spool, or stuck 1. When spool is 1) The clearance between the switching placed on the section and the spool is too large. neutral position, 2) The spool is not returned to the neutral the natural drop position completely. of the cylinder • Dust caught between the switching is large. section and spool, or stuck • Breakage or permanent set in fatigue of spring 3) Malfunction of ORV Refer to the above description marked with .

3. When the cylinder 1) Malfunction of load check valve is operated to • Dust caught between load check raise position, the valve and main frame. cylinder moves • Load check valve is stuck. downward reversely when • Breakage and permanent set in starting the operation. fatigue of spring Note). In case of abnormality that is marked with

1) Replace spool. 2) Measure pilot secondary pressure. • Disassemble and clean, or when stuck, replace the switching section and spool together. • Replace spring. 3) Measure the pressure of ORV. Refer to the above description marked with .

1) • Disassembly and cleaning. In case of the severe damage, replace the switching section and load check valve together. • Replace spring.

*, dont fail to replace the relief valve as an assy.

33 –II–2–17

(2) Relief valve The relief valve is essential for the performance and the safety, and it is difficult to set 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 regulating 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 poppet of respective valve is damaged, or the piston is stuck to the regulating valve.

• 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

4. Oil leakage

1) Damage on each seat section Wear of O-ring

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.

2) Respective part is stuck due to dust entered.

33 –II–2–18

• Replace spring.

3. PILOT VALVE (Attachment) 3.1 CONSTRUCTION

APPLY LOCTITE#277 (Hatched portion) 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

Parts 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

Parts 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 2.1 (15.2) 4.8 (34.7) 7 (50.6)

Parts name SPRING SPRING SPRING SPRING JOINT ; M14 DISK ADJUSTING NUT ; M14 BELLOWS (BOOTS)

Q'ty 2 2 2 2 1 1 1 1

3.2 DISASSEMBLY & ASSEMBLY (1) Tools No. a b c d

Tool Name

Remarks 1.5~10 kgf·m class Torque wrench (10~75 lbf·ft) 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

(2) Caution for disassembly & assembly 1) Exercise sufficient care to prevent entry of dust when disassembling and assembling components.

BELLOWS (BOOTS) LEAD WIRE

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.

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. : 22 mm 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). : 6 mm

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). : 22 mm (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). : 6 mm 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 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).

33 –II–3–4

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.

Possible 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.

33 –II–3–5

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

Parts 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

Parts 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 (1) Special jig for disassembly and assembly Special jig 1(for removal of bushing)

CENTERING HOLE IS ALLOWABLE (SMALLER THANø2mm)

(2) Precautions for disassembly and assembly 1) Disassemble and assemble the pilot valve paying attention to the protection for dust, dirt, etc. in order not to allow them to enter in. 2) Handle parts carefully not to damage 3) Write down the installing positions of respective part during disassembly, and assemble respective part to the position as they were before. 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 5) Contact pry bar (ø7 or less) to one end of cam shaft (413), and strike it slightly with a hammer.

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.

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). 11) Remove plug (202) with grease cup (203), packing (210) and O-ring (212).

Fig. 4-3

12) Remove piston (224). 13) Remove damping spring (336) from the casing. 14) Take out spring seat (218) from casing (102) with tweezer. 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) 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.

7) Fix upper casing (102) with vise and place the steel ball in it.

• Repair the parts damaged when being disas-

sembled, 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.

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).

Fig. 4-5

• 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.

13) Place grease cup (203) in plug (202). 14) Install push rod (214) on plug (202).

Pay attention to the corner of the casing

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).

Fig. 4-4

19) Tighten socket bolt (271) to the specified torque. 20) Install cam (420) on cover (201). 21) Insert cam shaft (413) from the outside pressing cam (420).

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

4.3 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) Repair unsmooth section. 1) Sliding part is not smooth. 2) Orifice of damping piston (224) is clogged. 2) Repair or replace damping piston.

33 –II–4–5

NOTES

5. SLEWING MOTOR 5.1 GENERAL VIEW Dr G7 SH PG

AIR BLEED PORT (AU)

Plug assy

MU SH B

B PG

PLUG ASSY

A·B

HYDRAULIC TIMER

Code A B MU Dr PG SH G7 G8

5.2 SPECIFICATIONS

Model

PF1/2 PF3/8 PF1/4

Gauge port

PF1/4

cc/rev (in /rev) 3

SK40SR-2

SK45SR-2

SG015E-501

SG015E-502A

27.2 (1.66)

Size

Port Main port Main port Make up port Drain port Slewing parking brake release port Slewing parking brake pilot port

Table. 5-1

Applicable model

Displacement

VIEW Z

Rotational direction : Inlet A port : CCW Inlet B port : CW (View from shaft end)

Fig. 5-1

sec

40.3 (10.6)

6 ± 1.5

kgf/m (psi) 165 (2,350) at 38.4 L (10.1 gal) /min 180 (2,560) at 40.3 L (10.6 gal) /min 2

1/16.34

Reduction Reducing ratio Weight

HYDRAULIC CIRCUIT

AIR BLEED PORT (AU)

G8 Z

kg (lb)

33 –II–5–1

43 (95)

1/17.01

5.3 CONSTRUCTION (1) Motor unit Relief valve of A port 34 33 32 h

Make up port

35 36

30 29

Relief valve of B port 16

18 b

20 21

11 A · B port 10

8 g

5 4

4-2 4-3

Mechanical brake release chamber

4-4 4-1

Section A-A

Table. 5-2

33 –II–5–2

Q'ty 1 1 1 1 3 3 2 2 2 2 1 5 1

(2) Reduction unit 50 49

55 57

58 59

A chamber

Drain port

B chamber

41 40 39 38

Fig. 5-3 Table. 5-3

Parts name Q'ty No. No. Parts name 1 38 Shaft 47 Sun gear (Spur gear 4) 1 39 Collar 48 Socket bolt : M12 X 80 1 40 O-ring : 1B P115 49 Sun gear Bearing 1 41 50 Holder 1 assy 1 42 Gear casing 51 Holder 1 1 43 Oil seal 52 Planetary gear (Spur gear 2) 1 44 Bearing 53 Shaft 1 1 45 Split collar 54 Needle Bearing 1 46 Ring gear 55 Thrust plate Note) Q’ty in ( ) are included within respective assemblies

33 –II–5–3

Parts name Q'ty No. 1 56 Holder 2 assy 6 57 Shaft 2 1 58 Holder 2 1 59 Needle bearing (1) 60 Planetary gear (Spur gear 5) (3) 61 Thrust plate 1 (3) 62 Spring pin (3) 63 Pin (3)

Q'ty 1 (4) (1) (4) (4) (4) (4) 2

(3)

Relief valve 64

65 66 67

68 69 70 71 72 73

74 75 76

Fig. 5-4 Table. 5-4 No. 64 65 66 67 68

Parts name Seat Poppet Spring Sleeve Piston

(4)

Hydraulic timer

Parts name Q'ty No. 74 Nut 1 75 O-ring 1 76 Cap 1 1 1

Parts name Q'ty No. 69 Spacer 1 70 O-ring 1 71 O-ring 1 72 Sleeve 1 73 Sleeve 1

Q'ty 1 1 1

81 82

Fig. 5-5 Table. 5-5 No. 77 78 79 80

Parts name O-ring Manifold Spring Poppet

Parts name Q'ty No. 81 O-ring 1 82 Cap 1 83 Spool 1 84 Plug 1

33 –II–5–4

Parts name Q'ty No. 85 Stopper 2 86 O-ring 2 87 Spring 1 2

Q'ty 1 2 1

5.4 Disassembling (1) Separating motor and reduction unit 1) Put matching mark on the mating face of unit. It is very helpful to put matching marks on the mating face of housing (5) and ring gear (46) to aid in installing them again.

Matching mark

2) Loosen socket bolt. Loosen socket bolts (48) [Opposhing flats : 10], place shaft (38) of the reduction unit directing downward, and lift and remove the motor. : 10 mm

The sealant is applied to the mating faces of housing (5) and ring gear (46), so take advantage of the notch shown in the right figure.

46 Notch

33 –II–5–5

(2) Disassembling motor 1) Remove relief valve (6) (Opposing flats : 27), cap (34) (Opposing flats : 22), spring (32), check valve (31), hydraulic timer (35) (Opposing flats : 5), plug assy (4) (Opposing flats : 8) installed on the motor. : 27 mm : 22 mm

6 37

: 5 mm Be sure to install the removed relief valve (6), cap (34), spring (32), check valve (31), hydraulic timer (35) and plug assy (4) on the original positions when reassembling them.

2) Loosen socket bolt. Loosen socket bolt (36) (Opposing flats : 8), place the output shaft of motor directing downward, and lift and remove cover (37).

: 8 mm

33 â&#x20AC;&#x201C;IIâ&#x20AC;&#x201C;5â&#x20AC;&#x201C;6

3) Remove inner race. Remove snap ring (23) by scriber then remove inner race of needle bearing (17), hook gear puller on the crescent groove of balance plate (22) and the male shaft of cover (37) and remove the inner race of needle bearing (17) because it is press-fitted in the male shaft of cover (37). Use care not to damage the sliding surface of balance plate (22) and not deform it by applying excessive force. The installing direction of balance plate (22) to cover (37) is specified, so put mark on cover (37) to show the installing direction when being assembled again.

17 (Inner race)

4) Remove O-ring. Remove O-ring (12) from cover (37).

33 â&#x20AC;&#x201C;IIâ&#x20AC;&#x201C;5â&#x20AC;&#x201C;7

5) Remove bushing. Remove bushing (20) and disk spring (18) on which Teflon ring (19) is fitted from cover (37).

6) Remove spring. Take out spring (14) from brake piston (11). 14 Measures can be taken so that position where spring (14) is fitted on brake piston (11) can be found easily. 5

33 –II–5–8

7) Pull brake piston out. It is difficult to pull brake piston (11) out of housing (5) because there is sliding resistance due to the interference of O-rings (9), (10). Therefore, use tapped hole (M6) provided on brake piston (11) and put it out by the manner shown in the right figure. Then, take out O-ring (9) from housing (5), and O-ring (10) from brake piston (11) respectively.

10 11 Crescent wrench

Place the support on the outer side of minor diameter.

9 Support Housing bore

8) Remove friction plate and separator plate. Remove friction plate (7) and separator plate (8).

8 7

33 â&#x20AC;&#x201C;IIâ&#x20AC;&#x201C;5â&#x20AC;&#x201C;9

9) Remove cylinder assy. Grasp the end section of cylinder (1), and pull the cylinder assy out of housing (5). 1 Be careful for oily cylinder (1) not to drop because it is slipped. Only outer race of taper roller bearing (3) is remained in housing (5). The end face “A” of cylinder (1) is sliding surface, so cover it with soft cloth in order not to damage. 5 Put matching marks or numbers on the piston bores of cylinder (1) and piston assy (24) so that they can be inserted in the same bores that the pistons have been inserted in when being disassembled.

10) Remove outer race of taper roller bearing. Remove the outer race of taper roller bearing (3) from housing (5).

5 (Outer race)

33 –II–5–10

11) Disassemble cylinder assy. 1. (Pull inner race, taper roller bearing out.) Attach a jig for removal under the inner race of taper roller bearing (3), hook a gear puller on two parts of jig and the spline end section of cylinder (1), and pull them out together.

2 3 (Inner race) Jig for bearing (See page 34-II-5-39) Rag

2. Pull collar (28) out, and then pull cam plate (26), return plate (25), piston assy (24) out of cylinder (1) together.

28 26 25

33 –II–5–11

3. Remove cam plate (26) moving it on the sliding surface of piston assy (24).

Pay attention during handling not to damage cam plate (26) and the sliding surface of piston assy (24).

4. Pull spring retainer (27) out of cylinder (1). 27

This completes disassembly of motor.

33 –II–5–12

(3) Disassemble reduction unit. 1) Remove sun gear and holder 1 assy. The mouth of holder 1 (51) is caulked by press after press-fitting shaft (53) in holder (51), so it is impossible to disassemble it further.

62 60

2) Remove spur gear 5 (60) and holder 2 assy (56). 57 3) Disassemble holder 2 assy. Drive spring pin (62) in shaft 2 (57). Spring pin (62) can not be reused.

Pull shaft 2 (57) out of holder 2 (58) supporting spur gear 5 (60) by hand, and then pull out thrust plate 1 (61), spur gear 5 (60) and needle bearing (59). And also pull spring pin (62) out of shaft 2 (57).

33 –II–5–13

4) Remove ring gear. Remove ring gear (46) from gear case (42). The mating face of ring gear (46) and gear case (42) is coated with liquid packing (Loctite #5699) to prevent oil leakage, so remove ring gear (46) making use of the notch on gear case (42).

Notch

5) Remove split collar. Remove split collar (45) fitted in shaft (38) by means of minus screwdriver and hammer.

45 38

33 –II–5–14

6) Remove shaft assy. Put two supports of about 300mm to secure removing distance for shaft (38) on the flange section of gear case (42), and pull the assy of shaft (38), collar (39) and inner race of taper roller bearing (41) by pushing the shaft end face with hydraulic press, etc.

Support

300 or more

7) Remove taper roller bearing. Remove taper roller bearing (44) from gear case (42). And, remove O–ring (40). Then, Pull out oil seal (43) by striking it with driver and hammer.

41 (Inner race)

Oil seal (43) can not be reused. 39 38

Where there is no abnormality on the bearing, the further disassembly is not required.

44 (Inner race)

44 (Outer race)

40 This completes the disassembly of reduction unit.

33 –II–5–15

5.5 ASSEMBLY (1) Assembling reduction unit 1) Matters to be prepared The following should be carried out in advance for reassembly. 1. Check every equipment for possible flaw due to the operation or disassembly, and when flaws were found, remove them with proper oil stone or emery paper, clean them with clean wash oil, and blow air to dry them.

41 (Inner race)

2. Replace sealing parts with new ones. 2) Apply grease on the roller portion of taper roller bearing (41). Brand name : Shell ALVANIA EP2 or equivalent Capacity : 45 cc (2.7 cu·in)

3) Press-fit oil seal. Degrease oil seal fitting section of gear case (42) and oil seal (43), and apply liquid packing (Loctite #5301J) on the outline of oil seal (43). Fit oil seal in gear case (42) with seal press-fitting jig and hand press. After press-fitting, apply grease on the lip section of oil seal (43) lightly.

Press-fit jig (See page 33-II-5-40)

33 –II–5–16

4) Fit pinion shaft assy. Put the shaft assy up, directing the output shaft downward. Fit outer race of taper roller bearing on gear case (42), hang it by crane, and install it on the shaft assy. Then,

a) Apply grease outside of the outer race of taper roller bearing (41). (To protect the outer race from dropping when hanging gear case (42).) b) Fit the seal protector on the spline section of shaft (38), and be careful not to damage the lip section of oil seal (43) when inserting it. In this state, the shaft (38) is free, therefore the weight is applied directly onto the end face of the shaft. [To prevent oil seal (43) from dropping and damage of shaft (38) due to its ownweight through gear case (42).]

43 (Oil seal)

41 (Outer race) Seal protector (See page 33-II-5-40)

38 (Shaft assy)

5) Fit taper roller bearing. Place gear case (42) directing the output shaft downward, then warm the inner race of taper roller bearing (41) in the “Environmental temperature +50°C (122°F)” and fit it on

41 (Inner race)

33 –II–5–17

6) Fit split collar. After adjusting the clearance of two split collars (45) by the following procedure, fit shaft (38) in the groove section. (The clearance is adjusted to -0.06

0.06mm when being delivered.) In the state where fitting split collar (45) of thickness 5.2 ± 0.01mm in the groove section of shaft (38) and pushing the taper roller bearing, measure the clearance with thickness gauge and change the thickness of split collar (45) so that the clearance between split collar (45) and shaft (38) becomes -0.06

0.06mm.

7) Apply liquid packing. Degrease mating face of gear case (42). Apply liquid packing “Loctite #5699” or equivalent along to the faucet section of ring gear (46). Apply it uniformly so that the diameter of the liquid packing extruded through the nozzle is about ø 1.5mm.

Liquid sealant

33 –II–5–18

8) Install ring gear. Degrease mating surface of ring gear (46). Match the phase of the pin hole of ring gear (46) and the position of pin (63) and bolt hole, and install it on gear case (42) softly.

9) Assemble holder 2 assy. Install spur gear 5 (60), needle bearing (59) and thrust plate 1 (61) on holder 2 (58). Then, install shaft 2 (57) on holder 2 (58).

This time, apply hydraulic oil on the inner face of spur gear 5 (60). Immediately before installation, match the phase of the pin hole of shaft 2 (57) and the pin hole of holder 2 (58).

33 –II–5–19

10) Fit spring pin. Drive spring pin (62) in shaft 2 (57). Drive spring pin (62) directing the split toward spur gear 5(60).

After driving spring pin (62), caulk two points on the mouth of holder 2 (58) with punch, etc. (to prevent spring pin (62) from slipping out.)

60 57

Caulking (Punch)

11) Install holder 2 assy and spur gear 4. Place holder 2 assy (56) assembled by the procedure shown in Article 9) in ring gear (46) moving it in mesh with the internal tooth softly, and also rotating holder 2 assy (56) so that the spline of shaft (38) engages with it. Place it in, moving spur gear 4 (47) in mesh with spur gear 5 (60) softly.

33 –II–5–20

12) Install holder 1 assy and sun gear. Place holder 1 assy (50) in ring gear (46) moving it in mesh with the internal tooth softly, and also rotating holder 1 assy (50) so that the tooth of holder 1 (51) engages with the tooth of spur gear 4 (47). Place it in moving sun gear (49) in mesh with spur gear 2 (52) softly.

13) Check assembly. Turn holder 1 assy (50) by hand and check that the output shaft rotates smoothly.

This completes the assembly of reduction unit.

33 –II–5–21

(2) Assemble motor. 1) Matters to be parepared Before reassembly, the following matters should be carried out in advance. 24 1. Check every part for possible flaw due to the operation or disassembly, and when flaws were found, remove them with proper oil stone or emery paper, clean them with cleaning solvent, and blow air to dry them.

Emery paper Surface plate

2. Replace sealing parts with new ones. 3. Lap the sliding surfaces of piston assy (24), cam plate (26) and balance plate (22) with emery paper #2000. 4. Before assembling the section including the sliding surface, apply clean hydraulic oil. 5. Install piston assy (24) on the same piston hole of cylinder (1) that it was installed in before disassembly.

33 â&#x20AC;&#x201C;IIâ&#x20AC;&#x201C;5â&#x20AC;&#x201C;22

2) Assemble cylinder assy

1. Apply hydraulic oil on the spherical section of cylinder (1) (contact section to spring retainer (27)) and fit spring retainer (27).

2. Insert piston assy (24) in the hole of return plate (25)

3. Install piston assy (24) and return plate (25) in cylinder (1) together.

25 24

At this time, insert piston assy (24) assembled before disassembly in the same hole. When inserting, apply hydraulic oil on the piston hole of cylinder (1).

33 –II–5–23

4. Apply hydraulic oil on the sliding surface of piston assy (24), attach cam plate (26), and then attach collar (28).

5. Press fit the inner race of taper roller bearing (3) in cylinder (1) with jig and hand press. Cover the end face of cylinder (1) with soft cloth, in order to prevent it from being damaged.

Press-fit jig (See page 33-II-5-38)

3 (Inner race)

33 –II–5–24

6. Press inner race (2) with jig. Cover the end face of cylinder (1) with soft cloth in order not to damage when press fitting.

Press-fit jig (See page 33-II-5-38)

2 (Inner race)

3) Place the outer race of taper roller bearing. Place the outer race of taper roller bearing(3) in housing (5). 3 (Outer race)

33 –II–5–25

4) Install cylinder assy. Hold the end face of cylinder (1) by hand, and place the cylinder assy in housing (5).

End face of cylinder

Make sure that spring retainer (27) is in place in the spot facing section of return plate (25). When the cylinder assy was housed in, as the spline shaft of cylinder (1) is protruded from the end face of housing (5) put the support of 30 to 50mm in size on the lower side of housing (5). Make sure that the end face of cylinder (1) is about 4mm (0.16 in) lower than the end face of housing (5). When the set value is insufficient, cam plate (26) is not in place exactly in the spot facing section, so lay housing (5) down directing the higher side of inner slope downward softly, and place cam plate (26) shaking cylinder (1) up and down slightly.

End face of housing

Stand or support

5) Install friction plate and separator plate. Install friction plate (7), and separator plate (8). 8 Apply hydraulic oil on the both sides. 7

33 –II–5–26

6) Fit O-ring. Fit O-ring (9) in housing (5) and O-ring (10) in brake piston (11). 10

Apply grease on O-rings (9) (10).

7) Install brake piston. Apply hydraulic oil on the outer sliding surface of brake piston (11) and place it in housing (5). As brake piston has the interference of O-rings (9) (10), it is hard to move, therefore put brake piston (11) horizontally and push it by hand at a stroke with jig.

Assembly jig (See page 33-II-5-38)

10 11

33 â&#x20AC;&#x201C;IIâ&#x20AC;&#x201C;5â&#x20AC;&#x201C;27

8) Fit spring. Fit spring (14) in brake piston (11). Fit spring (14) in the same position as that it was placed in before disassembly.

9) Install balance plate. Install bushing (20) and disk spring (18) in which Teflon ring (19) is placed in the bushing hole of cover(37) and balance plate (22) in which piston (16) and Teflon ring (15) are placed in. Pay attention to the installing direction of balance plate (22) and cover (37) put the marks before assembly.

22 15 16 20

A,B port side (Top dead point) 19

2-stepped groove

37 Timer side (Bottom dead point)

33 â&#x20AC;&#x201C;IIâ&#x20AC;&#x201C;5â&#x20AC;&#x201C;28

10) Fit inner race. Press fit the inner race of needle bearing (17) in cover (37) and fit snap ring (23).

17 (Inner

11) Fit O-ring. Fit O-ring (12) on cover (37). 12

Apply grease on O-ring (12).

33 –II–5–29

12) Apply sealant. Clean the surface of housing (5) mating with cover (37) respectively, and after greasing apply sealant Loctite #5301J on it as shown in the right figure.

Liquid sealant

13) Install cover. Raise cover (37) by hand and place it in housing (5) softly.

Then, have the clearance of 3mm between housing (5) and cover (37).

33 –II–5–30

14) Tighten bolt. [Clamping between cover (37) and housing (5)] Tighten socket bolt (36) (Opposing flats 8) to 6.6 kgf·m (48 lbf·ft).

Then, tighten 4 socket bolts (36) evenly so that housing (5) and cover (37) are installed face to face in parallel.

37 3mm

15) Install relief valve, etc. Install relief valve (6) [Opposing flats 27] on housing (5) and torque to 6 kgf·m (43 lbf·ft). Place check valve (31) and spring (32) in housing (5), place cap (34) [Opposing flats 22] in housing and torque to 6.6kgf·m (48 lbf·ft). Install hydraulic timer (35) [Opposing flats 5] in housing (5) and torque 1.2 kgf·m (8.7 lbf·ft). Install plug assy (4) [Opposing flats 8] on housing (5) and torque to 6 kgf·m (43 lbf·ft) Be sure to install the removed relief valve (6), cap (34), spring (32), check valve (31), hydraulic timer (35) and plug assy (4) on the positions where they were installed before disassembly.

Opposing flats 22

33 –II–5–31

16) Make sure of assembly. Release the inlet and outlet ports, apply the pilot pressure of 26 to 50kgf/cm2 (370 to 710 psi) to the brake release port (PG,SH ports), and check that the output shaft rotates one turn or more smoothly by applying pressure of 2 to 3kgf·m (14 to 22 lbf·ft). When it does not rotate smoothly, it may be caused by failure of the assembly. Disassemble and readjust it again. And, the drain port is to be open at that time.

This completes the assembly of motor.

PG port

SH port

33 –II–5–32

(3) Assemble reduction unit and motor. 1) Apply sealant. Clean the mating surfaces of ring gear (46) and housing (5) of the motor respectively, and after greasing apply sealant Loctite #5699J on it as shown in the right figure.

Liquid sealant

2) Install motor. Lift the motor up, place it on the reduction unit softly, torque capscrew (48) [Opposing flats 10] to 10.5 kgf·m (75.9 lbf·ft).

Match the phases of housing (5) and ring gear (46) to the match marks put before disassembly. 5

46 This completes the assembly of slewing motor assy. After installing the hydraulic motor on the actual machine, check that the set pressure of relief valve (6) is set to the specified pressure.

33 –II–5–33

5.6 MAINTENANCE STANDARD LIST Table 5-6 Inspection and position to be measured

Part name Piston assy (24)

Roughness of shoe

Reference value (allowable limit) 0.8S

Measuring instrument Repair and treatment Roughness gauge Repair by paper

sliding surface

lapping

Groove depth of shoe 0.35mm or more

Micrometer

sliding section Looseness between

Replace it with new one.

0.4mm or less

Dial gauge

piston and spherical

Replace it with new one.

contact section of shoe Piston diameter

Almost no wear, and when damaged or seized replace it with new one.

Cam plate (26)

Surface roughness

0.8S

Roughness gauge Lapping

Cylinder (1)

End face roughness

0.4S

Roughness gauge Lapping

Piston hole

Almost no wear, and when damaged or seized replace it with new one.

Balance plate (22)

Surface roughness

0.8S

Piston assy (24)

Clearance between pis- 0.04mm or less

Micrometer

Replace it with new

Cylinder (1)

ton and cylinder hole

Air micrometer

one.

Roughness gauge Lapping

Table 5-7 Part name

Inspection and maintenance standard

Taper roller bearing (3) (41) (44)

Replace bearing with new one by 3000 hours even if there is

Needle bearing (17) (54) (59)

no damage. Replace it with new one when assembling again after disassembly even in the 3000 hours.

Oil seal (43)

Replace it with new one where the lip is damaged. Replace it with new one by 3000 hours even if there is no leakage and the lip is not damaged. Replace it with new one when assembling again after disassembly even in the 3000 hours.

O-ring (9) (10) (12) (13) (33) (40) (70) (71) (75) (77)(81) (86)

Replace O-ring with new one where it is damaged. Replace it with new one by 3000 hours even if there is no leakage and the lip is not damaged. Replace it with new one when assembling again after disassembly even in the 3000 hours.

33 –II–5–34

5.7 CAUSE OF FAILURE AND MEASURES The measures to be taken for the abnormal operation and malfunction when operating hydraulic motor are shown below. Table 5-8 Phenomenon

Cause Internal damage of

Check from outside Measure the drain.

Repair

Measures

When there is no big Refer to Table 5-11.

motor

difference between the supply capacity to motor and the drain, it may be caused by the damage of the sliding section, so

Not rotated

disassemble and check it. Internal damage of

Keep the inlet and outlet Where the output shaft Replace the damaged

motor

ports of motor open, apply does not rotate smooth parts or the motor assy. the pilot pressure of 26~50 by the said pressure, it kgf/cm2 (370~710psi) to the may be caused by the brake release port, and try internal damage, so to rotate the output shaft by disassemble and check applying the about 2~3 it. kgf·m (14~22 lbf·ft).

The setting of relief

Measure

valve in the circuit is

pressure with pressure Reset the specified set

wrong.

gauge.

the

load pressure.

Large slipping volume

Wear or damage of motor sliding section

Refer to Table 5-11. Measure the drain.

When the drain is 3.6 L/min

and high pressure

(0.95 gal/min). or more, it

sealing section

may caused by the large leakage, and disassemble

The oil temperature is

and check it.

high, the internal

Measure

leakage of motor is

temperature.

the

oil Lower

the

temperature.

33 –II–5–35

oil

Table 5-9

Phenomenon

Cause

Check from the outside

Repair

Measures

Wear or seizure of the Keep the inlet and outlet Where the output shaft Check

parts

and

sliding section of motor ports of motor open, does not rotate smooth bearings shown from apply pilot pressure of by the said pressure, it item a to item e in 26~50 kgf/cm2 (370~710 may be caused by the Table 5-11, if there is a psi) to the brake release internal damage, so damage, replace it with port, and try to rotate the disassemble and check new one output shaft by applying it. the about 2~3 kgf·m

Poor torque, Noise

(14~22 lbf·ft). The setting of relief valve Measure the load pressure Reset the specified set in the circuit is wrong.

with pressure gauge.

Internal damage of mo- Check tor

pressure.

whether

the Where metallic foreign Repair the damaged

metallic foreign matter matter is found, it may be parts, or replace it with is contaminated in the caused by the internal new one. motor drain and drain damage of motor, so Replace filter.

the

motor

disassemble and check it . assy with new one.

A lot of air is contamin- Check oil in the tank Bleed air completely. ated in the oil.

and motor case.

Loosening of tightened Check the fittings of Tighten them to the section

pipe, fitting attaching specified torque. bolts and motor mounting bolts and every bolts of motor for looseness.

Seizure of motor slid- Check whether the meta- Where metallic foreign Repair the damaged ing section and rotary llic

Abnormal heat

section

foreign

matter

is matter is found, and parts, or replace it with

contaminated in the motor the output shaft does new one. drain and drain filter. And not rotate smooth by Replace

the

motor

apply pilot pressure of the said torque, it may assy with new one. 26~50kgf/cm2 (370~710 be

caused

psi) to the brake release internal

damage

the of

port, and try to rotate the motor, so disassemble output shaft by applying and check it. the about 2~3

kgf·m

(14~22 lbf·ft).

33 –II–5–36

Table 5-10

Oil leakage from oil seal

Oil leakage from the mating face

Phenomenon

Cause

Check from the outside

Repair

Measures

The O-ring is damaged.

Replace O-ring with new one.

The seal surface is

Repair

damaged.

surface, or replace it.

Looseness of bolt

the

sealing

Check bolts for loose- Tighten the specified ness.

torque.

Flaw or wear of seal

Repair, or replace motor

section of the shaft

assy with new one.

Abnormal pressure in Check internal pres- The pressure in the case Repair the damaged the case

sure of the case and is to be 3 kgf/cm2 (43 psi) parts or replace it with the drain volume.

or less, and where the new one. drain volume

is larger, Replace motor assy

disassemble and check it. with new one.

Table 5-11

Item

Parts to be inspected

Repair

Wear of sliding section of balance plate (22)

Repair of parts or replace of parts with new ones.

Damage of sliding section of cam plate (26)

Repair of parts or replace motor with new one.

Damage of sliding section of piston assy (24)

Repair of parts or replace motor with new one.

Wear of outside of piston of piston assy (24)

Repair of parts or replace motor with new one.

Wear of piston hole of cylinder assy (24)

Replace motor with new one.

Damage of Teflon ring (19)

Replace parts with new ones.

33 –II–5–37

5.8 JIGS (1) Jig for inner race (2) and taper roller bearing (3) press-fit.

(2) Jig for brake piston (11) assembly

33 –II–5–38

(3) Jig for taper roller bearing (3) removal 1) Guide

4-ø7 drill through

2) Plate (2 pcs.)

2-ø7 drill through

33 –II–5–39

(4) Jig for oil seal (43) press fit

(5)

Protector for seal

33 –II–5–40

6. SWIVEL JOINT 6.1 CONSTRUCTION F

B D

Tightening torque : kgf·m (lbf·ft)

G P G

P 5 E

A C 14

1 11 10 8 6

16 P

E D

D C

C B

12 15 7,17 13 4

T=4.75 (34.4)

Fig. 6-1 Construction

Table.6-1 No. 1 2 3 4 5 6 7 8 9

Parts name Stem Body Flange Spacer Pin Slipper seal Name Plate O-ring (1A P80) O-ring (1A G95)

33 –II–6–1

Q'ty 1 1 1 1 1 7 1 1 1

No. 10 11 12 13 14 15 16 17

Parts name Dust seal Dust seal Snap ring Capscrew (M10 X 30) Socket plug Lock washer Back-up ring Clevis

Q'ty 1 1 1 4 3 4 1 2

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

• 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.

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.

6.2.2 Disassembly Fix the body with vise. (1) Loosen bolt and remove flange (3). :13 mm or :13 mm

(2) Take out O-ring (9) , snap ring (12) and spacer (4).

9 12

(3) Remove stem(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 2 1

33 –II–6–2

(4) Remove dust seal (11) from the stem (1). 1

(5) Remove seal, etc. from the inside of the body.

• Be sure of the position of seal, etc. referring to the construction drawing.

• 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-ring that they are free from twisting.

• Don’t deform or bend the slipper seal locally.

(2) Install dust seal (10) on body (2).

(3) Install dust seal (11) on stem (1).

• Apply enough grease to the lip section of the dust seal.

(4) Install stem (1) on body (2).

• If stem (1) is pressed in too fast, the seal may be damaged.Do it slowly.

• The clearance between body (2) and stem (1)

is about 0.1mm (0.004 in). Push stem straight along the shaft center.

33 – I I – 6 – 4

(5) Fit spacer (4) and snap ring (12).

• Fit the snap ring in the groove accurately.

(6) Fit O-ring (9) and install flange (3).

(7) Install lock washer (15) and capscrew (13). : 17mm 3

• Tightening torque: 4.75 kgf·m (34.4 lbf·ft) • Put pipe through the locking pin of the shaft, and check that the shaft rotates smoothly at torque approx.8 to 11 kgf·m (58~80 lbf·ft).

15 13

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.

Replace all the seal parts. 4,000hr. All seal parts. Disassemble and All sliding portion. Check for abnormal wear, defects, Recondition in accordance with check whether the service limit. corrosion, etc. due to seizing, 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 the service limit. corrosion, etc. due to seizing, foreign material being caught, etc. Regarding the seal kit, replace

6.3.2 Parts Service Limit (1) Body, Stem Portion Seal parts and sliding portion

Judgment Criteria Wearing of surface treated with ultrasonic tempering, •and coming off of surface due to seizing, foreign

Remedy Replace.

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

Replace.

getting caught, etc.

Portions which slide against the spacer.

•Defects less than 0.1mm (0.004 in) deep. •Wearing by 0.5mm (0.02 in) or more, or abnormal wear. •Wear less than 0.5mm (0.02 in). Defects due to seizing or foreign material getting •caught, etc. which are within the wear limit of

Repair with an oil stone. Replace. Repair so that is smooth. Repair so that is smooth.

0.5mm (0.02 in) and within repairable level.

(2) Flange and Spacer Portion

Judgment Criteria

Portions of flange •Wearing by 0.5mm (0.02 in) or more, or abnormal wear. •which slide against the •Wear less than 0.5mm (0.02 in). stem end. Defects due to seizing or foreign material catching, •etc. •Spacer which are within the wear limit of 0.5mm (0.02 in) and to within repairable level.

33 –II–6–6

Remedy Replace. Repair so that is smooth. Repair so that is smooth.

(3) Slipper Seal

Portion

Remedy

Judgment Criteria

LOOSEN SEAL

1.5mm or more

0.5mm or more

•Loosen seal from grooves is excessive

Replace

Slipper seal width is 1.5mm (0.06 in) or more •smaller than the width of the seal groove.

Replace

•Unequal wear of 0.5mm (0.02 in) or more.

Replace

(4) O-ring

Portion

Remedy

Judgment Criteria LOOSEN O-RING

O-ring from seal grooves is •Loosen excessive

Replace

•Unequal wear of 0.5mm (0.020 in) or more.

Replace

0.5mm or more

(5) Backup Ring

Portion

Remedy

Judgment Criteria

Width 4mm or less Thickness

of 1.5mm (0.06 in) or less •Thickness Width of 4mm (0.16 in) or less.

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.

Pressure gauge

(1) Connect a pipe (3) between the hydraulic pump (2) and the stem (1) side port.

(2) Connect a pressure gauge to the body (4) side.

(3) Increase the pressure gradually to 315 kgf/cm2 (4480 psi) adjusting the relief valve (6), then perform 1 minute leak test.

• Open the neighboring ports on both sides and check visually for leakage from the ports.

• Check for external leakage, etc. by a color check.

33 –II–6–8

6.4 TROUBLESHOOTING

Troubles

Possible Causes

Remedy all the seal parts. •Replace Replace •Retighten.all the seal parts. •

External Oil Leakage

is defective. •O-ring Dust seal •Loosenessisofdefective. •screw of flange.attaching

Internal Oil Leakage

Slipper seal and back-up ring •Replace all the seal parts. •are defective. Excessive •surfaces. wear on sliding •Replace the assembly. Carry out grinding and honing. If excessive Stem and body are stuck •looseness •together. cause oil leakage, replace the assembly.

Stem Sticks Flange Looseness

•Capscrew tightening is insufficient. •Retighten with the specified torque.

33 –II–6–9

NOTES

Book Code No.

PJ34

02E ➁

NEW HOLLAND EH45 Model Cross-reference: SK45SR-2 is NEW HOLLAND Model EH45

TRAVEL SYSTEM TABLE OF CONTENTS PART I - REMOVING AND INSTALLING 1. TRAVEL SYSTEM'S PARTS.....................I-1-1 2. CRAWLER 2.1 Removal and installation (Rubber) ....I-1-1 2.2 Removal and installation (Iron) ..........I-1-3 2.3 Construction .....................................I-1-6 2.4 Maintenance standards ....................I-1-6 3. UPPER ROLLER 3.1 Removal and installation ..................I-1-8 3.2 Construction .....................................I-1-9 3.3 Disassembly and assembly ..............I-1-9 3.4 Maintenance standard ....................I-1-12 3.5 Tools and Jigs .................................I-1-12 4. LOWER ROLLER 4.1 Removal and installation ................I-1-13 4.2 Construction ...................................I-1-14 4.3 Disassembly and assembly ............I-1-14 4.4 Maintenance standard ....................I-1-18 4.5 Tools and Jigs .................................I-1-19 5. FRONT IDLER 5.1 Removal and installation .................I-1-20 5.2 Construction ...................................I-1-21 5.3 Disassembly and assembly ............I-1-21 5.4 Maintenance standards ..................I-1-23 5.5 Tools and jigs...................................I-1-23

6. IDLER ADJUSTER 6.1 Removal and installation .................I-1-24 6.2 Construction ...................................I-1-24 6.3 Disassembly and assembly ............I-1-25 6.4 Maintenance standard ....................I-1-27 7. SPROCKET 7.1 Removal and installation .................I-1-28 7.2 Maintenance standard ....................I-1-28 8.TRAVEL MOTOR 8.1 Removal and installation .................I-1-29 8.2 Maintenance standard ....................I-1-30 9. SLEWING BEARING 9.1 Removal and installation .................I-1-31 9.2 Construction ...................................I-1-32 9.3 Disassembly and assembly ............I-1-32 9.4 Maintenance standard ....................I-1-33 PART II - DISASSEMBLING AND ASSEMBLING 1. TRAVEL MOTOR 1.1 Outline ..............................................II-1-1 1.2 Required tools .................................II-1-4 1.3 Tightening torque............................II-1-10 1.4 Disassembling weight.....................II-1-10 1.5 Disassembly ...................................II-1-11 1.6 Assembly ......................................II-1-32 1.9 Service standards .........................II-1-35

34 –0–1 ➀

PJ34

PREFACE 1. This manual covers the procedures required for the dis/re-assembling of the machine in compilation by items. 2. This manual consists of: Part I - REMOVING AND INSTALLING, and Part II - DISASSEMBLING AND ASSEMBLING. 3. 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. 4. Please understand that it is impossible to accord the descriptions with all cases of the actual process for the removal/installation of the components, because of difference in the field conditions or defective section. 5. 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 required,

REVISION

DATE OF ISSUE

REMARKS

First Edition

October, 2001

S5PJ3402E

Second Revision

January, 2003

S5PJ3402E ➀ K·E

K·E

34 –0–2 ➀

Part I : REMOVING AND INSTALLING 1. TRAVEL SYSTEM'S PARTS

2. CRAWLER 5. FRONT IDLER 6. IDLER ADJUSTER 3. UPPER ROLLER 4. LOWER ROLLER 9. SLEWING BEARING

7. SPROCKET 8. TRAVEL MOTOR

Fig. 1-1 Name and location of parts

2. CRAWLER 2.1 REMOVAL AND INSTALLATION (Rubber) 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. : 19 mm

90°~110° SUPPORT WOOD BLOCK

Fig. 2-1 Crawler removing position

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

34 –I–1–1

(3) Put steel pipes in the rubber crawler, turn the sprocket reverse slowly and when the rubber crawler has separated from the idler, stop the rotating.

ROTATING DIRECTION

(4) Slide the rubber crawler sideways, and remove it.

STEEL PIPE

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.

Fig. 2-3 Removing rubber crawler

ROTATING DIRECTION

(2) Put steel pipes in the rubber crawler, turn the sprocket reverse slowly and when the rubber crawler has separated from the idler, stop the rotating. STEEL PIPE

(3) Slide the rubber crawler to the position to be set on idler exactly.

Fig. 2-4 Installing rubber crawler

(4) Confirm that the rubber crawler is engaged securely with the sprocket, idler and lower roller. (5) Tighten the grease nipple for the crawler adjuster, and adjust tension by feeding grease. : 19 mm T= 6 ± 1 kgf·m (43 ± 7 lbf·ft) Rubber shoe Appropriate tension A = 80 ~ 90 mm (3.2 ~ 3.6 inch)

GREASE GUN

Fig. 2-5 Feeding grease

Iron shoe Appropriate tension A = 160 ~ 180 mm (6.4 ~ 7.2 inch)

LOWER ROLLER

CRAWLER FRAME

Rubber shoe

Iron shoe

Fig. 2-6 Rubber crawler tension

34 –I–1–2

2.2 REMOVAL AND INSTALLATION (IRON) (1) Removal 1) The crawler track link includes a set of master pin (6), which should be placed them at the position front of the front idler. LOCK PIN

6 Fig. 2-7 Position of master pin

2) Put wood blocks A and B under the shoe at the top end of the crawler and between the link and the track frame to reduce the load to the master pin.

A 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. :19 mm 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 does not pop out.

GREASE NIPPLE

Fig. 2-9 Loosening grease nipple for adiustment

34 –I–1–3

4) Straighten the curve of lock pin, and draw out it striking by hammer.

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. Be careful not to be injured by scattering materials, when large hammer is used. Don’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 wood block just in case.

6 A 8 Fig. 2-10 Removing of lock pin

6) Move the machine back slowly, and remove it extending the crawler to the ground. Weight of iron crawler (One side) SK40SR-2 : 250 kg (550 lb) SK45SR-2 : 265 kg (580 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.

Fig. 2-11 Removing of master pin

WOOD BLOCK

Fig. 2-12 Removing of crawler

To front idler

Fig. 2-13 Direction of track link

34 –I–1–4

2) Move the crawler forward slowly by inserting the pry-bar in the master pin hole on the end of the crawler and assisting so that the sprocket engages with the track link, and also assist so that the crawler catches the normal position and engages with the front idler using pry-bar.

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

A 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 pry-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 broken piece.

• 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 of master pin

6) After completion of installation, adjust the tension of crawler by the same procedure of the rubber crawler. : 19 mm

GREASE NIPPLE

Fig. 2-17 Extension of track link

34 –I–1–5

2.3 CONSTRUCTION (1) Construction of rubber crawler No. 1

Part name Rubber crawler assy

Q'ty per machine 2

• Standard machine is provided rubber crawler. Fig. 2-18 Rubber crawler assy (2) Construction of iron crawler No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Q'ty (for one side) SK40SR-2 SK45SR-2 PH60D00001F1 YJ60D00001F3 35 37 35 37 1 1 1 1 1 1 1 1 35 37 35 37 1 1 2 2 144 152 144 152 36 38

Part name Shoe assy Track link (RH) Track link (LH) Master link (RH) Master link (LH) Master pin Lock pin Track pin Bushing Bushing Collar Bolt Nut Shoe

Fig. 2-19 Construction

2.4 MAINTENANCE STANDARDS (1) Rubber crawler Place M mark or machine center

B B

∞ mark at

CORE

RUBBER COVER

L 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 Sag of rubber crawler L

Standard value

Service limit

80~90 (3.2~3.6)

Cracks and cuts on rubber crawler

None

Breakage of steel cords

None

Contact surface of rubber crawler and lower roller

None

Height (H) Lug projection (h)

Repairable level

Unit : mm (in)

94 (3.8) 23 (0.9)

Remedy Adjustment

Where the depth of them does Where the depth of them not reach to the steel cords. reachs to the steel cords. None

Exist

Where 10 percent of core Where a half of core is is visible from outside. visible from outside. 75 (3.0) 0 (0)

34 –I–1–6

Replace Replace Replace Replace Replace

(2) Iron crawler (Track link) Pin

Master bushing Collar

Master link

Master bushing

Master pin

Track pin

Track bushing

Fig. 2-21

Table. 2 Code A B C

Item Link pitch Bushing O.D. Link height

Reference value

Unit: mm (in) Repairable level Service limit

Remedy

135 (5.31) ø35.02 +0.03 (1.379 +0.001 ) 0 0 65 (2.6) Basic dimension

139 (5.47) 143 (5.63) Parts over the service ø32 (1.26) ø31 (1.22) limit should be 61 (2.4) 60 (2.4) replaced with link assy. Fit Fit Interference of bushing Interference Interference +0.001 and link 0.05 0 (1.379 ) Shaft ø35.02 +0.03 0 0 (0.002) Replace Interference Interference Interference of track pin +0.001 0.05 0 ) Shaft ø22.03+0.03 0 (0.867 0 and link (0.002)

Interference of master pin and link

Clearance gap of link

Tightening torque of shoe bolt

Sag of iron crawler

Shaft

0 0 ø21.88-0.03 (0.861-0.001 )

0.5 (0.02) (one side)

Clearance 0~0.08 (0.003) 5 (0.2) (both side)

Replace link. 7 (0.3) (both side)

Apply engine oil to screw and tighten it 22 kgf·m (160 lbf·ft) 160~180 (6.4~7.2)

34 –I–1–7

Replace Retighten Adjust the tension.

3. UPPER ROLLER 3.1 REMOVAL AND INSTALLATION 3.1.1 Removing (1) Loosen the grease nipple for the crawler adjuster within one turn, to discharge the grease and slacken the crawler tension. : 19 mm GREASE NIPPLE

Turn the grease nipple slowly so it does not rotate more than one turn. Use cares so the grease dose not jet out.

Fig. 3-1 Adjusting crawler tension

(2) Push up the crawler,using hydraulic jacks.Place wood blocks and keep a clearance between the crawler. (3) Remove capscrews that fasten the upper roller, and separate upper roller assy from the lower frame. : 17 mm Weight of upper roller assy : 5 kg (11 lb) 3.1.2 Installation Before installing 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. Model Oil Volume

SK40SR-2, SK45SR-2 Engine oil SAE # 30 API CD grade 20 cc

(1) Insert the shaft of the upper roller assy into the lower frame. (2) Coat attaching capscrew with Loctite #262 and tighten it to the specified torque.

• •

WOOD BLOCKS

Fig. 3-2 Supporting crawler with wood blocks

Idler side Fasten the nut on to the idler side. UPPER ROLLER

Fig. 3-3 Removing and Installing of upper roller

: 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 wood blocks the same way as removal.

(3) After installing upper roller, tighten grease nipple for crawler adjuster, grease it, and adjust crawler tension. : 19 mm Tightening torque : 6 kgf·m (43 lbf·ft)

34 –I–1–8

3.2 CONSTRUCTION

No. 1 2 3 4 5 6

Part name Roller Shaft Plate Cover Bushing Floating seal

Part name Q'ty Q'ty No. 1 7 O-ring : 1A G45 1 1 8 Socket bolt : M8X22 2 1 1 9 Snap ring 1 1 10 Plug Collar 1 1 11 1

Fig. 3-4 Construction of upper roller 3.3 DISASSEMBLY AND ASSEMBLY 3.3.1 Disassembly (1) Remove plug (10) and drain out oil. : 5mm (2) Place the end face inside upper roller (1) on stand jig (f) and remove snap ring (9).

JIG f

(3) Remove cover (4) upwards, using the threaded hole for the plug. (4) Remove O-ring (7) from cover (4). (5) Loosen two socket bolts (8) and remove plate (3).

Fig. 3-5 Preparation for disassembly PUSH WITH PRESS

: 6 mm (6) Put the extrusion jig (h) against the end face of shaft (2) and extrude shaft (2) with retainer for floating seal (6), using a press or hammer.

JIG f

Fig. 3-6 Extruding shaft (7) Remove floating seal (6) from upper roller (1).

Fig. 3-7 Removing out floating seal

34 –I–1–9

(8) Remove the floating seal (6) from collar (11).

PUSH WITH PRESS

Collar is press fitted into shaft (2). Therefore do not disassemble it. (9) When extruding bushing (5), place upper roller (1) on the stand jig (f), put the extrusion jig (g) against the end face of bushing (5) and extrude it by means of a press. JIG f

Fig. 3-8 Removing floating seal 3.3.2 Installing Installing of the upper roller is performed in the reverse order of removing.

Fig. 3-9 Extruding bushing

PUSH WITH PRESS

(1) Place the upper roller (1) on the stand jig (f), and press the jig (h) against the end face of the bushing, and press it in a specified position. If you fail in this operation by pressing the bushing unevenly, the bushing is distorted and gets unserviceable. In that case, do not re-use the bushing.

Fig. 3-10 Pushing in bushing

(2) Two floating seals (6) make a pair. Attach one floating seal to retainer fixed in shaft (2), and another to the inside of upper roller (1).

• Prior to placing floating seal (6) in, apply engine oil lightly to seal surface.

(3) Put shaft (2) in upper roller (1), and press-fit it.

Fig. 3-11 Fixing floating seal

PUSH WITH PRESS

Fig. 3-12 Pressing shaft

34 –I –1–10

(4) Place upper roller (1) on the stand jig (f) and attach plate (3) to the end face of the shaft with socket bolts (8). In that case, coat the threaded part of socket bolts (8) with Loctite #242 beforehand. : 6 mm Tightening torque : 3.4 kgf·m (25 lbf·ft)

JIG f

(5) Fix O-ring (7) in the groove of cover (4).

• Coat grease to O-ring.

Fig. 3-13 Installing cover

(6) Install cover (4) to upper roller (1). Use a press in this operation as a press fit is used. (7) Fix snap ring (9) into upper roller (1). (8) Fill in 20cc of engine oil API grade CD #30 through the plug hole of cover (4). (9) Place seal tape around plug (10) and tighten it into the plug hole of cover (4). : 5 mm Tightening torque : 2.3 kgf·m (17 lbf·ft)

• After assembling the upper roller, confirm that

JIG f

oil is not leaking from it and that it rotates smoothly by hand.

Fig. 3-14 Filling oil

34 –I–1–11

3.4 MAINTENANCE STANDARD

Fig.3-15 Sectional view of upper roller

Table. 3-1 Code

Item

A B

Tread dia. Tread width

Clearance between shaft and bushing

Interference between roller and bushing

Tightening torque of socket bolt Oil Roller rotation

Repairable level

Standard value ø 82 (3.23) 102 (4.01) Tolerance Basic dimension

ø 73 (2.87) 95 (3.74) Fit -0.060 -0.0024 Clearance ø32 (1.26) Shaft -0.090 -0.0035 0.7 (0.03) Interference 0 0 ø36 (1.42) Hole -0.03 -0.0012 0 (0)

( (

) )

Service Remedy limit ø 70 (2.76) Replace 92 (3.62) Fit Clearance Replace 1.0 (0.04) bushing Clearance 0.01 (0.0004)

3.4kgf·m (25 lbf·ft)

Apply Loctite #242

Engine oil API grade CD SAE #30, 20cc Roller rotates smoothly by hand

Replenish Reassembly

3.5 TOOLS AND JIGS 3.5.1 Tightening tools Tools Socket Allen wrench

Unit : mm (in)

Unit : mm Opposing flats 19 , 24 5,6

3.5.2 Jig Symbol

Jig

Sketch

Symbol

Jig

Fixing jig

Stand jig

34 –I –1–12

Sketch

4. LOWER ROLLER LOWER ROLLER ASSY (1)

4.1 REMOVAL AND INSTALLATION 4.1.1 Removing (5 pcs. per crawler) (1) Slightly loosen capscrews M16 X 35 (2) fastening lower roller assy (1) to the lower frame.

CAPSCREW (2)

: 24 mm (2) As same as the case for removal of the crawler, loosen the grease nipple for crawler adjusting within one turn to discharge the grease, and release the tension on the crawler.

Fig. 4-1 Lower roller assy

: 19 mm (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 wood block under the lower frame to stabilize the machine.

90°~

90°~110°110° SUPPORT

(5) Remove the capscrews (2) fastening the lower WOOD BLOCK

: 24 mm Weight of lower roller assy : 10 kg (22 lb)

Fig. 4-2 Crawler removing position

4.1.2 Installing (1) Installing position of lower roller Distance from collar end and center of attaching capscrew is as follows. Rubber : 23 mm (0.91 in) Iron : 35 mm (1.38 in)

FRAME

(2) Coat the attaching capscrews (2) with Loctite #262 in advance.

COLLAR

Rubber crawler

Place the roller assy (1) between the crawler and lower frame. Fasten the capscrews (2) temporarily.

FRAME

: 24 mm (3) Lower the machine in full contact with the ground and tighten the capscrews (2) as specified.

COLLAR

: 24 mm T = 28.5 kgf·m (206 lbf·ft)

Iron crawler

(4) Tighten the grease nipple of the crawler adjuster. Lift the machine, and adjust the crawler tension by feeding grease.

Fig. 4-3 Installing position of lower roller (collar)

: 19 mm T = 6 kgf·m (43 lbf·ft)

34 –I–1–13

4.2 CONSTRUCTION

No. 1 2 3 4 5 6 7 8 9

Part name Roller Collar Collar Shaft Bushing Seal O-ring Snap ring Plug

Q'ty 1 1 1 1 2 2 2 2 2

Fig. 4-4 Construction of lower roller

4.3 DISASSEMBLY AND ASSEMBLY 4.3.1 Disassembly (1) Drain oil Remove plug (9) and drain out oil. (2) Removing snap ring (8) (3) Removing collar (2), O-ring (7) Put lower roller on jig (m) for repair stand so that the shaft is perpendicularly located, apply pushout jig (P) on shaft end on upper side, and push shaft (4) until the O-ring separate from collar (2) with press or mallet, and take out collar (2) and O-ring (7).

PUSH WITH PRESS

(4) Removing shaft (4) In addition, push out and remove shaft (4) together with the lower collar (3) and O-ring (7). The shaft (4) extrusion operation may cause the remaining lube oil to flow out and contaminate the floor. Prepare an oil container beforehand. (5) Removing collar (3), O-ring (7) Insert shaft (4) with collar (3) and O-ring (7) removed in the said procedure into roller (1) directing the collar (3) side upward, and take out collar (3) and O-ring (7) from shaft (4) in the same procedure as that described in Item (3).

Fig. 4-5 Removing shaft (4), collar (2), O-ring (7)

34 –I –1–14

(6) Removing floating seal (6) Take out floating seals (6) from collars (2), (3).

Fig. 4-6 Taking out floating seal (6) (7) Removing floating seal (6) Take out floating seal (6) from roller (1).

Fig. 4-7 Taking out floating seal (6) (8) Removing bushing (5) Since thickness of bushing (5) is thin, remove it through lathe or strip it with care not damage inner hole of roller. When the wear of bushing is not large, place roller (1) on jig (m) for repair stand and apply the end of push-out jig on the end face of bushing (5) end, push it out striking it with mallet. Hammer the inside surface of roller lightly so as not to damage the surface. Put the extrusion jig (n) uniformly over the circumference of bushing (5) and extrude it little by little. Fig. 4-8 Extruding bushing (5)

34 –I–1–15

4.3.2 Installing (1) Attach O-ring (7) to one side Install O-ring (7) to shaft groove.

• Grease O-ring. • Replace O-ring with new one without fail at reassembling.

(2) Press fitting bushing (5) Align inner hole of roller (1) and bushing (5) and press fit it vertically in capacity of press fit load, 3600 kg (7940 lb), in the condition that bushing push-in jig (q) is inserted into bushing (5).

Fig. 4-9 Attach O-ring (7) to one side

PUSH WITH PRESS

• Apply molybdenum disulfide grease on press•

fit section of bushing, and press fit it in ordinary temperature. Bushing which fails to press-fit because of the uneven pressing should not be fitted.

Fig. 4-10 Press fitting bushing (5)

(3) Press fitting collar (3) Fit O-ring to the one side of shaft (4) mating pin hole of collar (3) on which floating seal (6) is fit with pin hole of shaft (4) in advance.

• Care should be taken not to damage O-ring (7) while press-fitting collar (3) to shaft.

(4) Installing snap ring (8) (5) Attach floating seal (6) of roller side Fit floating seal (6) to inner holes on both ends of roller (1).

Fig. 4-11 Press fitting collar (3)

• Check that the seal surface is free from flaws, rusts, etc. before reusing the floating seal.

(6) Inserting roller (1) Insert roller (1) from the side where collar (3), Oring (7) is not press-fitted to the shaft (4).

Fig. 4-12 Inserting roller (1)

34 –I –1–16

(7) Installing O-ring (7) Install O-ring (7) to shaft groove.

PRESS

• Grease O-ring. • Replace O-ring with new one without fail at reassembling.

Snap ring groove

(8) Press fitting collar (2) Press-fit collar (2) to shaft (4).

• Press collar (2) to align snap ring (8) groove with end of collar.

(9) Installing snap ring (8)

Fig. 4-13 Installing O-ring (7), collar (2)

(10) Filling oil Remove plug (9) and fill in 110cc (6.7 cu·in) of engine oil API grade CD #30.

Tightening torque 2.4 kgf·m (17 lbf·ft)

(11) Check it for leakage Before tightening plug (9), check it for leakage in the condition of air pressure 2.0 kgf /cm2 (28 psi) (12) Installing plug (9) Apply oil resistant sealant on plug (9), and tighten it in the plug hole on the collar (2) end face. : 5 mm Tightening torque : 2.4 kgf·m (17 lbf·ft) After assembling the lower roller, confirm that oil is not leaking and that the roller rotates smoothly by hand.

34 –I–1–17

Fig. 4-14 Installing filling oil plugs (9)

4.4 MAINTENANCE STANDARD Before tightening plug, apply oil resistant sealant on it. Tightening torque 2.4 kgf·m (17 lbf·ft)

Fig.4-15 Lower roller (Track roller)

Table. 4-1 Code

Item

A B C

O.D. of flange Tread dia. Flange width

Clearance between shaft and bushing (Wrapped bushing)

Interference between roller and bushing Oil Roller rotation

Clearance between roller and collar

Unit : mm (in) Repairable level

Standard value

Service limit

Remedy

Reinforcement weld, repair or ø84 (3.31) ø80 (3.15) replace 12 14 Fit Fit Clearance Clearance Replace 0 0 ø35 (1.38) Shaft -0.025 -0.001 0.7 (0.028) 1.0 (0.39) bushing. Interference Clearance ø39 (1.54) Hole +0.025 +0.001 0 0 0 (0) 0.01 (0.0004) Engine oil API grade CD #30, 110cc (6.7 cu·in) Replenish. Rotates smoothly by hand. Reassembly.

ø150 (5.91) ø94 (3.70) 19.5 (0.768) Basic dimension Tolerance

( (

) )

Keep 2.5 ± 0.5 (0.1 ± 0.02).

34 –I –1–18

4.5 TOOLS AND JIGS Unit : mm Symbol

Tools

Bushing extrusion rod

Stand jig

Shaft extrusion jig

Bushing fixing jig

Sketch

34 –I–1–19

5. FRONT IDLER 5.1 REMOVAL AND INSTALLATION 5.1.1 Removing (1) Removing 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). Fig. 5-1 Removing idler

: 17mm Weight of idler assy : Approx. 32 kg (70 lb) Weight of idler adjuster assy : 23 kg (50 lb) The separated idler assy (a) is easy to fall down. Lay it down so it does not fall down, utilizing wood block.

c M10 X 50

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.

34 –I –1–20

Fig. 5-3 Installing idler

5.2 CONSTRUCTION

No. 1 2 3 4

Part name Idler Bushing Collar Seal

Part name Q'ty Q'ty No. 2 1 5 Pin 1 2 6 Shaft 2 7 O-ring (1A G 40) 2 2 2 8 Plug : PT1/8

Fig. 5-4 Constuction 5.3 DISASSEMBLY AND ASSEMBLY 5.3.1 Removing (1) Remove plug (8) on the side of collar (3) and drain oil. : 5 mm (2) Apply pin push bar (jig R) to the top of pin, and take out striking lightly by hammer. Fig. 5-5 Extruding pin (3) Put idler (1) on repair stand (U), apply pushout jig (S) on shaft (6), push out shaft (6) with collar (3), then remove collar (3).

PUSH WITH PRESS

(4) With idler (1) placed on the stand, tap bushing (2) lightly by hammer, while placing the bushing extruding rod (T) against the end face of bushing (2) evenly all round, till it comes out. (5) Take out floating seals (4) from idler (1), collar (3). If you intend to re-use floating seals (4), confirm that there is no scoring and rusting on the contact surface and store the floating seals in pairs by placing thick paper between the sealing faces.

Fig. 5-6 Extruding shaft

(6) Remove O-ring (7) from shaft (6).

Fig. 5-7 Removing bushing

34 –I–1–21

5.3.2 Assembly (1) Align inner hole of idler (1) and bushing (2) and press fit it vertically with press.

PUSH WITH PRESS

(2) Fit O-ring (7) to O-ring groove on shaft (2).

• Apply grease to O-ring (3) Installing collar (3) (See Fig. 5-9) Press fit the O-ring installed side of shaft into collar (3), and drive pin (5).

Fig. 5-8 Pressing in bushing (2) PRESSING

(4) Fit one piece of two (2) pieces type floating seal (4) on each side of collar (3) and idler (1). (5) Insert shaft (6) into idler (1).

• Apply gear oil to shaft. (6) Fit floating seal (4) on the other side of idler (1).

Fig. 5-9 Pressing in shaft (6)

(7) Fit floating seal (4) on the other collar (3), press fit it in shaft, and drive pin (5) in with mallet. (8) Filling oil / Inspection Fill in 70~80cc (4.3~4.9 cu·in) of engine oil API grade CD #30 through the plug hole of collar, place the screwed part of plug (8) with seal tape and put in plug (8).

Fig. 5-10 Inserting floating seal (4) PRESSING

: 5 mm

• After installing the idler assy to the idler adjuster

assy, make certain that no oil leaks from floating seal and plug (8) and that idler (1) rotates smoothly.

Fig. 5-11 Pressing in collar (3)

Fig. 5-12 Driving pin (5)

34 –I –1–22

5.4 MAINTENANCE STANDARD

Fig. 5-13 Front idler Table. 5-1 Front idler Item

Code A B C

Dia. of idler projection Tread dia. Flange width

Clearance between shaft and bushing

Interference between idler and bushing Oil Idler rotation

5.5 TOOLS AND JIGS (1) Tools Tools Socket Allen wrench

Unit : mm (in) Repairable level

Standard value ø364 (14.3) ø320 (12.6) 40 (1.57) Tolerance Basic dimension

Service limit

Remedy

ø312 (12.3) ø310 (12.2) 34 (1.34) 36 (1.42) Fit Fit -0.050 -0.0020 Clearance Clearance ø45 (1.77) Shaft -0.089 -0.0035 1.5 (0.059) 2.0 (0.079) Interference Clearance ø49 (1.93) Hole +0.020 +0.0008 -0.030 -0.0012 0 (0) 0.01 (0.0004) Engine oil API grade CD #30, 70~80cc (4.3~4.9 cu·in) Rotates smoothly by hand.

( (

) )

Symbol Unit : mm Opposing flats 19 , 24 5,6

Jigs

Replace

Replace bushing.

Replenish. Reassemble.

Sketch

Repair stand

(2) Jigs Symbol

Jigs

2pcs.

Sketch

Pin extruding jig

Shaft extruding jig

Bushing striking rod

Bushing press fitting jig

Collar press fitting jig

34 –I–1–23

6. IDLER ADJUSTER 6.1 REMOVAL AND INSTALLATION 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 remove idler assy (a), : 17 mm Weight of idler assy : 32 kg (71 lb) Weight of idler adjuster assy : 23 kg (51 lb)

Fig. 6-1 Disassembling idler assy

The separated idler assy is easy to fall down. Lay it down, utilizing wood block. 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. : 17 mm 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

No. 1 2 3 4 5 6 7 8 9 10

Fig. 6-2 Idler adjuster assy

34 –I –1–24

Part name Piston Grease cylinder Spring Bracket Nut : M27 Pin Oil seal O-ring : 1B G40 Spring pin Grease nipple

Q'ty 1 1 1 1 1 2 1 1 1 1

Holding-down nut

6.3 DISASSEMBLY AND ASSEMBLY (1) Disassembly 1) Before disassembling and assmbling the idler adjuster assy, prepare spring setting jig (V).

Retainer plate

Capacity of hydraulic jack : more than 5 tons (11000 lb)

V Hydraulic jack

Large power is needed to set the spring.Prepare a special jig before disassmbly and assembly. Base

2) Place a hydraulic jack between the jig base and the stand.

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 (V), 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 idler adjuster

8) Remove spring pin (9), press spring (3) lifting it with jack so that nut (5) can be turned freely, and remove nut (5) : 41 mm

Holding-down nut

Retainer plate

Fig. 6-5 Fixing idler adjuster assy

Fig. 6-6 Compression of spring

34 –I–1–25

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). Free length of the spring: Approx.340 mm (13.4 in) 10) Hook lifting eye nut (W) to screw M27 X P2 on grease cylinder (2) top end and hoist it.

Retainer plate

11) Remove the set of grease cylinder (2) and spring (3).

(2) Assembly Assembly is done in the reverse order of disassembly. 1) Insert grease cylinder (2) into spring (3) and attach lifting eye nut (W) to screw M27 X P2 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)

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 holdingdown 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 (2). Set length of the spring : 265 mm (10.4 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)

5 Holding-down nut

: 41 mm

Retainer plate

4 3 2

Fig. 6-9 Attach idler adjuster assy to the jig.

34 –I –1–26

5) Remove idler adjuster assy from jig. 6) Fit oil seal (7) and O-ring (8) to grease cylinder (2).

• Grease oil seal (7) and O-ring (8). 7) Fill up grease in cylinder (2), remove the grease nipple from piston (1) to discharge the inside air, and press in the piston by hand.

• Direct grease nipple hole downward to make air discharge easier.

8) Tighten grease nipple to piston (1). : 19 mm Tightening torque : 6kgf·m (43 lbf·ft)

6.4 MAINTENANCE STANDARD Table. 6-1 Code A B C D E F

Item

Unit : mm (in)

Rubber crawler

Iron shoe

265 (10.43) Installed length of spring 340.8 (13.42) Free length of spring 28 (1.10) Stroke 415 (16.34) SK40SR-2 Set length 428 (16.85) SK45SR-2 Nor scoring and rusting Visual check of piston Tightening torque of grease nipple 6 kgf·m (43 lbf·ft)

D (Rubber crawler) D (Iron crawler) A, B

Fig. 6-10 Idler adjuster assy.

34 –I–1–27

7. SPROCKET LOWER FRAME

7.1 REMOVAL AND INSTALLATION 7.1.1 Removing (1) Remove the crawler assy. (2) Place wood block under the lower frame so the sprocket is off the ground. (3) Loosen socket bolts (M10) for the attaching of the sprocket by means of allen wrench and remove the sprocket.

WOOD BLOCK

SPROCKET

Fig. 7-1 Free sprocket from load

: 8 mm Single weight of sprocket : 15 kg (33 lb) SOCKET BOLT

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. (2) Apply Loctite #262 to the sprocket attaching socket bolts and fasten the sprocket temporarily.

SPROCKET

Fig. 7-2 Removing sprocket

(3) Remove the wood block under the lower frame and tighten socket bolts with specified torque to fix sprocket and travel motor. : 8mm T= 18.5 kgf·m (134 lbf·ft)

TRAVEL MOTOR

(4) Install crawler 7.2 MAINTENANCE STANDARD

Fig. 7-3 Tightening socket bolts

Fig. 7-4 Sprocket Item Code A Width of sprocket teeth O.D. of sprocket B

Standard value 32 ø435.8

Repairable level 29 ø429

34 –I –1–28

Service limit 27 ø427

Unit : mm (in) Remedy Replace Welded repair, or replace

8. TRAVEL MOTOR 8.1 REMOVAL AND INSTALLATION 8.1.1 Removing (1) Remove the crawler assy.

LOWER FRAME

(2) Place wood block under the lower frame so the sprocket is off the ground. (3) Remove the capscrews (A10) located inside the lower frame and remove the cover (A1).

WOOD BLOCK

: 17 mm

SPROCKET

Fig. 8-1 Free sprocket from load

(4) Push the air breather of hydraulic oil tank sevral times and release air in the tank. : 22 mm (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, 27 mm, 32mm (6) Remove bolts (B2) that fasten the travel motor to the lower frame. On that occasion, put a matching mark between the lower frame and the travel motor.

Fig. 8-2 Removing cover / travel motor

: 22 mm (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) : 73 kg (161 lb) 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 attaching socket bolts (B4) with Loctite #262 and tighten them. : 22 mm T= 18.5 kgf·m (134 lbf·ft)

34 –I–1–29

Fig. 8-3 Removing / Installing travel motor

(3) Reconnect the hydraulic pipings as before, and tighten the joints with specified torque. DR

Port A, B DR P

Tube O.D Opposing flats Nut-sleeve joint (mm) (mm) Torque kgf·m (lbf·ft) 15 (108) 32 ø18 12 (87) 27 ø15 5 (36) 19 ø10

P A B

(4) Install the covers (A1) located inside the lower frame, and tighten bolts (A10). (See Fig. 8-2) Fig. 8-4 Installing hydraulic pipings

: 17 mm (5) Remove the wood block supporting the lower frame and install the crawler.

LEVEL PLUG FILLING PLUG

(6) Check the oil level in the reduction gear 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 : 1000cc (61 cu·in)

GL 90°

DRAIN PLUG

: 8mm (7) Checking oil level in reduction gear a) Stop the machine so the drain plug comes just 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.

Fig. 8-5 Checking oil level

Socket bolt for sprocket Loctite #262 18.5 kgf·m (134 lbf·ft)

TRAVEL MOTOR

OIL

TIGHTENING TORQUE

8.2 MAINTENANCE STANDARD Item Sprocket fixing bolt M14 Travel motor fixing bolt M14 Spec. and grade Volume

Spec.

Apply Loctite #262 18.5 kgf·m (134 lbf·ft) Gear oil SAE #90 1000 cc (61 cu·in)

34 –I –1–30

Socket bolt for travel motor Loctite #262 18.5 kgf·m (134 lbf·ft)

Fig. 8-6 Installing travel motor

9. SLEWING BEARING 9.1 REMOVAL AND INSTALLATION 9.1.1 Removing (1) Remove the upper slewing structure. (See Chapter PJ33 “Upper Slewing Structure”) (2) Remove capscrews (B) that fix the inner race of slewing bearing (A) : 22 mm 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 : 76 kg (168 lb) 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.

LOCTITE #262 18.5 kgf·m (134 lbf·ft)

(3) Coat the threads of the capscrews (B) with Loctite #262 and tighten all capscrews temporarily. LOWER FRAME

(4) Tighten the capscrews at 180½ intervals alternately, and tighten them up to a specified torque.

Section A-A

: 19 mm T= 18.5 kgf·m (134 lbf·ft) (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–1–31

9.2 CONSTRUCTION No. 1 2 3 4 5

Part name Q'ty No. Part name 1 Inner race 6 Plug 1 Outer race 7 Taper pin 76 8 Seal A Ball 62 9 Seal B Spacer Spacer (Adjusting) 14 10 Grease nipple

Q'ty 1 1 1 1 1

(3) Remove plug (6), using puller bolt made use of the threaded bore (M10) in the center of the plug. (4) After removing plug (6), take out balls (3) and spacers (4) (5) from the bore in order, while rotating outer race (2) slightly.

8 1

6 10

9.3 DISASSEMBLY AND ASSEMBLY 9.3.1 Disassembling (1) Remove seal A (8) fitted in the groove in the inner circumference on top of outer race (2) and seal B (9) fitted in the groove in the outer circumference under inner race (1), from the bearing, and place the bearing level on wood block. (2) Remove taper pin (7), using a hammer and push rod.

3,4,5

Fig. 9-4 Section of slewing bearing

2 WOOD BLOCK

6 9

9.3.2 Assembling (1) Degrease thoroughly the groove for seal A (8) located in the inner circumference of outer race (2) and the groove for seal B (9) located in the outer circumference of inner race (1). Coat the grooves with adhesive (Cyanoacrylate instant glue), fit seal B (9), and place inner race (1) on a surface plate.

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) coated with the specified grease (NLGI No.2 Lithium base with MoS2) alternately through the bore for plug (6) in outer race (2). When inserting balls (3) and spacers (4) (5), the raceways 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.

34 –I –1–32

4,5

Fig. 9-6 Removing balls / spacers

2 8

Fig. 9-7 Installing balls

(4) Install plug (6) to outer race (2), confirming the direction and the position of the bore for taper pin (7).

LIFTING BOLT

(5) Drive taper pin (7) into bore, and caulk the head of the taper pin with a punch.

HOOK ROD

(6) Coat seal A (8) with adhesive (Cyanoacrylate instant glue) and place it into groove of outer race (2). (7) Confirm that grease nipple (10) is useful. Apply grease (NLGI-2 MoS2) and confirm that the outer race rotates smoothly and that the lip of the seal is not scored. Grease amount : 180 g (6.3 oz) 9.4 MAINTENANCE STANDARD Regarding the maintenance standards for the wear of the slewing bearing, refer to the section PJ13 Maintenance Standards and Test Procedures, Article Measuring Slewing Performances.

34 –I–1–33

4,5

WOOD BLOCK Fig. 9-8 Installing spacer

NOTES

Part II : DISASSEMBLING AND ASSEMBLING 1. TRAVEL MOTOR 1.1 OUTLINE (1) General view Fill port PF3/8 Check / Level port PF3/8

D1 A P Z B D2

Gauge port G5 Drain port PF3/8

Gauge port View Z

Fig. 1-1

HYDRAULC CIRCUIT (High speed side)

D1 G5

(Low speed side)

D2 G6

Port name & size Table. 1-1 Code A B D1 D2 G5 G6 P

A B Fig. 1-2

Port Hydraulic oil fill / drain port

˝ Drain port ˝ Pressure detect port ˝ 1st / 2nd speed select port

Size PF1/2 PF1/4 PT1/8 PF1/8

Rotational direction(Viewed from “Z”) Inlet A port,outlet B port CW Inlet B port,outlet A port CCW

34 –II–1–1

(2) Sectional view (Exploded views of this unit are shown in the Parts Manual.)

A 35

19 O F

Section F-F 35

A Section E-E

18 29 12 E

36 34 20 22 9 25 7 24 6 102 8 19 33 36

221

236

228

227

225

230

254

237

223

226

275

1 190 161 162 103

17 132 149 177 167

Section B-B

106 105 31 2 169 115 116 151 110

108 107 104 135 139 112 243 B

266 150

224

23 4

109

273

C 263 275 222 221 299 220 201 145 218 264 273 114 233 219 Section A-0-A

27 275 30 113 241

Fig. 1-3

34 –II–1–2

252 280 268

Section C-C

(3) Parts list Table. 1-2 No. 1

2 3 19 35 4 9 12 22 23 6 7 8 17 18 20 21 24 25 27 29 30 31 33 34 36 42

105 106 161 162 102 103 104 107 108 109 110 112 113 114

Parts name Hub Spindle kit • Spindle assy. • • Spindle • • Hold flange • Reamer bolt • Capscrew RV gear assy • RV gear • Crank shaft • Spacer • Taper roller bearing • Needle bearing Input gear Spur gear kit • Spur gear Cover Pin Ring Snap ring Ball bearing Snap ring Snap ring O-ring (1B P8) O-ring (1B G200) O-ring Floating seal kit • Floating seal Plug (PF 3/8) Plug (PF 3/8) O-ring (1B P14) Parallel pin Piston kit • Piston assy. • • Piston • • Shoe Piston kit • Piston • • Shoe Shaft Swash plate Cylinder block Retainer plate Thrust ball Timing plate Washer Piston Spring Spring

Q'ty 1 1 1 1 1 2 2 1 2 2 4 4 4 1 1 2 1 28 1 2 2 1 4 2 1 1 1 2 1 2 3 2 1 9 1 1 1 1 1 1 1 1 1 1 1 2 1 8 1

No. 115 116 132 135 139 145 149 150 151 167 169 177 190

201 223 263 264 218 219 220 221 222 224 225 226 227 228 230 233 236 237 241 243 252 254 266 268 273 275 280 299

34 –II–1–3

Parts name Friction plate Separator plate Oil seal O-ring O-ring Snap ring Ball bearing Ball bearing Roller Pivot Plate Parallel pin Spring Rear flange assy • Rear flange kit • • Rear flange • • Spool • Spool kit • • Spool • • Oil stopper • Valve seat • Valve • Spring • Plug (PF 1/4) • Ring • Plug • Stopper • Plug • Valve • Spring • Spring • O-ring (1B P7) • O-ring (1B P22) • O-ring (1B P12) • Parallel pin • Socket bolt (M8 X 20) • Socket plug (PT 1/8) • Socket plug • Spring • Steel ball • O-ring (1B P11) • Orifice • Plug • Name plate

Q'ty 2 2 1 1 1 1 1 1 3 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 2 2 2 2 1 2 2 2 6 3 6 1 1 2 6 1 1

1.2 REQUIRED TOOLS (1) General tools

Specification 6mm (M8) (PF 1/4) 5mm (PF 1/8) 8mm (PF 3/8)

Tools No. 1 Allen wrench 2 3 4

Socket (Ratchet handle) Torque wrench Torque wrench adapter

5 6 7 8 9 10

Extension bar Hammer Plastic mallet _ Screwdriver Snap ring pliers Lifting device

11 12

Container Leather gloves

Q'ty One each One each

1 18 kgf·m, 56 kgf·m Nominal 24, 30 socket Nominal 5 key wrench, 6 key wrench, 8 key wrench 150 mm Nominal 12 L = 300 150 mm For shaft & hole Load capacity 300 kg or more Eye bolt (M12) Eye bolt (PF 3/8) Wire with hook Vat W450 X D300 X H120

(2) Apparatus Application (No. in Fig. 1-3) Disassembly & Assembly Parts cleaning 104, 149

Work bench Cleaning bath Press machine

149

Heating bath

Electric drill

1 Disassembling 161, 162, 112, 218 Parts drying 3

Drill Compressed air

Apparatus

Specifications

One each One each One each

1 1 1 1 1 1 set (2) (2) (1) 2 1 set

Remarks

Q'ty 1 set 1 set 1 set

For cleaning Capacity 150kg (330 lb) or more Capacity 100 °C or more Size500 X 500 X 500mm Handy drill (Max. hole Ø10) Ø2 Pressure 3~5 kgf/cm2 (43~71 psi)

1 set 1 1

1 set

Lathe

(3) Measureing instrument

Application (No. in Fig. 1-3) Snap ring (20) Snap ring (20) Ball bearing (21)

Apparatus Thickness gauge Outer micrometer Depth micrometer

Specifications Range 0.04~0.3 mm Range 0~25 mm Minimum graduation 0.01 Range 0~25 mm Minimum graduation 0.01

34 –II–1–4

Remarks

For

Q'ty 2 1

adjustment

(4) Jigs NAME : Working bench for travel motor • This is used to carry out the work for assembly and disassembly of travel motor easy and safe.

NAME : Fixing metal • This is used to connect spindle (2) and hub (1).

NAME : Retainer metal ( I ) • This is used to insert spring (114), washer (110), snap ring (145) into cylinder block (104). • This is used to remove spring (114) from cylinder block (104).

NAME : Retainer metal ( II ) • This is used to pull out bearing (149) from shaft (102).

34 –II–1–5

NAME : Retainer metal ( III ) • EThis is used to press fit oil seal (132) into oil seal fitting hole of spindle (2).

NAME : Retainer metal (IV) • Apply it on outer race of bearing (22) fitted on crankshaft (9) of RV gear assy, then strike it to insert RV gear assy securely.

NAM : Jig for adjusting the preload to the bearing • This is used to press fit bearing (21) in hub (1), and also used to measure clearance of bearing (21) in shaft direction.

* Detail of this Jig is shown on the next page.

Special nut

7 No.

1 3 4 6 7 8

4 8

34 –II–1–6

Q'ty Remarks Parts name Flange bolt 1 M20 X P2.5 Standard hold flange 1 Special nut 1 M20 X P2.5 Socket bolt 2 M6 X 40 Thrust bearing 1 51204 Guide ring 1

1 FLANGE BOLT

3 STANDARD HOLD FLANGE

8 GUIDE RING

4 SPECIAL NUT

34 –II–1–7

NAME : Steel rod ( I ) • This is used to remove ring (18) from hub (1).

NAME : Eye bolt for PF plug • This eye bolt is used to remove cover (8) from hub (1) with wire and crane. • Plug size is PF3/8

NAME : Long eye bolt • This eye bolt is used to sling up travel motor, spindle (2) and hub (1).

NAME : Spatula • This is used to remove timing plate (109) from rear flange (201).

NAME : Pin punch (Aluminum bar) • This is used to remove outer race of bearing (21).

34 –II–1–8

NAME : Pointed punch • This is used to remove ring (222) in pilot valve.

NAME : Cover removing jig • This is used to remove cover (8) from hub (1).

NAME : Floating seal fitting tool ( I ) • This is the tool that is used to assemble floating seal (31) to hub (1).

NAME : Floating seal fitting tool ( II ) • This is the tool that is used to assemble floating seal (31) to spindle (2) and hub (1).

NAME : Floating seal fitting tool ( III ) • This is the tool that is used to assemble floating seal (31) to spindle (2).

34 –II–1–9

1.3 TIGHTENING TORQUE

Application (No. in Fig.1-3) 19 33 34 35 224 226 243 221 254

Bolt, Nut Parts Reamer bolt Plug Socket plug Socket bolt Plug Plug Socket bolt Plug Socket plug

Size M16 P2.0 PF3/8 PF3/8 M16 P2.0 M25 P1.5 M20 P1.5 M8 P1.25 PF1/4 PT1/8-S

Opposing flats (mm) 24 8 8 24 30 8 6 6 5

Torque kgf·m (lbf·ft) 25.7 (186) 6.0 (43) 6.0 (43) 25.7 (186) 20.0 (145) 8.0 (58) 3.0 (22) 3.0 (22) 1.0 (7)

1.4 DISASSEMBLING WEIGHT

Application (No. in Fig.1-3) 1 2 201

Parts name

Weight kg (lb)

Travel motor assy. Hub Spindle Rear flange assy.

Approx. 57 (126) 11 (24) 20 (44) 6.15 (14)

34 –II–1–10

1.5 DISASSEMBLY (1) Preparation Prepare as below before disassembly : 1) Preparation of work bench • Prepare a work bench for the travel motor. • The work bench must be sufficiently solid to disassemble and reassemble the internal components of the travel motor and sufficiently spacious to place components so components do not fall or move during operation. • Place a rubber or plastic sheet on the work bench. 2) Preparation of tools and apparatus Prepare those tools and apparatus listed under Article. 1.2. (2) General precautions to be exercised at work

CAUTION • The internal components are wet with hydraulic oil and slippery during disassembly. Handle them with care because you may be injured by the fall of components or components may be damaged. • Such flammables as kerosene are used to clean components. Handle flammables as they are easy to be caught a fire.

1) Before disassembly, decide inspection points and check the nature of the trouble. 2) Handle the components with care as they are finished to high precision. Take care so as not to hit and drop the components 3) If the components are struck or twisted by force during disassembly, they develop burrs or broken in some cases. This makes the components unable to be reassembled or deteriorates the performances. Therefore, handle them with care. 4) If components are left separated or in the midst of disassembly, they develop rusting by humidity and dust. Take rust and dust prevention treatment in case work is suspended halfway. 5) During disassembly, leave a matching mark on the mating face of each component. 6) Arrange disassembled components in order as the work proceeds so they are not damaged or lost during work. 7) It is a rule to replace seals once disassembled. (even though they are not scored on an appearance) Get new seals ready before disassembly. 8) Photos and illustrations shown are typical models. Although they may differ from those in use, they do not affect the disassembly procedure.

34 –II–1–11

(3) Removing 1) Cleaning travel motor 1. Tighten the eye bolts into the tapped holes of the spindle (2). Eye bolt : M14

Fasten two eye bolts into the tapped holes so they are located diagonally opposite to one another.

2. Place a wire sling in the eye bolts, lift the travel motor by hoist, and carry in to the cleaning bath. Travel motor assy weight : Approx. 57kg (126 lb) 2 3. Clean the travel motor with a car brush. Since soil and sand are entered in the clearance (where the floating seal is fixed) between hub (1) and spindle (2), clean it with particular care. 1

2) Installing travel motor 1. Placing travel motor on working bench. Align threaded holes of hub (1) and working bench, and place travel motor in fixing hole of working bench slowly.

2. Fix travel motor with two socket bolts on working bench. : 12mm

CAUTION Tighten up the socket bolts securely. Unless tightened securely, the components drop as the travel motor is turned over and cause bodily injuries. Socket bolt

34 –II–1–12

33 3) Draining gear oil. 1. Turn over the travel motor. 2. Loosen one plug (33) and two plugs (34). : 8 mm • If the plug (33), (34) are removed and the travel motor is reversed, oil spills. Stop loosening the plug when it can be turned by hand. 3. Turn over the travel motor. • When draining out the gear oil, place a container under the work bench. 4. Remove one plug (33) and two plugs (34) from the cover (8) and drain out the gear oil. : 8 mm 5. Remove O-ring (37) from plugs (33), (34). • Don’t reuse these O-rings.

4) Removing cover. 1. Turn over the travel motor. 2. Mark on the mating surface between hub (1) and cover (8), using paint marker.

8 18

3. Find the mating part of ring (18), and punch at a point of the outside of the hub, approximately 20mm (0.8in) far away from the tip of ring (18) for drilling purpose.

34 –II–1–13

18 4. Drill through a 2mm (0.078 in) hole from the outside of hub (1) toward ring (18) using drill motor. • Put a drill against the punched hole and drill it through so the ring moves as it is pushed by the drill. • Wipe off the metal chips produced by drilling so they do not score the parts to be removed.

18 5. Put a steel bar into the hole and push ring (18). • In that case, the tip of the ring (18) stands out above the cover (8) as pressed by a steel bar.

8 8 6. Hold the tip of ring (18) sticking out of the cover (8) and draw the ring (18) out of the ring groove of the hub (1).

18 7. Fix two PF3/8 inside bolts of cover removing jig to the two tapped holes of cover (8) [to which plugs (33),(34) and fixed usually.]. • In case the cover (8) is hard to remove because of the resistance of the O-ring (29), lift it up while lightly tapping the outer rim of the cover by means of a plastic mallet.

Cover removing jig

34 –II–1–14

8 29 8. Tighten two bolts outside of jig then two bolts (installed in plug holes) inside of jig float with cover (8). 9. Remove O-ring (29) from cover (8). Do not reuse removed O-ring (29).

102 5) Removing input gear. 1. Remove snap ring (24) from shaft (102). When the snap ring is removed, the tip of the pliers slips from the snap ring hole and the snap ring jumps up in some cases. Be careful not to slip the pliers.

24 102 2. Remove input gear (6) from shaft (102).

6 6) Removing spur gear 1. Remove two snap rings (25) from crank-shaft (9).

When the snap ring is removed, the tip of the pliers slips from the snap ring hole and the snap ring jumps up in some cases. Be careful not to slip the pliers.

34 –II–1–15

7 2. Remove two spur gears (7) from crank-shaft (9).

9 3. Remove two snap rings (25) from crank-shaft (9). • When the snap ring is removed, the tip of the pliers slips from the snap ring hole and the snap ring jumps up in some cases. Be careful not to slip the pliers.

25 7) Removing rear flange 1. Turn over the travel motor • This work is intended to remove the plug easily when removing the inside of the rear flange. On that occasion, loosen the plug so it can be removed by hand. • Do not loosen the plug if you do not disassemble the inside of the rear flange.

224 (Inside of socket) 226

2. Loosen two plugs (224) • This work is intended to remove the plug easily when removing the inside of the rear flange. • Do not loosen the plug if you do not disassemble the inside of the rear flange. 3. Loosen two plugs (226)

34 –II–1–16

4. Loosen six socket bolts (243) from rear flange (201).

243 201 5. Remove rear flange (201) from spindle (2). Hold the rear flange by both hands, hold it up gently upright and remove it. Forced prying or striking it may cause timing plate (109) to fall and damage it.

2 6. Remove parallel pins (42) from spindle (2). 7. Remove eight springs (113) from spindle (2).

42 8.Remove O-ring (27),(30) from spindle (2). • Do not reuse removed O-ring (27), (30).

34 –II–1–17

8) Removing the rear flange fittings 1. Place rear flange (201) on a work bench, with the mating surface for spindle (2) facing up. 2. Remove timing plate (109) from rear flange (201). • If it is hard to remove the rear flange in some cases 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 screwdriver is put into the mating surface, the mating surface is scored, causing an oil leakage 3. Remove parallel pins (241) from rear flange (201).

201

109

241

201

4. Remove bearing (150) from rear flange (201).

201

150

9) Removing the brake valve parts from the rear flange. 1. Remove two plugs (224) of rear flange (201). : 30 mm

201

34 –II–1–18

224

2. Remove two stoppers (225) and two springs (228) from rear flange (201). 3. Remove spool (223) from rear flange (201). • To remove spool (223), place your hand on one part of the plug port of rear flange (201) and tilt it down. Then spool (223) falls down. Hold the tip and remove it.

223 (225, 228)

201

4. Remove two plugs (226) from rear flange (201).

226

201

5. Remove two springs (230) and two valves (227) from the rear flange (201).

226, 227, 230 236 6. Remove O-ring (236) from plug (224). • Do not reuse removed O-ring (236).

224

34 –II–1–19

201

237 7. Remove O-ring (237) from plug (226). • Do not reuse removed O-ring (237).

226 10) Removing 1st/2nd speed switching spool 1. Remove plug (221) from rear flange (201). 2. Remove O-ring (273) from plug (221). • Do not reuse removed O-ring (273).

221

201

3. Remove spool (263) and spring (266) from rear flange (201).

263, 266

201

11) Removing parking brake valve (219). • Remove the ring (222) only when replacing the valve (219). 1. Place the rear flange (201) on a work bench with its inner surface up. 2. Put the hooked rod against the notched part of the ring (222), while holding the valve seat (218) with a steel rod, and remove the ring (222) from the rear flange (201). • If the ring (222) is removed, the hole is scored , repair the hole well after it is removed.

34 –II–1–20

218, 222

201

If you blow jet air powerfully, it is very dangerous as the parts pops out from the rear flange, blow jet air gradually. 3. Plug the hole in valve seat (218), blow in jet air through the oil passage and then remove valve seat (218) from rear flange (201).

201

218

4. Hold the rear flange (201), shake it lightly with its hole down, then the valve (219) and the spring (220) can be removed.

219, 220

5. Remove O-ring (233) from valve seat (218).

220 219 218 222 233 • Do not reuse once removed ring (222), valve seat (218) and O-ring (233).

34 –II–1–21

12) Removing the parking brake

The sudden blowing of compressed air may cause parts to fly out incurring the danger of injury. Cover piston(112) for protection.

Protect cover 1. Blow jet air into the passage hole for the parking brake of the spindle (2) and take out the piston (112) from the spindle (2).

112

2. Remove O-ring (135),(139) from piston (112). • Do not reuse removed O-ring (135), (139).

112

139

13) Removing the hydraulic motor section • When placing the travel motor on its side, oil spills ; place a container under the travel motor. 1. Incline travel motor 90 degree. (Lay it down.) 2. Drain out the oil of the travel motor. 3. Remove separator plate (116), friction plate (115) two each and plate (169).

4. Hold cylinder block (104) by hand, separate shoe (106) adhered on swash plate (103) turning 2 or 3 times alternately.

115,116,169 104,(106)

Hold the cylinder block (104) in your hand before it comes out, turn it a few times, and cut off the shoe (106) adhered to the swash plate (103). If the cylinder block (104) is drawn out, the shoe (106) remains on the swash plate (103). As the result, the parts (piston, shoe, etc.) attached to the cylinder (104) come off the cylinder block (104) and fall into the spindle (2).

34 –II–1–22

135

5. Hold the cylinder block (104) and remove the shaft (102). 6. Remove piston assy[piston (105) and shoe (106)] and retainer plate (107) from cylinder block (104). • When removing the cylinder block, hold the retainer plate (107) by both hands and remove it with the piston assy. • The piston (105) and the shoe (106) are made in piece as they are reduced by the spherical surface of the piston. It is not possible to remove the piston from the shoe without damaging the shoe. When replacement is required, replace 9 sets of piston (105) and shoe (106). (Hereafter called piston assy.)

105,106

104

107

7. Remove the piston assy (105),(106) from retainer plate (107).[Nine pistons]

105,106

107 108

8. Remove thrust ball (108) from cylinder block (104).

104 9. Remove three rollers (151) from cylinder block (104).

151

34 –II–1–23

104

14) Removing spring (114) from inside the cylinder block. 1. Place cylinder block (104) on the press bench. • When removing the spring, align the JIG (I) with the washer in order to prevent the cylinder block from being damaged by contact. • Put a plastic sheet over the cylinder block so as not to score the surface of the cylinder block.

104 (Plastic sheet) 2. Apply retainer metal (I) on washer (110), remove snap ring (145) from the groove with snap ring plier pressing the metal with a press.

Retainer metal ( I ) Press

145 114 110

104

Release press slowly. Sudden releasing may cause spring to fly out incurring the danger of injury.

110

110 3. Remove the snap ring (145), washer (110), spring (114), and washer (110) from inside the cylinder block (104).

114

104

34 –II–1–24

102 15) Removing swash plate (103). 1. Removing swash plate (103) from shaft (102). • When removing it, check that pivot (176) is not adhered on swash plate.

103 166,177 2. Pull shaft (102) out of spindle (2). Then bearing (149) is removed together. • The shaft comes off easily if the tip of the shaft on the reduction gear side is tapped lightly, using a plastic mallet. If it is struck forcibly, shaft may be projected. Strike it with care.

3. Remove two pivots (167) and the parallel pin (177) from the spindle (2).

149

102

4. Blow compressed air through passage of spindle, and remove 1st/2nd-speed switching piston assy (piston, shoe) and spring (190) from spindle (2). • Piston (161) Piston assy • Shoe (162)

Compressed air

34 –II–1–25

1st/2nd speed switching assy (190)

16) Removing bearing (149). Press 104

• Remove it only when replacing the ball bearing.

Retainer metal (II) 1. Place the retainer metal (II ) on a press bench and put the shaft (102) in it. 2. Hold down the tip of the shaft by press and remove the bearing (149) from the shaft.

102

• Do not reuse the bearing. 17) Remove hold flange (3) 1. Turn over the travel motor. 2. Fix hub (1) and spindle (2) with fixed metal. Then, the fixed metals should be tightened on symmetrical positions each other.

If the hold flange (3) is removed without attaching the fixing metal, the hub (1) separates from the spindle (2), causing the spindle (2) to fall from the work bench. Fixing metal (This photo shows for other type.) 3. Turn over the travel motor.

When the snap ring is removed, the tip of the pliers slips from the snap ring hole and the snap ring jumps up in some cases. Be careful not to slip the pliers. 4. Remove two snap rings (20) from the hold flange (3).

5. Put matching mark on snap ring(20) and hold flange (3) with an oil paint marker. • This is to place them in the same positions as at installation.

34 –II–1–26

6. Turn over the travel motor. 7. Loosen two reamer bolts (19). : 24 mm • The threaded portion of reamer bolt (19) is provided with adhesive agent and may cause the seizure on the reamer portion where the adhesive agent is applied, leading to the difficulty of disassembling. Therefore loosen reamer bolt (19) slowly. If it is hard to turn in the middle way, tighten it one more time, then loosen it again.

(19)

• The tightening torque is 25.7kgf·m (186 lbf·ft). A torque more than it is needed to loosen the bolt because of adhesive. 8. Loosen two capscrews (35). : 24 mm • The threaded portion of capscrew (35) is provided with adhesive agent and may cause the seizure on the thread portion where the adhesive agent is applied, leading to the difficulty of disassembling. Therefore loosen capscrew (35) slowly. If it is hard to turn in the middle way, tighten it one more time, then loosen it again.

(35)

• The tightening torque is 25.7kgf·m (186 lbf·ft). A torque more than it is needed to loosen the bolt because of adhesive. 9. Turn over the travel motor again. 10. Remove hold flange (3) from spindle (2).

3 11. Put matchmarks on hold flange (3) and spindle (2) with paint marker. • This is intended to install the hold flange (3) in the same position as the spindle (2). • The two holes for reamer bolts (19) and two holes for capscrew in the spindle (2) are machined together. In case of they must be replaced, replace the spindle (2) and the hold flange (3) together as a set (assy). [Hereafter called spindle assy]

34 –II–1–27

18) Removing fixing metal. 1. Turn over the travel motor. 2. Remove two fixing metal.

Fixing metal (This photo shows for other type) 19) Removing spindle. 1. Place container for oil draining under work bench. 2. Tighten two eye bolts into the tapped holes of spindle (2) so they are located in diagonally opposite positions. 3. Hook sling to eye bolt, lift spindle (2) up and remove it from hub (1). Then, floating seal (31), outer race of bearing (22), and oil seal (132) are also removed together. Spindle weight : Approx. 20kg (44 lb)

2, 31, 22

20) Removing bearing, RV gear assy and pin 1. Remove bearing (21) from hub (1) striking pin(17) end face with punch and mallet. • Remove bearing (21) striking 3 or 4 points of perimeter evenly taking care for bearing not to be leaned. • When the fit section of outer race of bearing (21) is separated, bearing (21), RV gear assy and pin (17) drop from hub (1). So spread rubber mat under the working bench to protect them from damage. 2. Then, RV gear [RV gear A (4), crankshaft (9), bearing (22) bearing (23), spacer (12)] and pin (17) are also removed together.

34 –II–1–28

Hammer Aluminum bar

12 9

1 1 21

17 21

3. Clear away bearing (21), RV gear assy and pin (17). • Never remove bearing (22), bearing (23) and spacer (12) from crankshaft (9) except for replacement.

4. Turn over the travel motor. 5. Remove bearing (21) from hub (1). • Remove bearing (21) striking 3 or 4 points of perimeter evenly taking care for bearing not to be leaned.

21 21) Removing the spindle fittings. 1. Remove oil seal (132) from spindle (2).

132 2

• Never reuse removed oil seal (132).

2. Remove floating seal (31) from spindle (2).

34 –II–1–29

3. Remove the outer races (2 pcs.) of bearing (22) from spindle (2). • It is sometimes hard to remove the outer race of the bearing (22) as the outer race of the taper roller bearing comes in close contact with the attaching surface of the spindle by oil films of lubricating oil. In that case, tap the center of the attaching hole of spindle (2) by means of an aluminum rod. Then the outer race is removed easily as the oil film is cut.

22) Disassembling hold flange 1. Remove outer race of bearing (22) from hold flange (3).

2 23) Rough washing of parts. 1. Distinguish the four parts ; hub (1), spindle (2), cover (8), and rear flange (201) from other parts (hereafter called built-in parts). 2. Put the hub, spindle, cover and rear flange in a cleaning bath and clean them. • Soil and sand are adhered to the outer surface of parts in some cases ; clean them and remove soil and sand from the parts.

Cleaning solvent is flammable. Be careful not to cause fire. • Before cleaning stained parts, immerse them in cleaning solvent until dust and stain become soft and are floated to protect them from damaging when cleaning. 3. Put the built-in parts in a rough cleaning bath and clean the parts.

34 –II–1–30

201

24) Finish cleaning 1. Put parts in a finish cleaning bath containing cleaning solvent and clean them well, turning them slowly. 2. Wipe off the cleaning solvent adhered to the parts, using rag. • Blow compressed air in the inner surface of hub (1), spindle (2) and hold flange (3) to dry in the dust free and dry conditions. After drying, apply hydraulic oil to every part. • Inner surface of rear flange (201), hydraulic motor components, and RV gear assy are to be dried naturally in the dust free and dry conditions. After drying every part, apply hydraulic oil to every part. • Use care not to damage the surface of twenty eight pins (17) or lose them while handling.

34 –II–1–31

1.6 ASSEMBLY (1) Preparation of tools and apparatus Preparation of tools and apparatus listed under Article 1.5 DISASSEMBLY. (2) 1) 2) 3) 4)

General precaution Assembly it by reversing the procedure of disassembly. Assemble it in clean air condition. Do not use cloth gloves during assembly. Replace or repair the damaged parts during disassembly according to the instructions in the “Maintenance standard”. Replace O-ring, oil seal, etc. with new one. 5) Clean every part sufficiently, and blow them with compressed air do not use rag. 6) Prior to assembling, apply clean hydraulic oil to moving and sliding portions of hydraulic motor valve. 7) Tighten bolt and plug to the specified torque using torque wrench. 8) Replace reamer bolt with new ones. If it is unavoidably reused, remove completely the adhesive agent on reamer bolt, repair flaws on bolt seat surface with oilstone, and degrease it. 9) Prior to assembling, apply grease to lip portions of O-ring, oil seal, and floating seal to protect it from being damaged, and to moving section and sliding section. 10) After assembly, plug every port to protect the entry of dust, etc. 11) Photos and illustrations shown are typical models. Although they may differ from those in use, they do not affect the assembly procedure. (3) Preparatory arrangement for assembly After replacing parts with new ones, adjust the pre-load of bearing and thickness of snap ring without fail.

1. When the following parts are replaced, the pre-load adjustment of bearing is required : Hub (1), Spindle (2), Hold flange (3), Bearing (21) 2. When the following parts are replaced, the snap ring thickness adjustment is required : Spindle kit (2), Hold flange (3), Crankshaft (9), Spacer (12), Bearing (22)

Where replacing the above parts, the previously adjusted parts should be used. If unadjusted parts are used, the travel motor moves abnormally, causing early breakage.

34 –II–1–32

(4) Installing procedure 1) Installing hub (1) 1. Install two eye bolts (M14) into the tapped holes of hub (1) so they are located in diagonally opposite position. 2. Sling eye bolt of hub (1), and lift up and place it on working bench. Align hub (1) to the attaching holes of the work bench, while matching the holes in hub (1) with those in the work bench.

1 3. Fix hub (1) on working bench with socket bolts so they are located in diagonally opposite positions.

CAUTION Tighten up the socket bolts securely. Unless tightened securely, the components drop as the travel motor is turned over and cause bodily injuries.

Working bench 4. Insert bearing (21) in hub (1).

• Place a pin punch against the outer race of bearing (21), hammer it lightly all around and press in the bearing little by little.

5. Coat the O-ring of floating seal(31) with hydraulic oil and fit the O-ring into the floating seal groove of hub(1).

• When coating the O-ring of the floating seal with hydraulic oil, remove the O-ring from the floating seal and coat the entire surface of it with a thin film of hydraulic oil. • To fix the floating seal, match the O-ring into the groove of the hub and push it in. Make certain that the end face of the hub and the face of the floating seal are parallel with each other within a tolerance of 1mm (0.39in).

34 –II–1–33

2) Assembling spindle section. 1. Apply hydraulic oil on O-ring of floating seal (31), and fit floating seal in the groove of spindle (2). • Remove O-ring from floating seal and apply hydraulic oil on its lightly. • Fit floating seal so that spindle groove is in parallel with floating seal surface within 1mm (0.039 in) error after fitting O-ring in spindle groove rightly.

2. Insert two outer races of bearing (22) in holes of spindle (2) respectively.

3. Tighten two eye bots (M14) in the threaded holes on spindle (2) in symmetric situations. 4. Tighten eye bolt, and lift up spindle (2) and place it in hub (1).

5. Fix hub (1) and spindle (2) with fixing metal in symmetrical position. 6. Turn over the travel motor.

Fixing metal (This photo shows for other type.)

34 –II–1–34

3) Install RV gear assy. 1. Insert RV gear (4) to hub (1).

2. Fit two crankshafts (9) in holes for bearing (22) inside of spindle (2). Note : Then, bearing (22), bearing (23) and spacer (12) are already fitted in crankshaft (9).

9, 2, 22 3. Insert RV gear (4) to hub (1)

• Since teeth of RV gears (4) are engaged in phase, match punched point on the end, and fit it.

4 4. Insert twenty eight pins (17) between pin groove of hub (1) and tooth groove of gear. • Prior to inserting, apply hydraulic oil to pin (17).

34 –II–1–35

5. Insert bearing (21) to hub (1) • Apply pin punch on outer race of bearing (21), and strike it in all around with mallet to press fit.

21 4) Installing hold flange 1. Check that hub (1), spindle (2), hold flange (3) and two bearings (21) are not replaced with new ones. • If they are not replaced, proceed the next process 2. • Even if one of them is replaced, adjust hold flange (3) referring to Article “Pre-load adjustment procedure of bearing (21)” on page 34II-1-49, and proceed to next process 2. 2. Fit hold flange (3) to inner race of bearing (21) in hub (1).

3, 21

• Install hold flange (3) to bearing (21) on the same position as it was, put matchmarks on spindle (2) and crankshaft (9). • If it is difficult to insert hold flange (3) in inner race of bearing (21), strike hold flange (3) lightly and equally with plastic mallet to insert in bearing (21). 5) Tightening reamer bolt (19) and capscrew (35) 1. Coat the reamer part of reamer bolt (19) with antiseize lubricant and coat the threaded part of the reamer bolt with adhesive. • In case oily matter is stuck to the reamer bolt, degrease it and after cleaning, dry them in natural condition. Coat the reamer bolts with adhesive. • Fasten two reamer bolts (19) equally little by little. If you fasten one bolt first, hold flange (3) tilts, making bearing (21) unable to be pressed into hold flange (3). This causes reamer bolts (19) to seize themselves.

34 –II–1–36

3, 21

2. Tighten two reamer bolts (19) until hold flange (3) is fitted into bearing (21) evenly. 3. Tighten two reamer bolts (19) to the specified torque. : 24 mm, Torque : 25.7 kgf·m (186 lbf·ft) 4. Coat the threaded part of capscrew with adhesive. • In case oily matter is stuck to the capscrew, degrease it and after cleaning, dry them in natural condition. Coat the capscrew with adhesive. 5. Tighten two capscrews (35) to the specified torque. : 24 mm, Torque : 25.7 kgf·m (186 lbf·ft) 6. Turn over the travel motor. 7. Remove (two) fixing metal. 8. Turn over the travel motor. 9. Fit the outer race of bearing (22) to hold flange (3).

6) Fixing snap ring. 1. Check that spindle (2), hold flange (3), crankshaft (9), bearing (22) and spacer (12) are not replaced. • Go to next process 2 if nothing is replaced. • Even if one of them is replaced, adjust clearance in shaft direction of bearing (22) and proceed to next process. (Refer to Article“Clearance adjustment procedure of bearing (22) in shaft direction” in page 34-II-1-51.) • When replacement of snap ring (20) only is required, use the same snap ring as the removed snap ring (20) or select one equivalent to the removed one from 15 types.

34 –II–1–37

(35)

2. Fix snap ring (20) to the snap ring groove in hold flange (3). • Install two snap rings (20) meeting to matchmark on hold flange (3). When required to use new snap ring (20), use snap ring selected according to the specified thickness on Page 34-II-1-51, 52 process.

9 3. Put two snap rings (25) to crankshaft (9).

25 9 7) Installing spur gear (7). 1. Install two spur gears (7) to crankshaft (9). • Put the matching marks (punched) of two spur gears (7) as shown below and fix them to crankshaft (9). Position the matching marks (punched) on the spur gears as shown and install them.

7 9

2. Fix two snap rings (25) into the snap ring grooves of crankshaft (9).

34 –II–1–38

8) Install oil seal (132). 1. Turn over travel motor. 2. Coat the lip of the oil seal with lithium grease and fix oil seal (132) into the oil seal hole in spindle (2), using retainer metal (III) and a hammer.

Retainer metal (III)

132 2

9) Fixing shaft (102). Carry out the insertion work with leather gloves. Use care so as not to get burns. • Insert bearing (149) into shaft (102) so it comes in close contact with the flange of the shaft. 1. Put bearing (149) in heating bath and heat it at 100±10°C (212±18°F) for ten minutes and insert it into shaft (102). 2. Fix two parallel pins (177) into the pin holes of spindle (2). 3. Coat two pivots (167) with lithium grease and fix it into parallel pins (177) of spindle (2). 4. Install spring (190) and piston assy [piston (161), shoe (162)] on spindle (2). 5. Incline travel motor 90°. (Lay it down)

102

149

167 6. Install shaft (102) into spindle (2). • Install shaft (102) to spindle (2) taking care so as not to score the lip of oil seal (132) placed in spindle (2). Scoring of the lip causes oil leakage which leads to early damage of the travel motor.

34 –II–1–39

102

103

7. Install swash plate (103) to spindle (2). • Apply grease on contact surface of swash plate (103) with spindle (2). • Meet two pivots (167) with pivot attaching holes of swash plate and install swash plate (103) in spindle (2).

110 10) Installing cylinder block 1. Place washer (110), spring (114), washer (110) and snap ring (145), in that order into cylinder block (104). 2. Place cylinder block (104) on the press bench.

114

104 3. Put retainer metal (I) on washer (110) and fit snap ring (145) in the groove of cylinder block (104). • Put a plastic sheet over cylinder block (104) so the contact surface of cylinder block is not scored in contact with timing plate (109).

Plastic sheet

145

11) Installing hydraulic motor parts. 1. Put three rollers (151) into the holes of cylinder block (104). 2. Put thrust ball (108) on cylinder block (104). 3. Fit nine piston assy to retainer plate (107). • After fixing it, immerse the whole unit in hydraulic oil.

151

34 –II–1–40

104

4. Fit nine piston assy to cylinder block (104). • Match retainer plate (107) with the spherical part of thrust ball (108) and install them.

Piston assy

104

107

5. Install cylinder block (104) into shaft (102). • Insert cylinder block (104) into the spline of shaft (102) by aligning the spline hole with the spline of the shaft. • After installing the cylinder block, turn it by hand and make sure that it does not loose. If it loose, inspect it.

104 12) Installing parking brake. • Immerse friction plate (115) in hydraulic oil before fitting it. 1. Incline working bench 90° (Lay it horizontally.) 2. Install friction plate (115) and separator plate (116) on groove outside of cylinder block alternately. Then install friction plate first, and then separator plate. 3. Fit O-rings (135),(139) to the O-ring grooves of piston (112). In that case, coat O-rings (135), (139) with a thin film of grease. 4. Incline the travel motor 90° (Lay it down) 5. Install piston (112) into spindle (2).

169,115,116

• If it is hard to fit the piston (112) into the spindle (2) due to the resistance of O-rings (135),(139), lightly tap the end face of the piston (112), using a plastic mallet. • Take care so as not to score the O-rings when installing the piston.

112

34 –II–1–41

226

237

13) Installing the brake valve parts into rear flange 1. Fit two O-rings (237) to two plugs (226). • Coat O-ring (237) with grease. 2. Install valve(227) and spring (230) on plug (226). Then, apply grease on it to fit valve, spring and plug with the adhesion. 3. Install valve (227) and spring (230), and insert the plug (226) assembled in one piece in rear flange (201).

230, 227

• Place rear flange on the work bench by directing rear flange (201) with its plug attaching face up. Align the center of threaded hole with the plug (226) center. This prevents the O-ring from being damaged and spring (230) from coming off from valve (227) as the inner surface of the rear flange comes in contact with the valve. • Prevent spring (230) from deviation. Note that if spring (230) deviate from valve (227), the valve does not contact with the seat surface of rear flange (201) properly, causing oil leaks.

226, 237, 230, 227

201

4. After installing two plugs (226), temporarily fasten rear flange (201) by means of allen wrench. : 8 mm : Temporarily fastening 5. Install spool (223) into rear flange (201). • Coat the spool with hydraulic oil and insert the spool into the rear flange. Attach the spool by aligning the hole of the rear flange with the spool and prevent the inner surface of the rear flange and the outer surface of the spool from being damaged by mutual interference. In case damage resulting from interference should occur to the holes in the rear flange and the outer surface of the spool, internal leaks will occur after assembly, ultimately deteriorating the performances of the travel motor.

34 –II–1–42

223

201

6. Fit O-ring (236) to plug (224). • Coat O-ring (236) with grease. 7. Fit spring retainer (225) and spring (228) to plug (224). 8. Tighten two plugs (224) into rear flange (201) by hand. • When tighten the plugs into the rear flange, use care so as not to deform the spring. 9. Tighten two plugs (224) into rear flange (201) temporalily by means of spanner. : 30 mm

201 14) Installing fittings to rear flange. 1. Assembling 1st / 2nd speed select spool 1) Insert spring (226) and spool (263) into rear flange (201). 2) Fit O-ring (273) to plug (221). • Coat O-ring (273) with grease. 3) Tighten plug (221) into rear flange (201). : 6 mm, Torque : 3 kgf·m (22 lbf·ft)

34 –II–1–43

224, 225, 228

2. Apply hydraulic oil to bearing (150), and install it in rear flange (201).

201

150

3. Drive two parallel pins (241) in pin holes of rear flange (201).

241

201

4. Apply the surface of timing plate (109) in contact with rear flange (201). 5. Install timing plate (109) on rear flange(201) taking parallel pin (241) as a guide. • Install timing plate (109) until it is completely contacted with rear flange (201). Grease film is used to protect them from dropping.

109 6. Install eight spring (113) on rear flange (201). • Apply grease to spring (113) sufficiently in order to prevent drop of spring (113) from rear flange (201).

34 –II–1–44

201

15) Connecting rear flange with spindle. 1. Fix O-ring (27),(30) into the O-ring groove of spindle (2). • Fit O-ring (30) without application of grease. Application of grease may cause mistaking the oozed grease out of contact face of rear flange and spindle for the leaking oil. So never apply grease on O-ring (30).

27, 30

2. Fix two parallel pins (42) to spindle (2). 3. Fill hydraulic oil 0.3 L (0.08 gal) into spindle (2).

2 201

4. Align two parallel pins (42) set in spindle (2) with the pin holes of rear flange and install rear flange (201) to spindle (2).

2 5. Install six socket bolt (243) to spindle (2) and tighten them up. : 6 mm Torque : 3 kgf·m (22 lbf·ft)

243

34 –II–1–45

6. Tighten plug (224). : 30 mm, Torque : 20 kgf·m (145 lbf·ft)

224 (In socket) 226 7. Tighten plug (226) : 10 mm, Torque : 8 kgf·m (58 lbf·ft)

102 16) Installing input gear. 1. Turn over travel motor. 2. Fit input gear (6) to shaft (102). • Fix input gear (6) to shaft (102) by matching the teeth of two spur gears (7). When gear is not engaged, check it for possible error.

6 102 3. Fix snap ring (24) into the snap ring groove of the shaft (102).

34 –II–1–46

17) Installing cover (8) 1. Fill gear oil in hub (1). Oil volume : 1.0 L (0.26 gal) Type of oil : SAE #90 GL4 2. Fit O-ring (29) into the O-ring groove of cover (8). • Apply grease to O-ring (29).

1 3. Install hub (1) to cover (8). • Align the matching marks on cover (8) and hub (1) and install them. • Install cover (8) in hub (1), tapping the outer circumference of cover (8) lightly by means of a plastic mallet. Use care that if the cover is fixed powerfully by striking it hard, the Oring is scored and brings about an oil leakage.

1 8

4. Fix ring (18) into the ring groove of hub (1).

5. Wind seal tape on two plugs (33) and install it on cover (8). : 8 mm, Torque : 6 kgf·m (43 lbf·ft)

33, 37

34 –II–1–47

18) Removing travel motor 1. Remove the travel motor attaching bolts from the work bench.

2. Tighten two eye bolts (M14) into the threaded holes of spindle (2). • Tighten two eye blots so they are located in diagonally opposite positions. 3. Place the hook and wire sling in the eye bolts, lift the travel motor up by hoist and remove it from the work bench.

34 –II–1–48

19) Pre-load adjustment procedure of bearing • Therefore, when the parts exerting influences on the pre-load are replaced, assemble it temporarily in the following procedure and check the pre-load. If it is assembled without checking the pre-load, the malfunction of hydraulic motor may be caused and the life may be shortened. • Parts exerting influences on the pre-load. Hub (1), spindle (2), hold flange (3), bearing (21) • When the above parts are not replaced, omit this procedure, and proceed to the procedure shown in Item (3) on page 34-II-1-36. • Pre-load checking and pre-load adjusting procedure are described below.

1. Procedure of adjusting the pre-load to bearing. 1) Attach the bearing (21) pre-load adjusting jig to spindle (2), tighten special nut, and press fit bearing (21) into hub (1). : 30 mm Torque of special nut : 3 kgf·m (22 lbf·ft)

2) Determine the depth “A” through the measuring hole of bearing (21) preload adjusting jig, using a depth micrometer. 3) Since the dimension “B” of bearing (21) pre-load adjusting jig is known, determine the clearance “C” by the following formula : A : Actual value “C” = “A” _ “B” B : Dimensions of jig body C : Specified dimension

Depth micrometer

1 Bearing pre-load adjusting jig

34 –II–1–49

4) Then determine dimension “D” of hold flange (3). 5) After measurement steps 2) ~ 4), adjust hold flange (3) as follows : Dimension “C” his the specified dimension of hold flange.

I. When actual dimension “D” of hold flange (3) is 0.02mm (0.0008 in) smaller than a specified value “C” ; Cut surface F of hold flange (3) to a specified value “C” by lathe or something. II. Where the actual dimension of the hold flange falls within ± 0.02 mm (0.0008 in) of the specified clearance “C” ; Use the hold flange (3) as it is. III. When actual dimension “D” of the hold flange (3) is 0.02 mm (0.0008 in) larger than a specified value “C” ; Replace the flange with a new spindle assy. The adjustment allowance for new hold flange (3) is specified without exception. • Since hold flange and spindle are drilled at the same time, they are integrated in an assembly unit. Therefore they can not be replaced separately. Replace them as an assembly unit, that is, together with spindle. This assy is called as spindle assy. • To replace the spindle assy, disassembling and assembling works should be performed again. 6) Remove bearing pre-load adjustment jig from spindle (2). 7) After completion of hold flange adjustment in the procedure shown in Sections I, II, and III, proceed to the procedure shown in Item “2” on page 34-II-1-36.

34 –II–1–50

Bearing pre-load adjusting jig

20) Clearance adjustment procedure of bearing in shaft direction When the following parts have been replaced, it is necessary to adjust the axial clearance of taper roller bearing (22) to a specified value by adjusting the thickness of snap ring (20). If it is installed without adjustment, malfunction of hydraulic motor may be caused and the life may be shortened. Spindle (2), hold flange (3), crankshaft (9), spacer (12), bearing (22). • When the above parts are not replaced, the adjustment of thickness of snap ring is unnecessary. Proceed to the regular assembly shown in Item 5) in page 34-II-1-36. • The clearance adjustment procedure in shaft direction is described below.

Adjustment procedure. 1. Lightly tap the outer race of bearing (22) attached to crankshaft (9) using retainer metal (IV). • Put the RV gear assy in spindle (2) securely.

Retainer metal (IV) 2. Fix the thinnest snap ring (20) into the snap ring groove in hold flange (3).

34 –II–1–51

3. Lightly tap the outer periphery of snap ring (20). Confirm that the RV gear assy is securely set in spindle (2).

Retainer metal (IV) 4. Insert a thickness gauge between snap ring (20) and bearing (22) and measure the clearance. 5. Thickness measurement of snap rings • Set thickness of snap ring (max.) MAX.= Thickness of + Thickness of thickness presently set gauge snap ring • Set thickness of snap ring (min.) M I N .= Thickness of Thickness gauge

+ Thickness of 0.05 presently set (mm) snap ring

6. When the thickness of the snap ring has been determined, select one out of twelve kinds X through L (refer to page 34-II-1-54) and fit it to the hold flange. [Refer to “Dimensional List for Parts Required to Adjust the Clearance” in Article 1.8 on page 34-II-1-54.] 7. Install snap ring satisfying the set thickness, and proceed to the procedure in Article 6) Item “2” on page 34-II-1-38.

34 –II–1–52

Thickness gauge

1.7 PERFORMANCE INSPECTION • After completing the maintenance, carry out the performance inspection in the following procedure 1) Required measuring instrument

Pressure gauge [35 kgf/cm2 (500 psi)]

2 pcs

Measuring cylinder [5 L (1.3 gal)]

1 pc

Stop watch

1 pc

2) Test procedure

Installing hydraulic

Install motor in lower frame (sprocket section), and connect pipe.

motor and piping

However, don't install crawler. [To carry out performance test of motor (No load)] NOTE 1. Connect pipes so that pressure gauge is install, and the drain rate of hydraulic motor can be measured. 2. Never use hammer to install motor, but install it using bolts holes softly.

Hydraulic motor revolution

Running-in of hydraulic motor

10 rpm

20 rpm

Condition Rotation direction No load

Operating time

Forward

Every 1minute

Reverse

or more

Performance Inspection of motor

Warming up ................ Warm up motor until the temperature rises to the following temperature 1

•

Hydraulic oil temp 45~55°C (113~131°F)

•

Reduction unit outer temp.

40~80°C (104~176°F)

Performance test ....... Measure the following items, and determine if it is allowable or not. 2

Allowable standard

Hydraulic motor drive pressure...16 kgf/cm2 (228 psi) or less /10 rpm Hydraulic motor drain level...0.5 L(0.13 gal) /min./10 rpm

Allowable

Not allowable

Install crawler

Disassemble and adjust again

34 –II–1–53

1.8 DIMENSIONS OF CLEARANCE ADJUSTING PARTS

SKETCH

MODEL OF TRAVEL MOTOR

GM06VN

Snap ring [20]

Marks

34 –II–1–54

Dimension t mm(in)

over 1.75 to 1.80 (0.069 to 0.071) incl.

over 1.80 to 1.85 (0.071 to 0.073) incl.

over 1.85 to 1.90 (0.073 to 0.075) incl.

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.

1.9 SERVICE STANDARDS Removal and inspection of motor must be performed according to this maintenance standard. Handle every parts carefully, and use care particular that moving section and sliding section are not damaged. (1) Replace all seals (O-ring, oil seal, floating seal) once used even if no damage is seen. (2) Wear parts maintenance standard 1) Replace any part that shows damage on appearance. 2) Replace such parts that show the following abnormalities.

Item No. (2) (3) (19) (35) (4) (9) (12) (22) (23) (20) (21)

(201)

(223) (102) (104)

Parts Spindle kit Spindle Hold flange Reamer bolt Capscrew RV gear assy RV gear Crankshaft

Trouble

Reference value Allowable value

• Severe damage to appearance • Abnormal wear such as scoring is present.

• The RV gear tooth surface shows uneven wear. • Crankshaft-related parts do not move smoothly when crankshaft (9) is turned.

Spacer Conical roller bearing Needle roller bearing Snap ring • The end face of the circumference is abnormally worn Ball bearing • Dent is present. • Flaking is seen. • Uneven wear is present Rear flange kit • Part in contact with spool (223) is scrached. Rear flange • Clearance with spool is large. Clearance on Clearance on • Surface in contact with valve (227) is scratched. diameter diameter • Depth to the contact surface with valve (227) 33 µ 7~13 µ is large. (0.0003~0.0005 in) (0.0013 in) • Outer circumference is scored. Spool • Outer circumference is worn unevenly. • Contact surface with oil seal (132) is worn. Shaft • Spline is worn. • Spline is worn. Cylinder block • Bore surface is worn badly. • Sliding surface with timing plate (109) is scored or worn unevenly.

34 –II–1–55

Item No.

Parts

Piston assy (105) Piston (106) Shoe (107) Retainer plate (108) Thrust ball (109) Timing plate (115) Friction plate (116) Separator plate (227) Valve (149) Ball bearing (150) Ball bearing (263) Spool

Trouble • Clearance is present in the axial direction between piston (105) and shoe (106). • Shoe is worn abnormally. • Shoe is worn unevenly. • The end face of the circumference is worn unevenly. • Spherical sliding part with retainer plate (107) is worn unevenly. • Sliding surface is seized or worn unevenly. • Both end faces are worn unevenly. • Specified torque can not be reached. • Seizure is seen. • Seat surface is scored. • Dent is present • Flaking is seen. • Uneven wear is present • Outer circumference is scored.

34 –II–1–56

Reference value Allowable value

Clearance 0.05 mm (0.0020 in)

Clearance 0.15 mm (0.0059 in)

Braking torque Braking torque 6.6 kgf·m 6.6 kgf·m (48 lbf·ft) (48 lbf·ft) or over

Book Code No.

PJ42

02E ➀

NEW HOLLAND EH45 Model Cross-reference: SK45SR-2 is NEW HOLLAND Model EH45

TROUBLESHOOTING (HYDRAULIC SYSTEM) TABLE OF CONTENTS 1. GENERAL PRECAUTIONS ........................................................................1-1 2. TROUBLE DIAGNOSIS : Hydraulic relation ...............................................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 power is low. .........................................................................1-6 2- (4) Travel independent operation deviates. ..........................................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

PJ42

42 –0–1 ➀

REVISION

DATE OF ISSUE

REMARKS

First Edition

October, 2001

S5PJ4202E

Second Revision

January, 2003

S5PJ4202E ➀ K·E

K·E

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.

Make field investigation.

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.

Verifying background of trouble occurred.

Diagnosing trouble by means of troubleshooting.

42 â&#x20AC;&#x201C;1â&#x20AC;&#x201C;1

2. TROUBLE DIAGNOSIS: Hydraulic relation

Attachment

Attachment operational failure (1) (excluding dozer operation and EU type swing operation)

(2) Travel speed is slow. (3) Attachment operating power is low.

Pump

Slewing operation

Travel operation

(4) Malfunction of attachment (1) Travel operational failure (2) Travel speed is slow. 2

(3) Travel operating power is low. deviates in travel (4) It independent operation. (1) Slewing operational failure (2) Slewing speed is slow.

(3) Slewing operating power is low. Malfunction of slewing (4) operation (1) Engine speed is reduced due to pump load. (2) Malfunction of pump

Abbreviation E/G SOL SW ATT C/V R/V V P/V

: : : : : : : :

Engine Solenoid Switch Attachment Control valve Relief valve Valve Pilot valve

42 â&#x20AC;&#x201C;1â&#x20AC;&#x201C;2

Operation control pilot valve

Pilot valve

Travel pilot valve

Hydraulic cylinder

Travel motor unit

Slewing motor unit

Shuttle valve

Check valve

Actuator

Attachment & slewing spool

Travel spool

Travel straight valve

Each port & slewing R/V

Main gear pump R/V

Travel & ATT main R/V

Valve

Gear pump

Trochoid pump (for pilot)

Phenomenon

Pump

Main pump

Classification

Reference No.

Causes

3. TROUBLESHOOTING

Attachment operational failure (excluding dozer operation and EU type swing operation)

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.

YES

Is delivery pressure of YES pilot pump is Approx. 35 kgf/cm2 (500 psi) or over? NO

Spool stick of C/V exists.

YES Check C/V spool for

possible failure. Check lever lock SOL or lever lock S/W for possible failure. (To Troubleshooting for Electric system) Failure of ATT pilot valve Failure of pilot pump or failure of R/V for pilot

Attachment operating speed is slow.

1 – (2) Is each operating speed of boom, arm and bucket within the standard value?

Is the number of travel sprocket rotations within the standard value?

YES

Failure of cylinder

YES

Failure of pump

Operating speed is not NO within the standard value. Does corresponding spool move?

Failure of C/V spool

YES

Set cylinder to stroke end,disconnect hose on NO the return side,apply pressure,and check that leaking inside of piston is within the standard value.

Cylinder error

Attachment operating power is low.

1 – (3) Is main relief pressure within standard value ?

Failure of main relief V

YES

Is over load relief pressure NO within standard 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 standard value.

Failure of cylinder

42 –1–3

1– (4) Natural drop of YES attachment is large.

Is oil tightness of each cylinder is within standard value?

Is leaking inside of cylinder within standard value?

Failure of C/V spool Failure of lock valve Failure of over load relief valve

YES

Attachment operational failure

Failure of cylinder

Boom, arm and bucket operating power is low and slow, travel deviate YES occurs simultaneously.

Travel straight valve does not return.

Any of attachments can not be operated in combination, or travel is possible, but boom, arm and bucket don’t move.

Travel straight valve does not switch.

YES

Failure of swing cylinder

Operational failure

Check on P/V or replace it

KAI

YES

Does swing spool in C/V move?

EU, OCEANIA

Adjust wire.

YES

Disconnect hose between C/V and swing cylinder on the C/V side, and check the delivery pressure. YES

Impossible to hold

Failure of C/V swing spool. Failure of pump. Failure of swing cylinder

Check the anti cavitation valve in C/V for dust, etc.

YES

42 –1–4

2 – (1) Travel operational error

Is travel pilot pressure normal?

Is delivery pressure of pilot pump is Approx. 35kgf/cm2 (500psi) or over?

YES

Does travel spool move?

Failure of pilot pump Failure of relief valve for pilot 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 – (2) Is travel sprocket speed YES within standard value?

Travel sprocket speed YES Is much wear dust accumulated on hydchanges in 1&2 speed. raulic oil return filter? NO

Is much wear dust contaminated in hydraulic oil for travel reduction unit?

Failure of travel motor spool

Failure of travel motor

YES

Failure of travel reduction unit

Travel speed change spool moves normally.

YES

Is travel motor drain within standard value?

YES

Failure of travel motor

Check on travel 1,2 speed SOL.V. (To troubleshooting for Electric System)

Is ATT operating speed YES Is travel pilot other than travel speed pressure normal? within standard value?

YES

Does C/V spool move?

Failure of C/V travel spool

To 2-(1)

Is E/G speed within standard value?

YES

Failure of pump

E/G speed error

YES

Adjust accel wire.

42 –1–5

Adjust E/G speed.

Travel power is low.

2– (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?

YES

Is much wear dust accumulated on hydraulic oil return filter?

YES

Does the 2nd speed change NO spool in travel motor move normally?

Is much wear dust contaminated in hydraulic oil for travel reduction unit?

YES

Failure of travel reduction unit. Failure of spool in travel motor.

YES

Does monitor indicate 2nd-speed by switching travel 2nd-speed SW on?

Failure of travel motor.

Failure of 2nd-speed S/W or failure of cluster.

YES

To Troubleshooting for Electric System.

Travel independent operation deviates.

2– (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 bend of hose of YES travel line and oil leakage?

Replace hose.

Is travel spool full stroked?

Is travel pilot pressure normal?

YES

Check on travel pilot V or replace it. Check on C/V travel spool or replace it.

Does the travel deviation change in reverse by changing YES 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?

The travel spool moves unsmoothly. 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 standard 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?

Is the lever lock SOL normal.

YES YES

Does the slewing P/V move normally.

Does slewing spool in C/V move?

Adjust lever lock SOL or lever lock SW. (To Troubleshooting for Electric System) Failure of slewing P/V. Failure of C/V slewing spool.

YES

Is much wear dust accumulated on hydraulic oil return filter?

YES

Slewing motor error when it dust gun metal powder. Slewing reduction unit error when dust is iron powder.

3 – (2)

Slewing speed is slow.

Is slewing speed within standard value at no load?

YES

Is slewing relief pressure within standard value?

Failure of slewing relief V.

YES

Is slewing motor drain within standard value?

Is dozer operating speed within standard value?

YES

Failure of slewing motor.

Failure of C/V slewing spool.

Is engine speed within standard 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 slanted digging operation of slewing and arm. It is impossible to slewing because of poor slewing power at slope.

Is gear pump main relief pressure within standard value?

Improper gear pump main relief pressure.

YES

Is slewing relief pressure within standard value?

Failure of slewing relief V.

YES

Is much wear dust accumulated on hydraulic oil return filter?

YES

Slewing motor error when dust is gunmetal powder. Slewing reduction unit error when dust is iron powder.

42 –1–7

Slewing operational failure

3– (4) It is impossible to hold slewing stop position on a slope.

YES

Is slewing parking brake power within standard value?

Slewing drift after slewing inertia exerted on it is large.

YES

Is slewing brake power within standard value?

Parking brake spring in slewing motor or friction plate is failure.

Is slewing relief pressure within standard value?

YES

Failure of slewing relief V Failure of slewing motor

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 NO 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

42 –1–8

Check air intake through piping on the suction side. Replace parts inside of pump. Check coupling for severe wear. (Refer to Article before mentioned.)

Book Code No.

PJ43

02E ➀

NEW HOLLAND EH45 Model Cross-reference: SK45SR-2 is NEW HOLLAND Model EH45

TROUBLESHOOTING (ELECTRICAL SYSTEM) TABLE OF CONTENTS TABLE OF CONTENTS 1. TROUBLE DIAGNOSIS ....................................................................................1-1 2. TROUBLESHOOTING .....................................................................................1-2 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 2-(2) Slewing / Swing switching operation can not be carried out (KAI) .........1-7 3-(1) Travel 1, 2 speed change can not be carried out. ..................................1-7 4-(1) Deceleration switching operation can not be carried out........................1-8 5-(1) Travel alarm (OPT) does not sound .....................................................1-10

PJ43

43 –0–1 ➀

REVISION

DATE OF ISSUE

REMARKS

First Edition

October, 2001

S5PJ4302E

Second Revision

January, 2003

S5PJ4302E ➀ K·E

K·E

43 –0–2 ➀

Travel alarm

Travel operation

Travel 1 & 2 speed can 3 (1) not be changed.

Deceleration

Attachment operation General

Causes

Phenomenon

2 (3) Working light does not light up.

(4) Hourmeter does not actuate.

(5) Fuel gauge does not actuate.

(6) Water temperature does not actuate.

Deceleration switching 4 (1) operation in option can not be carried out.

Gauge cluster Current limiter Working light Decel motor Horn Travel alarm Coolant temp.sensor Fuell level sensor Ttavel 1,2 speed SOL Lever lock SOL Engine stop SOL Slewing/Swing switching SOL Horn switch Working light switch Travel 1,2 speed switch Lever lock limit switch Deceleration switch Slewing/Swing switching SW Slewing lever pressure SW Travel pressure SW Engine stop SOL relay Charging indicator relay Safety relay Timer unit Holding ciruit unit Switching relay Slewing/Swing holding relay Slewing/Swing switching relay Fuse,Disconnection,Short circuit,Looseness Others

Reference No.

Classification

1. Trouble Diagnosis : Electric System Electrical Sensor Solenoid equipment

(1) Engine does not start.

(2) Horn does not sound.

All controls does not function. (1) {Excluding swing (EU) and dozer operations}

Slewing/Swing switching (2) operation can not be carried out. (KAI)

Travel alarm (OPT) 5 (1) does not sound

Abbreviation

Decel : Deceleration SOL : Solenoid SW : Switch

43 â&#x20AC;&#x201C;1â&#x20AC;&#x201C;1

Switch

Relay

2. Troubleshooting

Engine does not start.

1 – (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.

NO Voltage of B terminal of

Replace starter cable.

starter motor(M-1) is 12V.

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.

NO Voltage of black-white

Check on harness.

harness (C terminal) at connector (CN-7F) of safety relay (R-2) is 12V.

NO Voltage of white-red

harness (S terminal) at eyelet terminal of safety relay (R-2) is 12 V.

NO Voltage of S terminal

of starter motor(M-1) is 12V.

Malfunction of safety OK Replace safety relay. relay. NO

Check on generator. Disconnection of harness between safety relay(R-2) and starter motor.

Check on harness.

Replace starter motor.

43 –1–2

Starter functions, but engine does not start. (When key is in ON position,) Voltage between green-red YES Failure of engine stop and black harness of solenoid valve (SV-3). connector (CN-303F) of engine stop solenoid valve (SV-3) is 12V for 1 second Voltage between yellowYES Disconnection of harness when key is in ON position. 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-303F) 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.5 fuse in box is blown.

YES

Harness is shortcircuited to frame.

Check that harness in fuse box are free from disconnection.

Voltage of key switch ACC terminal 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 â&#x20AC;&#x201C;1â&#x20AC;&#x201C;3

Horn does not sound.

1 – (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 on short-circuit of diode (D-1).

Working light does not light up.

1 – (3) When key is switched ON,

Voltage between light greenred and black harness of working light (L-2) is 12V when working light switch (SW-2) is ON.

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.

43 –1–4

Check that line in the fuse box is free from disconnection.

Hourmeter does not actuate.

1– (4) When engine is starting, Voltage between whiteVoltage of pink line of green and black harness YES connector (CN-27F) of connectors (CN-27F) of gauge cluster (E-6) of gauge cluster (E-6) is is 0V. 12V.

Replace gauge cluster. Failure of gauge cluster. NO

Disconnection of harYES Voltage of white-green ness between cluster harness of fuse box is 12V. gauge (E-6) and fuse box.

Disconnection of harness between whitegreen and green-white harness and charge indicator relay (R-8). Check on harness.

YES NO

Check on generator (E-2). Check on charge indicator relay.

Disconnection of harness NO between gauge cluster

(E-6) and charge indicator relay (R-8). Check on harness.

No.6 fuse is blown.

YES Harness is short-

circuited to frame.

Fuel gauge does not actuate.

1 – (5)

Check harness on the short-circuited section. Check that harness in fuse box is free from disconnection.

When key is switched on, Voltage between whiteResistance of yellow-black hargreen and black harness YES ness in connector (CN-27F) of YES of connector (CN-27F) gauge cluster (E-6) is changed Disconnection of harof gauge cluster (E-6) by moving fuel sensor. NO ness between gauge is 12V. (Full : 10Ω, Empty : 90Ω). cluster (E-6) and level NO gauge (SE-1). Disconnection of harVoltage of white-green YES ness between gauge line of fuse box is 12V. cluster (E-6) and fuse

Check or replace gauge cluster. Check on harness.

Check on harness.

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 on the short-circuited section.

When key is switched ON, Voltage between white- YES Resistance of yellow-red harYES green and black harness ness in connector (CN-27F) of of connector (CN-27F) gauge cluster (E-6) is changed Disconnection of harof gauge cluster (E-6) by coolant temperature. NO ness between gauge is 12V. (At 67°C:80Ω, At 105°C : 24Ω) cluster (E-6) and water NO temperature sensor Disconnection of har(SE-2). Voltage of white-green YES ness between gauge harness of fuse box is 12V. cluster (E-6) and fuse box.

Check and replace gauge cluster. Check on harness.

Check on harness.

No.6 fuse is blown.

YES Harness is short-

circuited to frame.

43 –1–5

Check harness on the short-circuited section. Check that harness in fuse box is free from disconnection.

All controls do not function, (except dozer operation and EU swing operation)

2– (1) When key is switched ON, When safety lever was lowered, Voltage between green-white 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).

YES

Voltage of pink-blue harness of terminal (F-2) of the left lock lever switch (SW-9) is 12V.

YES

Voltage of yellow-black harness of plug (F-1) of the right lock lever switch (SW-8) is 12V.

Disconnection of harness between lock lever switch (SW-9) and lock lever solenoid valve(SV-1).

Check on harness.

Failure of lock lever switch (SW-9).

Replace lock lever switch(SW-9).

Disconnection of harness between lock lever switch (SW-9) and lock lever switch (SW-8).

Check on harness.

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.

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

Slewing / swing switching operation can not be carried out (KAI)

2 – (2) When key is switched ON. • Swithching operation dose not change from slewing to swing.

When slewing / swing select switch is depressed. Voltage between light green and black harness of connector (CN-115F) YES of slewing/swing select solenoid (SV-12) is 12V.

Check on slewing/ swing select solenoid. (To troubleshooting for hydraulic system).

Voltage between green Voltage between ground white and black harness and green / white harYES of connector (CN-63F) ness of connector (CNof slewing / swing select 63F) of slewing/swing relay is 12V. select relay. NO

Voltage between ground and white harness of connector (CN-64F) of slewing / s wing select switch (SW-28) is 12V.

Check and replace.

No.3 fuse is blown.

Disconnection of har-

NO ness between relay

and fuse. YES Harness is short-

circuited to frame.

Disconnection of harness between slewing / s wing select switch (SW-28) and slewing / s wing select relay (R-14).

Check on harness.

Failure of slewing / s wing select switch (SW-28).

Check on harness.

Check harness on the short-circuited section. Check that line in the fuse box is free from disconnection.

Replace slewing / s wing select switch. Check on slewing lever pressure switch RH (SW-31) slewing lever pressure switch LH (SW-32) and harness.

Voltage between blue green and black harness YES of connector (CN-67F) of switch change relay (R-22) is 12V. NO

Voltage between ground and yellow / g reen harness of connector (CN- YES Failure of switch change relay (R-22). 67F) of switch change relay (R-22) is 12V. NO

Replace switch change relay. Disconnection of har-

No.3 fuse is blown.

NO ness between relay

YES

Harness is shortcircuited to frame.

Check on harness.

and fuse. Check harness on the short-circuited section. Check that line in the fuse box is free from disconnection. To be continued

43 –1–7

• Swithching operation dose not change from swing to slewing.

When slewing / swing select switch is not depressed. Voltage between light green and black harness of connector (CN-115F) of slewing / s wing select solenoid (SV-12) is 12V.

Check on slewing / swing select solenoid. (To troubleshooting for hydraulic system).

YES

Voltage between green/ white and black harness of connector (CN-68F) of slew ing/swing select relay (R14) is 12V.

Failure of slewing/swing select relay (R-14).

Check and replace.

Failure of slewing/swing select switch (SW-28).

Check and replace.

YES

Voltage between ground and green/white harness of connector (CN-64F) of slew ing / s wing select switch (SW-28) is 12V. YES

Voltage between ground and white / r ed harness of connector (CN-68F) of diode (D13) is 12V.

Check on harness between slewing/swing select switch and slewing / s wing select relay.

YES

Failure of slewing lever pressure switch RH (SW31) or slewing lever pressure switch LH (SW-32). Check on following harness. Fuse box No, slewing lever pressure switch and slewing/swing holding relay.

43 –1–8

Check and replace.

Travel 1 & 2 speed change can not be carried out.

3– (1) When key is switched ON,

(regardless of 1st, 2nd speed mode)

Voltage of yellow-black harness NO of connector (CN-109F) of travel 2nd-speed solenoid valve (SV-2) is 12V. YES

Disconnection of harness between fuse box and travel 1&2speed solenoid valve (SV-2).

Check on harness.

No.2 fuse is blown. Harness is short-circuited to frame.

Check harness on the shortcircuited section. Check that line in fuse box is free from disconnection.

Voltage of white-green harness of connector (CN-1F) of holding circuit unit (E-14) is 12V. YES

Disconnection of harness between fuse box and holding circuit unit(E-14).

Check on harness.

YES

No.6 fuse is blown. YES

Harness is short-circuited to frame.

Check harness on the shortcircuited section. 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 (SW3) is pressed.

Check on harness of travel 1&2-speed switch, and between travel 1&2-speed switch and holding circuit unit.

Check on sequence (holding) circuit unit.

YES

43 –1–9

Decel change operation can not be carried out.

4– (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 decel motor.

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.

Disconnection of harness between fuse box (E-1) and decel relay (R-3).

Check on harness.

No.2 fuse is blown.

Check on harness on the short-circuited section.

YES

Check that harness in fuse box is free from disconnection. 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).

Check on decel motor.

Disconnection of harness between decel motor (M-4) and decel relay (R-3).

Check on harness.

Failure of decel relay (R-3).

Replace decel relay.

Failure of sequence (holding) circuit unit.

Replace sequence (holding) circuit unit.

Failure of decel switch (SW-11).

Check on decel switch.

Disconnection of harness between decel switch (SW-11) and sequence (holding) circuit unit (E-14).

Check on harness.

When decel operation is ON, Voltage of blue-black harness YES of connector (CN-6F) of decel relay (R-3) is 0V. NO

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. NO

43 –1–10

Travel alarm (OPT) does not sound

5– (1) When travel is operating (Inching operation is allowed).

Voltage between yellow / b lue YES and black harness of connector (CN-116M) of travel alarm (E-20) is 12V.

Check and replace travel alarm system.

Voltage between ground and yellow / b lue harness of connector (CN-114F) is 12V.

Check and replace harness of travel alarm.

YES

When travel right (Forward) is operated. Travel right (Forward) pressure switch (SW-24) is continued.

Malfunction of travel right (Forward) SW.

Check and replace the pressure SW.

Malfunction of travel right (Reverse) SW.

Check and replace the pressure SW.

Malfunction of travel left (Forward) SW.

Check and replace the pressure SW.

Malfunction of travel left (Reverse) SW.

Check and replace the pressure SW.

Disconnection of harness between travel alarm connector and fuse box.

Check on harness.

Harness is short-circuited to frame.

Check harness on the shortcircuited section.

When travel right (Reverse) is operated.

Travel right (Reverse) pressure switch (SW-25) is continued. When travel left (Forward) is operated.

Travel left (Forward) pressure switch (SW-26) is continued. When travel left (Reverse) is operated.

Travel left (Reverse) pressure switch (SW-27) is continued.

YES

Voltage between ground and yellow / b lue harness of connector (CN-114F) is 12V.

YES

No.1 fuse is blown.

YES

Check that line in the fuse box is free from disconnection.

43 –1–11

NOTES

Book Code No.

PJ44

02E ➀

NEW HOLLAND EH45 Model Cross-reference: SK45SR-2 is NEW HOLLAND Model EH45

TROUBLESHOOTING (ENGINE) TABLE OF CONTENTS 1. TROUBLE DIAGNOSIS: ENGINE .....................................................................I-1 2. TROUBLESHOOTING .......................................................................................I-3 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

PJ44

44 –0–1 ➀

REVISION

DATE OF ISSUE

REMARKS

First Edition

October, 2001

S5PJ4402E

Second Revision

January, 2003

S5PJ4402E ➀ K·E

K·E

44 –0–2 ➀

Output drops down

Other trouble

Trouble

Starting trouble 1

Rotation trouble 2 (3)

4 (1)

(1)

(5)

Flywheel gear damaged

Defective head gasket

Check fuel feed

Internal part seizure

Valve spring fatigue

Piston ring worn

Piston liner worn

Crank shaft oil seal defective

Engine dealer Suction/ Lubrication exhaust system Cooling system

Governor spring fatigue

Control rack movement not smooth

Compression pressure low

Radiator fin clogged

Check thermostat

Fuel mixed

Check relief valve

Check if engine oil gets into comb. chamber / lacks for lub.

Fuel system

Air cleaner and muffler

Electric

Valve spring fatigue

Serviceman

Valve clearance

Electric

Injection pump

Gas/fluid

Check nozzle

Engine

Check injection timing

Machine

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

Probable Cause/Component

Improper viscosity or level of engine oil, or leakage

Improper specific gravity of battery electrolyte

Filters

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

Engine mechanical

(1) Starter not rotate

(2) Starter rotates but hard to start

(1) Idling not smooth

(2) Medium speed hunting

High speed not smooth

Not reach max. speed

Engine output not enough

Overheat

(2) Knocking at high temperature

Large amount of black exhaust gas

White exhaust gas

(2) Excessive oil consumption

(3) Excessive fuel consumption

(4) Engine not stop when key turned OFF

When key turned OFF, power supply

disconnected but engine does not stop

44 â&#x20AC;&#x201C; 1 â&#x20AC;&#x201C; 1

NOTES

44 – 1 – 2

NOTES

2. TROUBLESHOOTING 1 – (1)

Starter not rotate

Check battery voltage OK

Check IN side of starter motor OK

Check battery electrolyte level and specific gravity

12 V detected at terminal B of starter motor (M-1)

Charge or replace battery

Replace starter motor

12 V detected at terminal B of key switch

Replace fusible link 45 A

OK NO

12 V detected at terminal C of key switch

Replace key switch

OK (hereafter key held in start position)

Check IN side of safety relay OK

Check OUT side of safety relay

12 V detected at NO black/white wire (terminal C) of connector (CN-7F) of safety relay (R-2)

Check harness

12 V detected at white NO Defective safety relay /red wire (terminal S) of connector (CN-7F) NO of safety relay (R-2)

Replace safety relay

Check generator

Check IN side of starter motor

12 V detected at terminal S of starter motor (M-1)

NO Harness between

safety relay (R-2) and starter motor broken

Check harness

Replace starter motor

44 –1–3

Starter rotates but hard to start

1 – (2) Check starter power

Less

Check battery electrolyte level and specific gravity

Charge or replace battery

Check engine itself

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 air intake system

Air cleaner clogged Check indicator

Check fuel feed system

Check fuel air bleed Check fuel meter Check water separator Check fuel filter Check fuel quality

Check electrical system

12 V detected for glow plug

Feed pump performance Check injection pump Check injection nozzle Check injection timing

YES

Defective glow plug

Defective harness between key switch and 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 held in ON position.

44 –1–4

Change engine oil

Check high pressure tube Check injection nozzle Cylinder compression pressure not equal Check injection pump Check thermostat Check if air/water mixed in fuel

2– (1)

Idling

Idling not smooth

Idling speed too high

Adjust engine speed

Medium speed hunting

Check control rack Check governor spring

Medium speed

Rotation trouble

2– (2)

High speed

2– (3) Check if air mixed in fuel

YES

Release air

Check air intake 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 E/G lamp lighted

Check work condition 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 intake system

Air filter clogging Check indicator

Check engine oil filter OK

Check air cleaner filter

Check fuel feed system

Check if air mixed in fuel

Release air

Check engine oil

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/lacks for lub.

Check compression pressure Check valve clearance Valve spring fatigue Control rack not smooth Piston ring worn Defective head gasket

Check engine mechanical

Note: Check in the condition of operating at high speed.

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

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

Large amount of black exhaust gas

Check air cleaner

Replace air element

4 – (1) Exhaust trouble

Check engine oil viscosity Check if engine oil too much OK

Check gas leakage through head gasket

Large amount of white exhaust gas

Check if water mixed in fuel

Check injection nozzle Check injection timing Check injection pump Check valve clearance Valve spring fatigue Check piston ring defect

Check water separator

Check if engine oil gets into comb. chamber/lacks for lub. Large amount of blowby gas Gas leakage through gasket

Check compression pressure Check injection timing

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 ground under engine and oil pan

Tighten packing and seal or replace if necessary

(Check if engine oil too much) OK

Check if breather hose depressed or clogged

Replace breather hose

Check fuel quality

Instruct to feed proper fuel

Check engine oil viscosity

Instruct to feed proper engine oil

Check if engine oil gets into comb. chamber/lacks for lub.

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

Check compression pressure Note: Check in the condition the proper fuel is used.

44 –1–7

Engine does not stop when key turned OFF

4 – (4) Engine stop solenoid valve (SV-3) normally energized

Engine stop solenoid valve incorrectly installed

Correct engine stop solenoid valve installation

Check resistance of starter key terminal (between terminals B and ACC)

YES Resistance 0 Ω Replace key switch detected between terminals B and ACC

YES

Check harness

Note : Check with the engine start key held in OFF position.

44 –1–8

Book Code No.

PJ51

02E ➀

NEW HOLLAND EH45 Model Cross-reference: SK45SR-2 is NEW HOLLAND Model EH45

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 4TNE88 and others.

ENGINE MODEL 4TNE88-EYBC

APPLICABLE MACHINES SK45SR-2

PJ51

51 –0–1 ➀

REVISION

DATE OF ISSUE

REMARKS

First Edition

October, 2001

S5PJ5102E

Second Revision

January, 2003

S5PJ5102E ➀ K·E

K·E

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.

6-75750NA Jan 04 Bur