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1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
SECTION 1 GENERAL
This section explains the safety hints and gives the specification of the machine and major
components.
SECTION 2 STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
SECTION 3 HYDRAULIC SYSTEM
This section explains the hydraulic circuit, single and combined operation.
SECTION 4 ELECTRICAL SYSTEM
This section explains the electrical circuit, monitoring system and each component. It serves not
only to give an understanding electrical system, but also serves as reference material for trouble
shooting.
SECTION 5 MECHATRONICS SYSTEM
This section explains the computer aided power optimization system and each component.
SECTION 6 TROUBLESHOOTING
This section explains the troubleshooting charts correlating "problems" to "causes".
SECTION 7 MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
SECTION 8 DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling
each component, as well as precautions to be taken for these operations.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your HYUNDAI distributor for the latest information.
0-1
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating Revised edition mark(ںڹڸš)
Any additions, amendments or other changes When a manual is revised, an edition mark is
will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the
Get the most up-to-date information before you pages.
start any work.
Revisions
Filing method Revised pages are shown at the list of revised
1. See the page number on the bottom of the pages on the between the contents page and
page. section 1 page.
File the pages in correct order.
2. Following examples shows how to read the Symbols
page number. So that the shop manual can be of ample
Example 1 practical use, important places for safety and
2-3 quality are marked with the following symbols.
Item number (2. Structure and
Function)
Consecutive page number for Symbol Item Remarks
each item.
Special safety precautions are
3. Additional pages : Additional pages are necessary when performing the
indicated by a hyphen(-) and number after the work.
Safety
page number. File as in the example.
Extra special safety precautions
10 - 4 are necessary when performing
10 - 4 - 1 the work because it is under
Added pages internal pressure.
10 - 4 - 2
10 - 5 Special technical precautions or
Ɠ Caution
other precautions for preserving
standards are necessary when
performing the work.
0-2
3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.
Example
1. Method of using the Conversion Table to convert from millimeters to inches
Convert 55mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as ڞ, then draw a
horizontal line from ڞ.
(2) Locate the number 5 in the row across the top, take this as ڟ, then draw a perpendicular line
down from ڟ.
(3) Take the point where the two lines cross as ڠ. This point ڠgives the value when converting
from millimeters to inches. Therefore, 55mm = 2.165 inches.
0 1 2 3 4 5 6 7 8 9
0-3
Millimeters to inches 1mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
0 1 2 3 4 5 6 7 8 9
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
0-4
Liter to U.S. Gallon
1ֻ = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.631 25.625 25.889 26.153
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
0-5
kgm to lb.ft 1kg.m = 7.233 lb.ft
0 1 2 3 4 5 6 7 8 9
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 10005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
0-6
kg / cm2 to lb / in2 1kg / cm2 = 14.2233 lb /in2
0 1 2 3 4 5 6 7 8 9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 5603 2617 2631 2646 2660 2674 2688
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
0-7
TEMPERATURE
Fahrenheit-Centigrade Conversion.
A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse
is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
Ɓ
C Ɓ
F Ɓ
C Ɓ
F Ɓ
C Ɓ
F Ɓ
C Ɓ
F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
0-8
R290LC-3 Service Manual http://ce.hhi.co.kr/eng/parts/sm/R290lc-3/c_exca1.htm
1 of 1 6/16/2011 10:53 AM
SECTION 1 GENERAL
GROUP 1 SAFETY
DO
NOT
OPERATE
1-1
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your
telephone.
1-2
KEEP RIDERS OFF EXCAVATOR
Only allow the operator on the excavator. Keep riders
off.
Riders on excavator are subject to injury such as being
struck by foreign objects and being thrown off the
excavator. Riders also obstruct the operator's view
resulting in the excavator being operated in an unsafe
manner.
1-3
SUPPORT MACHINE PROPERLY
Always lower the attachment or implement to the
ground before you work on the machine. If you must
work on a lifted machine or attachment, securely
support the machine or attachment.
Do not support the machine on cinder blocks, hollow
tiles, or props that may crumble under continuous load.
Do not work under a machine that is supported solely by
a jack. Follow recommended procedures in this manual.
1-4
BEWARE OF EXHAUST FUMES
Prevent asphyxiation. Engine exhaust fumes can
cause sickness or death.
If you must operate in a building, be positive there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open doors
and windows to bring enough outside air into the area.
1-5
SERVICE MACHINE SAFELY
Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing or necklace when you work near
machine tools or moving parts. If these items were to
get caught, severe injury could result.
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
1-6
AVOID HEATING NEAR PRESSURIZED FLUID
LINES
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials.
Pressurized lines can be accidentally cut when heat
goes beyond the immediate flame area. Install fire
resisting guards to protect hoses or other materials.
1-7
USE TOOLS PROPERLY
Use tools appropriate to the work. Makeshift tools,
parts, and procedures can create safety hazards.
Use power tools only to loosen threaded tools and
fasteners.
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
wrenches.
Use only recommended replacement parts.(See Parts
catalogue.)
1-8
GROUP 2 SPECIFICATIONS
1. MAJOR COMPONENT
Engine
Main pump
Tooth Bucket Turning joint Swing motor
Hydraulic oil tank
Main control valve
1-9
2. SPECIFICATION
1) ROBEX 290-3
I(I') D
C
E
G
F
H
J M
K N
A B(L)
1-10
2) ROBEX 290LC-3
I(I') D
C
E
G
F
H
J M
K N
A B(L)
1-11
3) ROBEX 290NLC-3
I(I') D
C
E
G
F
H
J M
K N
A B(L)
1-12
3. WORKING RANGE
A
A'
F
D
E
B'
C
B
8ft
Description 2.10 m(6' 11")Arm 2.50 m(8' 2")Arm 3.05 m(10' 0")Arm 3.75 m(12' 4")Arm
Max. digging reach A 10020 mm (32' 9") 10360 mm (34' 0") 10800 mm (35' 5") 11400 mm (37' 5")
Max. digging reach on ground A' 9815 mm (32' 2") 10160 mm (33' 4") 10600 mm (34' 9") 11220 mm (36' 10")
Max. digging depth B 6440 mm (21' 10") 6950 mm (22' 10") 7500 mm (24' 7") 8200 mm (26' 11")
Max. digging depth (8ft level) B' 6240 mm (20' 5") 6740 mm (22' 1") 7300 mm (23' 11") 8010 mm (26' 3")
Max. vertical wall digging depth C 581 mm (19' 0") 6060 mm (19' 11") 6410 mm (21' 0") 7080 mm (23' 3")
Max. digging height D 10070 mm (33' 0") 10130 mm (33' 3") 10160 mm (33' 4") 10340 mm (33' 11")
Max. dumping height E 6930mm (22' 7") 7040 mm (23' 1") 7110 mm (23' 4") 7300 mm (23' 11")
Min. swing radius F 4380 mm (14' 4") 4260 mm (14' 0") 4230 mm (13' 11") 4140 mm (13' 7")
164KN 164KN 164KN 164KN
Bucket digging force 16700 kgf 16700 kgf 16700 kgf 16700 kgf
36817 lbf 36817 lbf 36817 lbf 36817 lbf
167 KN 140 KN 120 KN 108 KN
Arm crowd force 17000 kgf 14300 kgf 12200 kgf 11000 kgf
34700 lbf 31526 lbf 26896 lbf 24251 lbf
1-13
4. WEIGHT
1-14
5. LIFTING CAPACITIES
1) ROBEX 290LC-3
(1) 6.25m(20' 6") boom, 2.1m(6' 11") arm equipped with 1.1m3(CECE heaped) bucket and 810mm(32")
triple grouser shoe.
1-15
(2) 6.25m(20' 6") boom, 2.5m(8' 2") arm equipped with 1.1m3(CECE heaped) bucket and 810mm(32") triple
grouser shoe.
(3) 6.25m(20' 6") boom, 3.05m(10' 0") arm equipped with 1.1m3(CECE heaped) bucket and 810mm(32")
triple grouser shoe.
1-16
(4) 6.25m(20' 6") boom, 3.75m(12' 4") arm equipped with 1.1m3(CECE heaped) bucket and 810mm(32")
triple grouser shoe.
Load radius At max. reach
Load point 1.5m(5' 0") 3.0m(10' 0") 4.5m(15' 0") 6.0m(20' 0") 7.5m(25' 0") 9.0m(30' 0") Capacity Reach
height
m(ft)
9.0m kg *3680 *3680 8.54
(30' 0") lb *8110 *8110 (28.0)
7.5m kg *3800 3270 9.65
(25' 0") lb *8380 7210 (31.7)
6.0m kg *4019 *4019 *2620 *2620 *3960 2740 10.39
(20' 0") lb *8860 *8860 *5780 *5780 *8730 6040 (34.1)
4.5m kg *4550 *4550 *4080 3500 *4130 2440 10.83
(15' 0") lb *10030 *10030 *8990 7720 *9110 5380 (35.5)
3.0m kg *12940 *12940 8010 *8010 *6190 *6190 *5290 4690 *4810 3360 4019 2280 11.02
(10' 0") lb *25830 *28530 *17660 *17660 *16350 *13650 *11660 10340 *10600 7410 8860 5030 (36.2)
1.5m kg *9740 *9740 *10670 9910 *7590 6330 *6090 4410 *5270 3200 3980 2230 10.97
(5' 0") lb *21470 *21470 *23520 21850 *16730 13960 *13430 9720 *11620 7050 8770 4920 (36.0)
Ground kg *9970 *9970 *12480 9240 *8730 5930 *6800 4170 5390 3070 4120 2300 10.69
line lb *21980 *21980 *27510 20370 *19250 13070 *14990 9190 11880 6770 9080 5070 (35.1)
-1.5m kg *8980 *8980 *12330 *12330 *13300 8940 *9430 5690 7080 4019 5300 2980 4480 2520 10.14
(-5' 0") lb *19800 *19800 *27180 *27180 *29320 19710 *20790 12540 15610 8860 11680 6570 9880 5560 (33.3)
-3.0m kg *11860 *11860 *15680 *15680 *13290 8880 *9590 5620 7020 3970 5200 2970 9.27
(-10' 0") lb *26150 *26150 *34570 *34570 *29300 19580 *21140 12390 15480 8750 11460 6550 (30.4)
-4.5m kg *15200 *15200 *18430 *18430 *12410 9020 *9050 5690 *5590 3940 7.95
(-15' 0") lb *33510 *33510 *40630 *40630 *27360 19890 *19950 12540 *12320 8690 (26.1)
-6.0m kg *14890 *14890 *10230 9380
(-20' 0") lb *32830 *32380 *22550 20680
(5) 6.25m(20' 6") boom, 3.05m(10' 0") arm equipped with 1.1m3(CECE heaped) bucket and 810mm(32")
triple grouser shoe.
1-17
(6) 6.25m(20' 6") boom, 3.75m(12' 4") arm equipped with 1.1m3(CECE heaped) bucket and 810mm(32")
triple grouser shoe.
Load radius At max. reach
Load point 1.5m(5' 0") 3.0m(10' 0") 4.5m(15' 0") 6.0m(20' 0") 7.5m(25' 0") 9.0m(30' 0") Capacity Reach
height
m(ft)
9.0m kg *3680 *3680 8.54
(30' 0") lb *8110 *8110 (28.0)
7.5m kg *3800 3180 9.65
(25' 0") lb *8380 7010 (31.7)
6.0m kg *4019 *4019 *2620 *2620 *3960 2660 10.39
(20' 0") lb *8860 *8860 *5780 *5780 *8730 5860 (34.1)
4.5m kg *4550 *4550 *4080 3400 3660 2360 10.83
(15' 0") lb *10030 *10030 *8990 7500 8070 5200 (35.5)
3.0m kg *12940 *12940 8010 *8010 *6190 *6190 *5290 4570 *4810 3260 3470 2200 11.02
(10' 0") lb *28530 *28530 *17660 *17660 *13650 *13650 *11660 10080 *10600 7190 7650 4850 (36.2)
1.5m kg *9740 *9740 *10670 9670 *7590 6160 *6090 4280 4790 3100 3430 2150 10.97
(5' 0") lb *21470 *21470 *23520 21320 *16730 13580 *13430 9440 10560 6830 7560 4740 (36.0)
Ground kg *9970 *9970 *12480 9000 *8730 5760 6260 4050 4640 2970 3540 2220 10.69
line lb *21980 *21980 *27510 19840 *19250 12700 13800 8930 10230 6550 7800 4890 (35.1)
-1.5m kg *8980 *8980 *12330 *12330 *13300 8690 8710 5530 6090 3890 4560 2890 3850 2430 10.14
(-5' 0") lb *19800 *19800 *27180 *27180 *29320 19160 19200 12190 13430 8580 10050 6370 8490 5360 (33.3)
-3.0m kg *11860 *11860 *15680 *15680 *13290 8640 8620 5450 6040 3840 4490 2880 9.27
(-10' 0") lb *26150 *26150 *34570 *34570 *29300 19050 19000 12020 13320 8470 9900 6350 (30.4)
-4.5m kg *15200 *15200 *18430 18360 *12410 8780 8700 5520 *5590 3820 7.95
(-15' 0") lb *33510 *33510 *40630 40480 *27360 19360 19180 12170 *12320 8420 (26.1)
-6.0m kg *14890 *14890 *10230 9140
(-20' 0") lb *32830 *32830 *22550 20150
1-18
2) ROBEX 290LC-3
(1) 6.25m(20' 6") boom, 2.1m(6' 11") arm equipped with 1.1m3(CECE heaped) bucket and 810mm(32") triple
grouser shoe.
(2) 6.25m(20' 6") boom, 2.5m(8' 2") arm equipped with 1.1m3(CECE heaped) bucket and 810mm(32") triple
grouser shoe.
Load radius At max. reach
Load point 1.5m(5' 0") 3.0m(10' 0") 4.5m(15' 0") 6.0m(20' 0") 7.5m(25' 0") Capacity Reach
height
m(ft)
9.0m kg *4770 *4770 7.04
(30' 0") lb *10520 *10520 (23.1)
7.5m kg *4810 4210 8.40
(25' 0") lb *10600 9280 (27.6)
6.0m kg *5330 5000 *4920 3430 9.25
(20' 0") lb *11750 11020 *10850 7560 (30.3)
4.5m kg *7930 *7930 *6420 *6420 *5730 4850 *5080 3020 9.75
(15' 0") lb *17480 *17480 *14150 *14150 *12630 10690 *11200 6660 (32.0)
3.0m kg *10580 10310 *7670 6630 *6350 4630 4830 2830 9.97
(10' 0") lb *23320 22730 *16910 14620 *14000 10210 10650 6240 (32.7)
1.5m kg *12690 9530 *8840 6220 *7000 4410 4810 2790 9.91
(5' 0") lb *27980 21010 *19490 13710 *15430 9720 10600 6150 (32.5)
Ground kg *13600 9210 *9620 5960 7320 4260 5040 2930 9.59
line lb *29980 20300 *21210 13140 16140 9390 11110 6460 (31.5)
-1.5m kg *13070 *13070 *13590 9160 *9870 5860 7250 4190 5630 3290 8.96
(-5' 0") lb *28810 *28810 *29960 20190 *21760 12920 15980 9240 12410 7250 (29.4)
-3.0m kg *14990 *14990 *18270 *18270 *12810 9280 *9470 5910 *5990 4090 7.94
(-10' 0") lb *33050 *33050 *40280 *40280 *28240 20460 *20880 13030 *13210 9020 (26.0)
-4.5m kg *15310 *15310 *10950 9580 *5550 *5550 6.28
(-15' 0") lb *33750 *33750 *24140 21120 *12240 *12240 (20.6)
1-19
3) ROBEX 290NLC-3
(1) 6.25m(20' 6") boom, 2.1m(6' 11") arm equipped with 1.1m3(CECE heaped) bucket and 810mm(32") triple
grouser shoe.
(2) 6.25m(20' 6") boom, 2.5m(8' 2") arm equipped with 1.1m3(CECE heaped) bucket and 600mm(24") triple
grouser shoe.
Load radius At max. reach
Load point 1.5m(5' 0") 3.0m(10' 0") 4.5m(15' 0") 6.0m(20' 0") 7.5m(25' 0") Capacity Reach
height
m(ft)
9.0m kg *4770 *4770 7.04
(30' 0") lb *10520 *10520 (23.1)
7.5m kg *4810 3720 8.40
(25' 0") lb *10600 8200 (27.6)
6.0m kg *5330 4420 *4920 3000 9.25
(20' 0") lb *11750 9740 *10850 6610 (30.3)
4.5m kg *7930 *7930 *6420 6280 *5730 4270 4930 2620 9.75
(15' 0") lb *17480 *17480 *14150 13850 *12630 9410 10870 5780 (32.0)
3.0m kg *10580 9010 *7670 5830 *6350 4059 4670 2440 9.97
(10' 0") lb *23320 19860 *16910 12850 *14000 8950 10300 5380 (32.7)
1.5m kg *12690 8270 *8840 5430 *7000 3840 4650 2400 9.91
(5' 0") lb *27980 18230 *19490 11970 *15430 8470 10250 5290 (32.5)
Ground kg *13600 7960 *9620 5180 7090 3690 4870 2520 9.59
line lb *29980 17550 *21210 11420 15630 8140 10740 5560 (31.5)
-1.5m kg *13070 *13070 *13590 7910 *9870 5080 7020 3630 5450 2850 8.96
(-5' 0") lb *28810 *28810 *29960 17440 *21760 11200 15480 8000 12020 6280 (29.4)
-3.0m kg *14990 *14990 *18270 16330 *12810 8020 *9470 5120 *5990 3570 7.94
(-10' 0") lb *33050 *33050 *40280 36000 *28240 17680 *20880 11290 *13210 7870 (26.0)
-4.5m kg *15310 *15310 *10950 8310 *5550 *5420 6.28
(-15' 0") lb *33750 *33750 *24140 18320 *12240 *11950 (20.6)
1-20
(3) 6.25m(20' 6") boom, 3.05m(10' 0") arm equipped with 1.1m3(CECE heaped) bucket and 600mm(24")
triple grouser shoe.
Load radius At max. reach
Load point 1.5m(5' 0") 3.0m(10' 0") 4.5m(15' 0") 6.0m(20' 0") 7.5m(25' 0") 9.0m(30' 0") Capacity Reach
height
m(ft)
9.0m kg *4230 *4230 7.68
(30' 0") lb *9330 *9330 (25.2)
7.5m kg *4320 3340 8.92
(25' 0") lb *9520 7360 (29.3)
6.0m kg *4770 4490 *4460 2730 9.72
(20' 0") lb *10520 9900 *9830 6020 (31.9)
4.5m kg *5760 *5760 *5220 4310 4560 2390 10.20
(15' 0") lb *12700 *12700 *11510 9500 10050 5270 (33.5)
3.0m kg *9920 *9920 *9490 9240 *7050 5880 *5900 4059 *4520 2900 4320 2220 10.40
(10' 0") lb *21870 *21870 *20920 20370 *15540 12960 *13010 8950 *9960 6390 9520 4890 (34.1)
1.5m kg *11860 8360 *8320 5440 *6620 3820 5360 2770 4290 2170 10.35
(5' 0") lb *26150 18430 *18340 11990 *14590 8420 11820 6110 9460 4780 (34.0)
Ground kg *9240 *9240 *13180 7900 *9260 5120 7030 3630 *4780 2680 4460 2260 10.05
line lb *20370 *20370 *29060 17420 *20410 11290 15500 8000 *10540 5910 9830 4980 (33.0)
-1.5m kg *10010 *10010 *12980 *12980 *13530 7750 *9710 4970 6910 3520 4920 2520 9.45
(-5' 0") lb *22070 *22070 *28620 *28620 *29830 17090 *21410 10960 15230 7760 10850 5560 (31.0)
-3.0m kg *13560 *13560 *17530 15890 *13070 7800 *9560 4960 6930 3540 *5800 3070 8.50
(-10' 0") lb *29890 *29890 *38650 35030 *28810 17200 *21080 10930 15280 7800 *12790 6770 (27.9)
-4.5m kg *17740 *17740 *16770 16340 *11670 8020 *8530 5120 *5790 4370 7.01
(-15' 0") lb *39110 *39110 *36970 36020 *25730 17680 *18810 11290 *12760 9630 (23.0)
-6.0m kg *8360 *8360
(-20' 0") lb *18430 *18430
(4) 6.25m(20' 6") boom, 3.75m(12' 4") arm equipped with 1.1m3(CECE heaped) bucket and 600mm(24")
triple grouser shoe.
1-21
6. BUCKET SELECTION GUIDE
1) ROBEX 290-3
0.7 m3 CECE 0.9 m3 CECE 1.1 m3 CECE 1.3 m3 CECE 1.5 m3 CECE 1.6 m3 CECE
heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket
PCSA CECE Without With Weight 2.10 m Arm 2.50 m Arm 3.05 m Arm 3.75 m Arm
heaped heaped side cutter side cutter (6' 11") (8' 2") (10' 0") (12' 4")
Applicable for materials with density of 2000 kg/m3 (3370 lb/yd3) or less
Applicable for materials with density of 1600 kg/m3 (2700 lb/yd3) or less
Applicable for materials with density of 1100 kg/m3 (1850 lb/yd3) or less
1-22
2) ROBEX 290LC-3, ROBEX 290NLC-3
0.7 m3 CECE 0.9 m3 CECE 1.1 m3 CECE 1.3 m3 CECE 1.5 m3 CECE 1.6 m3 CECE
heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket heaped bucket
PCSA CECE Without With Weight 2.10 m Arm 2.50 m Arm 3.05 m Arm 3.75 m Arm
heaped heaped side cutter side cutter (6' 11") (8' 2") (10' 0") (12' 4")
Applicable for materials with density of 2000 kg/m3 (3370 lb/yd3) or less
Applicable for materials with density of 1600 kg/m3 (2700 lb/yd3) or less
Applicable for materials with density of 1100 kg/m3 (1850 lb/yd3) or less
1-23
7. UNDERCARRIAGE
1) TRACKS
X-leg type center frame is integrally welded with reinforced box-section track frames. The design
includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock
absorbing springs, and assembled track-type tractor shoes with triple grousers.
2) TYPES OF SHOES
Triple grouser
Model Shapes
Shoe width mm (in) 600(24) 710 (28) 810 (32) 900 (35)
Operating weight kg (lb) 27500 (60600) 28100 (61900) 28400 (62600) 28700 (63300)
R290-3
Ground pressure kg/cm2 (psi) 0.57 (8.11) 0.49 (6.97) 0.43 (6.12) 0.40 (5.69)
Overall width mm (ftin) 3200 (10' 6") 3310 (10' 10") 3410 (11' 2") 3500 (11' 6")
Shoe width mm (in) 600 (24) 710 (28) 810 (32) 900 (35)
Operating weight kg (lb) 28400 (62600) 28800 (63500) 29100 (64200) 29400 (64800)
R290LC-3
Ground pressure kg/cm2 (psi) 0.54 (7.68) 0.47 (6.68) 0.41 (5.83) 0.37 (5.26)
Overall width mm (ftin) 3200 (10' 6") 3310 (10' 10") 3410 (11' 2") 3500 (11' 6")
Shoe width mm (in) 600 (24) 710 (28) 810 (32) 900 (35)
Operating weight kg (lb) 28000 (61700) 28500 (62800) 28800 (63500) 29100 (64200)
R290NLC-3
Ground pressure kg/cm2 (psi) 0.52 (7.40) 0.44 (6.26) 0.39 (5.55) 0.35 (4.98)
Overall width mm (ftin) 2990 (9' 9") 3100 (10' 2") 3200 (10' 5") 3300 (10' 9")
Quantity
Item
ROBEX 290LC-3, 290NLC-3 ROBEX 290-3
Carrier rollers 2 EA 2 EA
Track rollers 9 EA 8 EA
Track shoes 51 EA 48 EA
1-24
8. SPECIFICATIONS FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
2) MAIN PUMP
Item Specification
1-25
3) PILOT PUMP
Item Specification
Item Specification
Type 7 spool
Operating method Hydraulic pilot assist
Main relief valve pressure 320 kg/cm2 (4550 psi)
Overload relief valve pressure 350 kg/cm2 (4980 psi)
5) SWING MOTOR
Item Specification
6) TRAVEL MOTOR
Item Specification
1-26
7) REMOTE CONTROL VALVE
Item Specification
8) CYLINDER
Item Specification
9) SHOE
Standard 810 mm (32") 0.43 kg/cm2 (6.12 psi) 48 3410 mm (11' 2")
600 mm (24") 0.57 kg/cm2 (8.11 psi) 48 3200 mm (10' 6")
R 290-3
Option 710 mm (28") 0.49 kg/cm (6.97 psi)
2
48 3310 mm (10' 10")
900 mm (35") 0.40 kg/cm (5.79 psi)
2
48 3500 mm (11' 6")
Standard 810 mm (32") 0.41 kg/cm (5.83 psi)
2
51 3410 mm (11' 2")
600 mm (24") 0.54 kg/cm2 (7.68 psi) 51 3200 mm (10' 6")
R 290LC-3
Option 710 mm (28") 0.47 kg/cm (6.68 psi)
2
51 3310 mm (10' 10")
900 mm (35") 0.37 kg/cm (5.26 psi)
2
51 3500 mm (11' 6")
Standard 600 mm (24") 0.52 kg/cm (7.40 psi)
2
51 2990 mm (9' 9")
710 mm (28") 0.44 kg/cm2 (6.26 psi) 51 3100 mm (10' 2")
R 290NLC-3
Option 810 mm (32") 0.39 kg/cm (5.55 psi)
2
51 3200 mm (10' 5")
900 mm (35") 0.35 kg/cm (4.98 psi)
2
51 3300 mm (10' 9")
1-27
10) BUCKET
Standard 1.27 m3 (1.66 yd3) 1.1 m3 (1.44 yd3) 5 1290 mm (51") 1410 mm (56")
0.79 m (1.03 yd )
3 3
0.7 m (0.92 yd )
3 3
3 890 mm (35") 1010 mm (40")
1.03 m (1.35 yd )
3 3
0.9 m (1.18 yd )
3 3
4 1090 mm (43") 1210 mm (48")
Option 1.50 m3 (1.96 yd3) 1.3 m3 (1.70 yd3) 5 1490 mm (59") 1610 mm (63")
1.73 m (2.26 yd )
3 3
1.5 m (1.96 yd )
3 3
6 1696 mm (67") ӧ
1.85 m (2.42 yd )
3 3
1.6 m (2.09 yd )
3 3
6 1800 mm (71") ӧ
1-28
10. RECOMMENDED OILS
SAE 30
SAE 15W-40
Tank; ISO VG 32
270 (71.3)
Hydraulic tank Hydraulic oil ISO VG 46
System;
380 (100.3)
ISO VG 68
NLGI NO. 1
Fitting Grease As required
(Grease nipple)
NLGI NO. 2
Mixture of
Radiator antifreeze
35 (9.2) Ethylene glycol base permanent type
(Reservoir tank) and water
50 : 50
1-29
SECTION 2 STRUCTURE AND FUNCTION
GROUP 1 PUMP DEVICE
1. STRUCTURE
The pump device consists of main pump, regulator and gear pump.
Pi1
A3
B3
Dr P1
a4 Pi2
Qmin adjusting screw Qmax adjusting screw Qmax adjusting screw
Regulator Regulator
Pi1 Pi2
Dr
Dr B3
B1
a3
a1 a2
Front pump Port block Rear pump Gear pump
2-1
1) MAIN PUMP(1/2)
The main pump consists of two piston pump(front & rear) and valve block.
A
789 532 548 724 792 954
732 214 531 702 534 901 719
535
808
953
886
717
406
261
824
111
774
127
710
123 251 401 211 156 157 313 312 725 314 468 141 152 113
490 212 153 158 114 124 466 885 728 151 271
2-2
MAIN PUMP(2/2)
544
542
543
545
541 (079)
725
466
725
325
407
VIEW A
2-3
2) REGULATOR(1/2)
615
613
A 611
B
A
KR3H-9N29
P2
438 Pf
801 Pi
924
SECTION B-B B
413 438
438
656
Port name port size
Pi
735 A Delivery port 1"
B Suction port 3"
Pi Pilot port PF 1/4-15
Pf Powershift port PF 1/4-15
P2 Companion delivery port -
496 724 725 436
2-4
REGULATOR(2/2)
734 653 654 836 651 652 601 624 629 630 628
655
641 801
814 925
898
631 627
732
733
732
622
2-5
3) GEAR PUMP
434
850
311
312
355
732
307
309
710 435 361 353 310 308 434 466
725
2-6
2. FUNCTION
1) MAIN PUMP
The pumps may classified roughly into the rotary group performing a rotary motion and working as
the major part of the whole pump function: the swash plate group that varies the delivery rates: and
the valve cover group that changes over oil suction and discharge.
2-7
(3) Valve block group
The valve block group consists of valve
block(312), valve plate(313) and valve
plate pin(885).
The valve plate having two melon-shaped
ports is fixed to the valve block and feeds 312
and collects oil to and from the cylinder
block. 313
885
The oil changed over by the valve plate is
connected to an external pipeline by way
of the valve block.
Now, if the drive shaft is driven by a prime
mover(electric motor, engine, etc), it
rotates the cylinder block via a spline
linkage at the same time. If the swash
plate is tilted as in Fig(previous page) the
pistons arranged in the cylinder block
make a reciprocating motion with respect
to the cylinder block, while they revolve
with the cylinder block.
If you pay attention to a single piston, it
performs a motion away from the valve
plate(oil sucking process) within 180
degrees, and makes a motion towards
the valve plate(or oil discharging process)
in the rest of 180 degrees. When the
swash plate has a tilting angle of zero,
the piston makes no stroke and
discharges no oil.
2-8
2) REGULATOR
Regulator consists of the negative flow control, total horse power control and power shift control
function.
Delivery flow, Q
control in which the delivery flow Q
decreases as the pilot pressure Pi rises.
With this mechanism, when the pilot
pressure corresponding to the flow
required for the work is commanded, the
pump discharges the required flow only,
and so it does not consume the power Pilot press, Pi
uselessly.
2-9
ڸFlow reducing function
P1 CL
B(E)
874
897
C
A
875
611
As the pilot pressure Pi rises, the pilot piston(643) moves to the right to a position where the
force of the pilot spring(646) balances with the hydraulic force.
The groove(A) in the pilot piston is fitted with the pin(875) that is fixed to lever 2(613). Therefore,
when the pilot piston moves, lever 2 rotates around the fulcrum of point B [fixed by the fulcrum
plug(614) and pin(875)]. Since the large hole section(C) of lever 2 contains a protruding
pin(897) fixed to the feedback lever(611), the pin(897) moves to the right as lever 2 rotates.
Since the opposing-flat section(D) of the feedback lever is fitted with the pin(548) fixed by the
tilting pin(531) that swings the swash plate, the feedback lever rotates around the fulcrum of
point D, as the pin(897) moves.
Since the feedback lever is connected with the spool(652) via the pin(874), the spool moves to
the right.
The movement of the spool causes the delivery pressure P1 to connect to port CL through the
spool and to be admitted to the large diameter section of the servo piston. The delivery
pressure P1 that is constantly admitted to the small diameter section of the servo piston moves
the servo piston to the right due to the area difference, resulting in decrease of the tilting angle.
When the servo piston moves to the right, point D also moves to the right. The spool is fitted
with the return spring(654) and is tensioned to the left at all times, and so the pin(897) is pressed
against the large hole section(C) of lever 2.
Therefore, as point D moves, the feedback lever rotates around the fulcrum of point C, and the
spool is shifted to the left. This causes the opening between the sleeve(651) and spool(652) to
close slowly, and the servo piston comes to a complete stop when it closes completely.
2-10
ڹFlow increasing function
P1 CL
B(E)
874
897
C
875
611
Small diameter
Servo piston D chamber
Large diameter 548
chamber
531
As the pilot pressure Pi decreases, the pilot piston(643) moves to the left by the action of the
pilot spring(646) and causes lever 2(613) to rotate around the fulcrum of point B. Since the
pin(897) is pressed against the large hole section(C) of lever 2 by the action of the return
spring(654) via the spool(652), pin(874), and feedback lever(611), the feedback lever rotates
around the fulcrum of point D as lever 2 rotates, and shifts the spool to the left. Port CL opens
a way to the tank port as the spool moves. This deprives the large diameter section of the
servo piston of pressure, and shifts the servo piston to the left by the discharge pressure P1 in
the small diameter section, resulting in an increase in the flow rate.
As the servo piston moves, point D also moves to the left, the feedback lever rotates around the
fulcrum of point C, and the spool moves to the right till the opening between the spool and
sleeve is closed.
2-11
ںAdjustment of flow control characteristic
The flow control characteristic can be
adjusted with the adjusting screw.
Adjust it by loosening the hexagon 801
924
nut(801) and by tightening(or loosening)
the hexagonal socket head screw(924).
Tightening the screw shifts the control
chart to the right as shown in the figure.
Ɠ Adjusting values are shown in table.
Delivery flow, Q
adjusting starting amount
screw(924) pressure
change
amount
Pilot press, Pi
2-12
(2) Total horsepower control
The regulator decreases the pump tilting
angle(delivery flow) automatically to limit
the input torque within a certain value
Delivery flow, Q
with a rise in the delivery pressure P1 of
the self pump and the delivery pressure
P2 of the companion pump.
(The input horsepower is constant when
the speed is constant.)
Since the regulator is of the simul
Delivery press, (P1+P2)
taneous total horsepower type that
operates by the sum of load pressures of
the two pumps in the tandem double-
pump system, the prime mover is
automatically prevented from being
overloaded, irrespective of the load
condition of the two pumps, when
horsepower control is under way.
Since this regulator is of the simultaneous
total horsepower type, it controls the
tilting angles(displacement volumes) of
the two pumps to the same value as
represented by the following equation :
Tin = P1ţq/2ॏ + P2ţq/2ॏ
= (P1+P2)ţq/2ॏ
The horsepower control function is the
same as the flow control function and is
summarized in the following.(For detailed
behaviors of respective parts, refer to the
section of flow control).
2-13
ڸOverload preventive function
P1 CL
B(E)
897
P2 P1
875
611
When the self pump delivery pressure P1 or the companion pump delivery pressure P2 rises, it
acts on the stepped part of the compensating piston(621). It presses the compensating
rod(623) to the right till the force of the outer spring(625) and inner spring(626) balances with
the hydraulic force. The movement of the compensating rod is transmitted to lever 1(612) via
pin(875).
Lever 1 rotates around the pin(875) (E) fixed to the casing(601).
Since the large hole section(F) of lever 1 contains a protruding pin(897) fixed to the feedback
lever(611), the feedback lever rotates around the fulcrum of point D as lever 1 rotates, and then
the spool(652) is shifted to the right. As the spool moves, the delivery pressure P1 is admitted
to the large diameter section of the servo piston via port CL, causes the servo piston move to
the right, reduces the pump delivery, flow rate, and prevents the prime mover from being
overloaded.
The movement of the servo piston is transmitted to the feedback lever via point D. Then the
feedback lever rotates around the fulcrum of point F and the spool is shifted to the left. The
spool moves till the opening between the spool(652) and sleeve(651) is closed.
2-14
ڹFlow reset function
P1 CL
B(E)
897
P2 P1
875
As the self pump delivery pressure P1 or the companion pump delivery pressure P2 decreases,
the compensating rod(623) is pushed back by the action of the springs(625 & 626) to rotate
lever 1(612) around point E. Rotating of lever 1 causes the feedback lever(611) to rotate
around the fulcrum of point D and then the spool(652) to move to the left. As a result, port CL
opens a way to the tank port.
This causes the servo piston to move to the left and the pump's delivery rate to increase.
The movement of the servo piston is transmitted to the spool by the action of the feedback
mechanism to move it till the opening between the spool and sleeve is closed.
2-15
ںLow tilting angle(low flow) command preferential function
As mentioned above, flow control and horsepower control tilting angle commands are
transmitted to the feedback lever and spool via the large-hole sections(C & F) of levers 1 and 2.
However, since sections C and F have the pins(٤4) protruding from the large hole(٤8), only the
lever lessening the tilting angle contacts the pin(897) ; the hole(٤8) in the lever of a larger tilting
angle command is freed without contacting the pin(897). Such a mechanical selection method
permits preference of the lower tilting angle command of the flow control and horsepower
control.
ڻAdjustment of input horsepower
Since the regulator is of total cumulative horsepower type, adjust the adjusting screws of both
the front and rear pumps, when changing the horsepower set values. The pressure change
values by adjustment are based on two pumps pressurized at the same time, and the values will
be doubled when only one pump is loaded.
2-16
b. Adjustment of inner spring
626
Adjust it by loosening the hexagon nut
(801) and by tightening(or loosening)
the adjusting screw QI(925).
801
Tightening the screw increases the flow
and then the input horsepower as
925
shown in the figure.
Ɠ Adjusting valves are shown in table.
Delivery flow, Q
(min -1) (Turn) (kgf/cm2) (kgfňm)
2-17
(3) Power shift control
898 P1 CL
B(E)
897
Pf
P2 P1
875
611
2-18
(4) Adjustment of maximum and minimum flows
ڸAdjustment of maximum flow 808
Adjust it by loosening the hexagon
954
nut(808) and by tightening(or loosening)
the set screw(954).
The maximum flow only is adjusted
without changing other control
characteristics.
Delivery flow, Q
Tightening amount Flow change
of adjusting screw amount
(953)
2-19
GROUP 2 MAIN CONTROL VALVE
9
1. STRUCTURE 2
8 7
6
1 Plunger
2 Logic check assy
3 Check assy
4 Load check assy Section J-J
5 Orifice assy Section B-B Section F-F
6 Check valve assy
7 Foot relief assy
8 Selector valve assy
9 Logic valve assy
1
10 Relief assy
TR
11 Option port
TL OPT
AM BKT
SW BM
2
Section A-A Section E-E
4 3 3 4
A E
10 10
11
F F
OPT
B B
Section H-H
C H
5 C H 5
10
10
D D
A E
Section D-D
2-20
STRUCTURE
42
39
39 80
52
6 53
2 39 41
17 3
7 46 9 57 13
2728 58 14
11 47
26 8 59
4 29
25 11 32
23 4 30
2728 25
33
31
51 30
23
5049
9
10
40
18 39
34
35
14
13
39 54 56
42
79
39
80
2-21
STRUCTURE
64
49
50 55 62
60
55
48
47
60 55
50
49
61 55
55 60
75
74 63
73
61
55
78
65
66 47
76
68 48
69 77
67
71
70
39
72
2-22
STRUCTURE
13
1 29 14
2
3
47 81 32
46 11
30 1615
33 13
30 31 14
12
4 32 29
5 30
33
30 31
9 42 40
39 39
10 8 37 38
7 3 36
2
6
25
18 4 26
19 11
35 28
34 27 17
20 25
14 4 11
13 53 49 28
39 27
50 23 22
52
21 45 3
1516 40 39 44
42 43 2
38
39 24
40 36
37
39
41
2-23
2. FUNCTION
1) HYDRAULIC CIRCUIT DIAGRAM
Pi P3 a fr
A7
B7
b7
a7
A6
B3 B6
A3
a3 b6
a6
b3
B2 A5
A2 B5
a2 a5
b5
b2 A4
B1
A1 B4
a1 b4
b1 a4
c
Rs c a R b P3
2-24
2) BASIC OPERATION
(1) Neutral circuit
Oil discharged from P1 flows in from
control valve's entrance port PL and
goes through center bypass passages
of each plunger to reach the end of the Logic valve assembly
stream.
Foot relief assembly
Logic valve assembly and foot relief
assembly are installed between the end
of the stream and the tank passage. FR
FL
In neutral, the logic valve assembly is in
unload status; the foot relief assembly
onloads and sends signal F L to the
pump, minimizing the flow of P1 pump.
Oil discharged from pump P2 flow as
above, minimizing the flow of the P2
TR
pump.
TL OPT
AM BKT
SW BM
PL P1 P2
PR
FR PP
FL
P1 P2
2-25
(2) Bucket operation circuit
Oil from pump P2 is fed into cylinder port
A R5 by adding pressure to bucket
plunger pilot port ar5 and the oil from
actuator flow tank through cylinder port
BR5.
At this time, center bypass passage is Foot relief assembly
closed, pressure signal FR from foot
relief valve become low, the actuator is
FR
operated at maximum output power by FL
maximum discharge of pump.
The P1 pump is in unload status.
TR
TL OPT
AM BKT
SW BM
AR5
BR5
br5 ar5
BKT
BKT
PL P1 P2
PR
FR PP
FL
P1 P2
2-26
(3) Arm flow summation circuit
TR
TL OPT
AM BKT
SW BM
AL2 BL2
al2 bl2
AM AM
PL P1 P2 PR
FR PP
FL
P1 P2
2-27
(4) Boom up flow summation circuit
AM BKT
SW BM
BR4 AR4
ar4
br4
SW Logic check assembly BM
BM
PL P1 P2 PR
FR PP
FL
P1 P2
2-28
(5) Boom down flow circuit
TL OPT
AM BKT
SW BM
BR4 AR4
br4
ar4
Logic check assembly BM
BM
PL P1 P2 PR
FR PP
FL
P1 P2
2-29
(6) Swing priority circuit
AL2 BL2
AM al2 bl2
AM
SW
PL P1 P2 PR
FR
PP
Parallel FL
P1 P2 feed passage
Orifice
2-30
(7) Travel priority circuit
TR
PL P1 P2 PR
FR
PP
To pi1 port
SW Parallel FL
feed passage
Orifice
P1 P2
2-31
3) OPERATIONAL DESCRIPTION OF CONTROL VALVE
(1) Plunger operation
ڸNeutral position of plunger
C1 C2
Pilot port a
Pilot port b
Spring
Low pressure
passage Center bypass Low pressure
High pressure feed passage
passage
In neutral, spring sets the plunger at the neutral position; the high pressure feed passage is shut
off by the plunger; oil from the pump flows through the center bypass.
2-32
ڹOperation of plunger
C2
C1
Pilot port a
Pilot port b
Spring
Low pressure Center bypass
passage
High pressure Low pressure
feed passage passage
When actuated(pressure is applied to pilot port a), the plunger moves to the left; the center
bypass is shut off; oil from the center bypass pushes up the check valve C1 and flows into
cylinder port A via the high pressure feed passage. Meanwhile, oil from the parallel feed
passage pushes down check valve C2 and flows into cylinder port A via the high pressure feed
passage.
The return oil from cylinder port B flows into the tank via the low pressure feed passage.
Ɠ Reversed when pressure is applied to pilot port b.
2-33
(2) Foot relief valve operation
ڸfp is lower than spring force
C D E Spring
fp
From logic valve
A B
Pressure signal
To low pressure Cartridge sent out to the pump
passage
Oil from the logic valve flows into the tank via passage(A), orifice(B) of poppet.
Pressure fp generated by orifice(B) is led to the pump via hole(C), passage(D) and hole(E), to
control the pump delivery flow.
C D E Spring
fp
From logic valve
A B
Pressure signal
To low pressure Cartridge sent out to the pump
passage
If a large amount flows due to delayed pump response, etc., and pressure fp reaches the preset
spring force, then the poppet is lifted and functions as a relief valve.
2-34
(3) Selector valve operation
ڸStraight travel signal : ON
If any actuator is operated when traveling, travel straight signal pressure reaches a spring force,
the spool(A) moves to the left the high pressure passage for travel of the companion valve(TL)
and the high pressure passage for travel(TR) are connected, and equal amount of oil flows to TR
and TL.
The spring sets spool in position; which shuts off the high pressure feed passages of TR and TL.
2-35
(4) Logic check valve operation
ڸBoom down or neutral
when boom up pilot pressure is not supplied to Pi port
d2
d1
Pi
Manifold
Boom up
pilot signal
b
Orifice c
E D To boom high pressure feed
passage of 4 plunger side
If Pa > Pb
Poppet (E) is moved to left by the force of Pa(d2 - d1), because d1<d2 and passage from a to b is
blocked.
If Pa < Pb
Passage from b to a is blocked by the check valve (B). also, passage from b to a is blocked by
d1<d2 and Pa<Pb.
2-36
ڹBoom up
When boom up pilot pressure is supplied to Pi port
Piston (c) moves to left; passage (A) is shut off.
When Pa > Pb
d2
d1
Pi
Manifold
Boom up
pilot signal
b
Orifice c
E D To boom high pressure feed
passage of 4 plunger side
The pressure of chamber(1) is equal to pressure Pb; poppet (E) is lifted; oil flows through from a
to b.
When Pa < Pb
d2
d1
Pi
Manifold
Boom up
pilot signal
b
c
Orifice E D To boom high pressure feed
passage of 4 plunger side
2-37
(5) Overload relief valve operation
ڸOverload working operation
3
1 2 A B
d3 d1 K d2 d4
Cylinder port
J H G Low pressure E D C
passage tank F
Hydraulic oil from cylinder port enters chamber (2) via orifice (J) of piston (H). Because d1<d2
and d3 <d4, poppets (G) and (F) are securely seated.
3
1 2 A B
Cylinder port
J H G Low pressure F D C
passage tank E
When hydraulic pressure reaches the preset force of spring (B), poppet (A) opens; oil flows around
poppet (A) and into the low pressure passage via side hole (C) and passage (E).
2-38
3
1 2 A B
Cylinder port
Low pressure E D C
J H G passage tank F
Oil flow is formed; pressure drops before and behind orifice (J); piston (H) moves to right and
seats at the tip of poppet (A).
3
1 2
A B
Cylinder port
Low pressure E D C
J H G passage tank F
Hydraulic oil from chamber (1) enters chamber (2) via throttle (K) at the tip of poppet (A); it flows
around poppet (A) and into the low pressure passage via side hole (C) and passage (E).
Pressure drops before and behind throttle (K), making pressure of chamber (1) x area
d1 >pressure of chamber (2) x area d2; poppet (G) is lifted and hydraulic oil flows into the low
pressure passage.
2-39
ڹMake up operation
3
1 2 A B
d3 d1 K d2 d4
Cylinder port
J H G Low pressure E D C
passage tank F
Poppet (F) is securely seated because the cylinder port pressure is normally higher than the
tank pressure and d3 <d4.
3
1 2 A B
Cylinder port
J H G Low pressure F E D C
passage tank
When the cylinder port pressure drops(closer to negative pressure) until the cylinder port
pressure is lower than the tank pressure, poppet (F) opens receiving the tank pressure for the
difference in area between d3 and d4; oil flows from the tank passage to the cylinder port in order
to prevent cavitation.
2-40
(6) Logic valve
ڸPilot port : Release
Oil from center by pass flow into pilot port via orifice of poppet(A).
Oil flow is formed;pressure drops before and behind orifice, making pressure of chamber(1)ó
pressure of chamber(2); poppet(A) is lifted and oil flows into foot relief valve.
Pilot port
1
From center bypass
Pilot port
Orifice
1
From center bypass
2-41
GROUP 3 SWING DEVICE
1. STRUCTURE
Swing device consists swing motor, swing reduction gear.
Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve.
Relief valve
A B MU
A, B
P3
SH Dr
Reduction gear Swing motor Time delay valve
SH
Port Port name Port size
A MU B
2-42
1) SWING MOTOR
993 117 121 118 114 706 707 702 712 472 488 355 351 469 051
106
438
432 444
106 A 303
443
471 A
304
101
491
437
124
468
487
433
401
301 994 122 123 113 116 111 742 743 031 131 451
464 485
Section A-A
2-43
2) REDUCTION GEAR
102
401
231 312 311
801
911
201
288
211
287
912
286
204 285
403
284
210
282
2-44
2. FUNCTION
1) ROTARY PART
When high pressurized oil enters a cylinder through port(a), which is the inlet of balance plate(131),
hydraulic pressure acting on the piston causes axial force F. The pressure force F works via the
piston(121) upon the return plate(123) which acts upon the swash plate(124) via an hydrostatic
bearing. Force F1 perpendicular to swash plate(124) and force F2 perpendicular to cylinder center.
Being transferred to the cylinder block(111) through piston, force F2 causes rotational moment at
surroundings of cylinder.
Since cylinder block has 9 equidistantly arrayed pistons, rotational torque is transmitted to cylinder
shaft in order by several pistons connected to the inlet port of high pressurized oil. When the
direction of oil flow is reversed, rotational direction of cylinder is also reversed. Output torque is
given by the equation.
pźq F
T= , q=ZňAňPCDňtanѴ , F1= , F2=F tanҋ, S=PCDźtanҋ
2० COSѴ
Where p : Effective difference of pressure(kgf/cm2)
q : Displacement(cc/rev)
T : Output torque(kgfňcm)
Z : Piston number
A : Piston area(cm2)
ҋ: Tilting angle of swash plate(degree)
S : Piston stroke(cm)
Low High
pressure oil pressure oil
F1 F2
131
2-45
2) MAKE UP VALVE
In the system using this type of motor, there is no counter balance functioning valve and there
happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation
caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency.
A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure
feed pressure required when the hydraulic motor makes a pumping action. The boost pressure
acts on the hydraulic motor's feed port via the make up valve.
Pressurized oil into the port B, the motor rotate counterclockwise.
If the plunger of MCV moves neutral position, the drain oil from Mu port run into motor via right
make up valve, which prevent the cavitation of motor.
A B
MU
2-46
3) RELIEF VALVE
1 Body
2 Seat
3 Plunger
1 4 Spring
5 Rod
8 6 Piston
8 Spring seat
9
9 Shim
6
4
3
3
P1
T
1
2-47
ڸPorts (P, R) at tank pressure.
g n h 5 3 m
6 A2 4 1 A1
ڹWhen hydraulic oil pressure(PźA1) reaches the preset force(FSP) of spring(4), the plunger(3)
moves to the left as shown. Also the oil flow chamber g via orifice m and n.
P1źA1=FSP+PgźA2
FSP+PgźA2
P1 =
A1
g n 4 m
P=P1
2-48
ںWhen the pressure of chamber g reaches the preset force(FSP) of spring(4), the piston(6) moves
right and stop the piston(6) hits the end of body(1).
g n 4 m
P=P2
ڻWhen piston(6) hits the end of body(1), it stops moving to the right any further. As the result, the
pressure in chamber g equals PS .
PS źA1=FSP+PsźA2
FSP
PS =
A1-A2
P=PS
2-49
4) BRAKE SYSTEM
(1) Control valve swing brake system
This is the brake system to stop the swing motion of the excavator for during operation.
In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance
created by this throttling works as a brake force to slow down the swing motion.
A B A B A B
2-50
ڹOperating principle
a. When the swing control lever(1) is set to the swing position, the pilot oil go to the swing control
valve(2) and to SH of the time delay valve(3) via the shuttle valve(4), this pressure shift time
delay valve so, pilot pump charged oil(P3) go to the chamber G.
This pressure is applied to move the piston(6) to the upward against the force of the spring(9)
thus releasing the brake force.
712
G SH
702
2-51
b. When the swing control(1) lever is set the neutral position, the time delay valve(3) shifts the
neutral position and the pilot oil blocked chamber G.
Then, the piston(6) is moved lower by spring force and the return oil from the chamber G is
drain.
712
G SH
702
2-52
GROUP 4 TRAVEL DEVICE
1. CONSTRUCTION
Travel device consists travel motor and gear box.
Travel motor include counter balance valve, cross over relief valve.
Am A N B Bm
Dr Dr
Pi
Pi Pi
View A
Dr
2-53
1) TRAVEL MOTOR(1/2)
111 742 741 709 707 702 708 461 545 547 472 705 461 303
121
568
123
567
122
116
131
202
452 568
113 567
272
107 464
485
101
491 103
304 451
435 507
471
102 506
105 505
506 511
507
504
510
509 461 501 114 201 502 503 508 512 546 509 461 533 531 572 571
2-54
TRAVEL MOTOR(2/2)
366
364
365
711 712
485 713
464
710
350
E
714
702
Section E- E
E
401
567
568
022 C/B Spool sub assy 402 Hex socket screw 568 O - ring
350 Relief valve 464 VP plug 702 Brake piston
361 Washer 485 O - ring 710 Spring guide
362 C/B spring 541 Seat 711 Spool
364 C/B cover 542 Stopper 712 Bushing
365 O - ring 543 Steel ball 713 Spring
366 Hex socket screw 567 VP plug 714 RO plug
401 Hex socket screw
2-55
2) REDUCTION GEAR
30 6 27 7 1 31
4
26
46
11
5
45
10
24
32
42
9
25
12
21
15
44
19
18
36
32
16
20 41 22 13 20 36 17 14 23 20 37 8 35 33 2 29 34
2-56
2. FUNCTION
1) ROTARY GROUP
Y
111 A 121
wi
ri F P
fi
wi
Ni
Shaft
Y
High pressure Low pressure
The high pressure oil sent by the hydraulic pump passes through the valve casing (303) and valve
plate(131) and is led into the cylinder block(111).
The motor has such construction that the above high pressure oil is led only to the cylinders on one
side in respect to the line Y-Y which connects the upper and lower dead points of the stroke of the
pistons(121).
The high pressure oil works on the piston(121) to push the swash plate with the force fi(fi = PźA,
where P : supply pressure, and A : pressure receiving area), and the force Fi is generated as its
reaction force. This Fi is divided by the swash plate(201) having a tilting angle ҋinto the thrust
component Ni and radial one Wi.
The Wi generates a torque Ti = Wi ź ri in respect to the line Y-Y.
The torque generated by each piston on the high pressure side is summed up into a resultant
torqueȐ(riźWi), which produces torque for rotation.
This torque gives a rotating force to the cylinder block(111) through the pistons.
Since the cylinder block is spline-coupled with the shaft, the rotating force is transmitted to the shaft
accordingly.
2-57
2) COUNTERBALANCE VALVE
Am P Bm
L K
H Cv Cm
Dv
2'
1'
Av Bv
Port Bv is connected to the hydraulic pump and Port Av, to the tank. The oil supplied from the
hydraulic pump passes through Bv, Cv and C' in sequence, pushes up the poppet of the check
valve, passes through K to Port Bm, and is supplied to the hydraulic motor to turn it.
Therefore, the pump discharge oil pressure increases, and the pressure is led via passage G to
spring room E and via the ball check valve to dumping room M. When the pressure in rooms E
and M exceeds the value equivalent to the force of the spring which holds the spool at its neutral
position, the spool begins to move left. Since the working oil in room N flows into room F via orifice
1' or clearance 2' and that in room F is discharged via passage G' through port Av to the tank, the
spool moves left to have passage L-Dm-D'-Dv composed. In addition, passage Cv-H-P is also
composed, and the pump discharge pressure in port Bv is led to port P.
Because of the orifice or clearance provided for the working oil flow from room N, this changeover
motion of the spool is comparatively slow.
When the pump discharge pressure is higher, the spool movement is larger and the above opening
area of the spool is larger.
When the pump discharge pressure falls, pressures in rooms E and M fall and the spool will move
right due to the spring on the room F side.
Since working oil in room M flows to room E via orifice 1 and that in room E, to port Bv via passage
G, the spool moves right.
When the pressure at port Bv falls down to the tank pressure, the pressure in room E also falls to
the tank pressure and becomes equal to that in room F, and so the spool returns to its neutral
position.
2-58
3) DISPLACEMENT CHANGEOVER SECTION
As a supporting mechanism for the swash plate (201) on which the shoes (122) slide, the pillar
system is adopted to support the load with semi-cylindrical sliding bearings provided at both ends of
the mechanism.
The capacity is changed by changing the tilting angle of this swash plate.
This is a mechanism that has the tilting angle pistons arranged opposed to each other with the
swash plate inserted in between, and the tilting angle of the swash plate is decided in two positions
(Large and Small) by controlling the flows to and from these piston rooms with the displacement
changeover valve section.
(1) External pilot pressure : Pi = 0 Large displacement
Room B
Room A
External pilot pressure
Pi=0
Sb
B
A Sa
531 571
533
High
pressure oil
High pressure
High pressure wotking oil
selector valve
By means of the built-in high pressure selector mechanism in the valve casing (303), the high
pressure oil working on the motor functions to port P of the displacement-changeover valve. This
pressure becomes the servo pressure. Since the spool (531) assembled in the displacement
changeover valve is pressed to plug (571) by thy spring (533), the high pressure oil at port P flows
to port Sa.
This high pressure oil flows from port Sa through the oil passage (passage A) in the valve casing
and casing (272) and works to room A.
The oil in room B flows through passage B and port Sb into the drain line.
With high pressure applied, the displacement-changeover piston (501) is pushed right and the
swash plate (201) moves in the arrowed direction around rotation center O. The swash plate
moves until it touches stopper L (503), and then is fixed there.
2-59
(2) External pilot pressure : Pi ն 20kgf/cm2 small displacement
Room B
Room A
External pilot pressure
Pi ն20kgf.cm2
B Sb
A Sa
531 571
533
High
pressure oil
High pressure
wotking oil
High pressure
selector valve
The force working on the spool (531) of the displacement-changeover valve becomes higher than
that of the spring (533), and the spool moves left. The high pressure oil flows from port P of the
displacement-changeover valve through port Sb and passage B to room B where it works.
The oil in room A flows through passage A and port Sa into the drain line.
The displacement piston (501) is pushed left by the high pressure oil and the swash plate moves
in the arrowed direction. The swash plate moves until it touched stopper S (504), and then is
fixed there.
2-60
4) RELIEF VALVE
The relief valve mainly has the following two functions :
(1) To keep the starting pressure of the hydraulic motor at a constant value and bypass to the return
line excessive oil generated at the motor inlet depending upon the acceleration speed of the
driven inertia.
(2) To generate a brake pressure at the outlet during stopping of the driven inertia, and stop it
forcedly.
Port B
Port A
Poppet A
Seat A
Room A
2-61
5) NEGATIVE BRAKE
The negative brake is released applying to the brake piston (702) the pressure led through the built-
in counterbalance spool sub-assembly (022).
With no pressure working, the brake force is always ensured.
303
111
101
The brake force is the friction force generated on the surfaces of the friction plates (742) spline-
coupled with the cylinder block, when their rotation is restricted by the casing (272), separator plate
(741), and brake piston all connected with the pins (709).
Without pressure being applied to the brake piston, the brake piston is pushed by ten brake springs
(705), and the friction plate and separator plate are held between the brake piston and casing.
This holding force functions as the friction force. This friction force restrains the shaft (101) spline-
coupled with the cylinder block, and thus functions the brake.
2-62
6) PRESSURE RELEASE VALVE (flow control valve)
This brake is of a back pressure-insensitive type. In other words, since the counterbalance spool
used is overlapped at the neutral position, the pressure release valve prevents the circuit back
pressure from working into the brake room when the machine stops traveling and works, and so the
specified brake torque is available even on a slope.
During normal traveling, the pressure coming through the counterbalance valve is applied to the
brake room to release the break, and is also applied to the pressure release valve section.
This pressure release valve is of a constant differential pressure type, and irrespective of the
working pressure, the passing flow is constant and approximately 1 to 2 ֻ/ min.
When the condition changes from traveling to stop, the counterbalance spool returns to its neutral
position. With the counterbalance spool at its neutral position, the brake piston is pushed by the
brake spring, and the oil in the brake room flows to the motor drain line via the pressure release
valve. Then the brake torque is generated.
2-63
7) RELEASING METHOD OF NEGATIVE BRAKE
In releasing the negative brake without applying the brake releasing pressure, follow the procedures
shown below.
Remove two plugs (464) from the valve casing (303). Double (single)-ended wrench (27mm)
Tighten an M16 screw of 130mm in length into a tapped hole of Hexagon bar spanner (14mm)
the brake piston (702), and pull out the brake piston. Then the
condition having the brake release pressure is attained and the
brake is released.
Note : Even with the negative brake released, the hydraulic motor will not turn. When it is difficult to
generate the working pressure due to failure of the pump or so, and the whole machine is to
be pulled for transportation without removing the hydraulic motor, connect pressure
measurement ports AM and BM with a short hose or something. Then the machine can be
pulled slowly.
2-64
8) REDUCTION GEAR
The reduction gear is composed of a three-stage planetary gear mechanism shown in the following
figure. Since the sun gear is designed to have a floating mechanism, errors of the gears and
carrier pin hole pitches will not affect the gears' lives heavily.
R3 R2 R1
C3 C2 C1
P3 P2 P1
S3 S2
S1
The input rotation of the hydraulic motor is transmitted to No. 1 sun gear (S1) and this drives No. 1
planetary gears (P1). This No. 1 planetary gears (P1) drive No.1 ring gear (R1) with the same
force as the meshing tangential force with No. 1 sun gear (S1), and also No. 1 carrier (C1) with the
same force as the meshing reaction force. In other words, No. 1 planetary gears (P1) revolve
rotating. This rotation of No. 1 carrier (C1) becomes the output of the 1st stage, and is transmitted
directly to No. 2 sun gear (S2).
(No. 1 carrier is spline-coupled with No. 2 sun gear.) Similarly the revolution of No. 2 planetary gear
(P2) are transmitted via No.2 carrier (C2) to No. 3 sun gear (S3). Since No. 3 carrier (C3)
supporting No. 3 planetary gears (P3) are fixed, No. 3 planetary gears (P3) do not revolve, but
rotates to drive No. 3 ring gears (R3).
Therefore, the rotating case is driven by the overall driving torque of numbers.
1,2 and 3 ring gears. This reduction ratio is expressed as shown below:
(ZS1 + Zr1) (ZS2 + Zr2) (ZS3 + Zr3)
i= -1
ZS1ňZS2 ňZS3
where Z : Number of teeth of each gear
The direction of rotation is reverse to that of the input shaft.
2-65
GROUP 5 RCV LEVER
1. STRUCTURE
The casing has the oil inlet port P(primary pressure) and the oil outlet port T(tank). In addition the
secondary pressure is taken out through ports 1, 2, 3, 4 and 5 provided at the bottom face.
Port 5 is only RCV lever of LH.
19Ɓ
19Ɓ
25Ɓ
Single
Simultaneous operation
operation Handle bending direction
(NO.3 push rod direction)
33Ɓ 33Ɓ
3 2
45Ɓ
P T
5
4 1
A Port LH RH Port
size
2-66
CROSS SECTION
The construction of the pilot valve is shown in the attached cross section drawing. The casing has
vertical holes in which reducing valves are assembled.
The pressure reducing section is composed of the spool(201), spring(241) for setting secondary
pressure, return spring(221), washer 1(215), spring seat(216) and washer 2(217). The spring for
setting the secondary pressure has been generally so preset that the secondary pressure is 5 to 19 ָf/
ֲ (depending on the type). The spool is pushed against the push rod(212) by the return spring.
When the push rod is pushed down by tilting the handle, the spring seat comes down simultaneously
and changes setting of the secondary pressure spring.
In case of the two point type electric switch is fitted, as shown in the attached cross section drawing, the
roller(451), switch lever(452) and switch(455) are built in the inside of the handle(401). When the center
of the handle cap(402) provided at the handle head is pushed, the roller is come down, and the switch
lever contacted with the roller tilts to make the switch function. The cord(456), connected to the switch,
is led through the handle section and casing to the outside.
2-67
CROSS SECTION
451
402
421
422
453
454
452
401
455
431
458
411 456
457 412
413
501
323
301
459 315
302
312
213
212
211
151
214
215
216
241
121
217
125
221
201
126
101
122
292
293
294
111 291
2-68
2. FUNCTION
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and
applying the output pressure(=secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
elements.
(1) Inlet port(P) where oil is supplied from hydraulic pump.
(2) Output ports(1,2,3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port(T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port or tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2-69
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown
below and the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.
5 6
3
1
3
P T
2 4
2-70
(1) Case where handle is in neutral position
T
241
221
201
P
1 3
The force of the spring(241) that determines the output pressure of the pilot valve is not applied to
the spool(201). Therefore, the spool is pushed up by the spring(221) to the position of port 3 in the
operation explanation drawing. Then, since the output port is connected to tank port T only, the
output port pressure becomes equal to tank pressure.
2-71
(2) Case where handle is tilted
212
201
1 3
2-72
(3) Swing shuttle function(LH only)
212
201
1 5 3
2-73
GROUP 6 RCV PEDAL
1. STRUCTURE
The casing (spacer) has the oil inlet port P(primary pressure), and the oil outlet port T(tank). In
addition the secondary pressure is taken out through ports 1,2, 3 and 4 provided at the bottom face.
Ɓ 12.4
12.4 Ɓ
1 2
3 4
Port Port name Port size
2-74
CROSS SECTION
The construction of the RCV pedal is shown in the below drawing. The casing has vertical holes in
which reducing valves are assembled.
The pressure reducing section is composed of the spool (8), spring(11) for setting secondary pressure,
return spring (18), stopper 1 (13), spring seat (12) and shim(9). The spring for setting the secondary
pressure has been generally so preset that the secondary pressure is 5 to 19 kgf/ cm2 (depending on the
type). The spool is pushed against the push rod (19) by the return spring.
When the push rod is pushed down by tilting pedal, the spring seat comes down simultaneously and
changes setting of the secondary pressure spring.
25
7 6 24
21 5
22 23
20 16 4
14 17
19 15
15 13
12 11
18
30
1
9, 10
8 26 27 28 29
2-75
2. FUNCTION
1) FUNDAMENTAL FUNCTIONS
The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This
function is carried out by providing the spring at one end of the main control valve spool and
applying the output pressure(=secondary pressure) of the pilot valve to the other end.
For this function to be carried out satisfactorily, the pilot valve is composed of the following
elements.
(1) Inlet port(P) where oil is supplied from hydraulic pump.
(2) Output ports(1,2,3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.
(3) Tank port(T) necessary to control the above output pressure.
(4) Spool to connect output port to inlet port or tank port.
(5) Mechanical means to control output pressure, including springs that work on the above spools.
2-76
3) OPERATION
The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown
below and the attached operation explanation drawing.
The diagram shown below is the typical application example of the pilot valve.
5 6
3
1
2
2 4
2-77
(1) Case where pedal is in neutral position
11
8
T
18
1 2
The force of the spring (11) that determines the output pressure of the pilot valve is not applied
to the spool (8). Therefore, the spool is pushed up by the spring (18) to the position of port 2 in
the operation explanation drawing. Then, since the output port is connected to tank port T
only, the output port pressure becomes equal to tank pressure.
2-78
(2) Case where pedal is tilted
19
1 2
2-79
SECTION 3 HYDRAULIC SYSTEM
GROUP 1 HYDRAULIC CIRCUIT
1 PUMP
2 MCV
3 SWING MOTOR
4 TRACK MOTOR
5 RCV PEDAL
6 RCV LEVER
7 RCV LEVER
8 BOOM CYL
9 BUKT CYL
10 ARM CYL
11 TURNING JOINT
12 SOLENOID VALVE
13 CHECK VALVE
14 CHECK VALVE
15 CHECK VALVE
16 HYD TANK
17 OILCOOLER
18 BREATHER
19 BY PASS VALVE
20 RETURN FILTER
21 STRAINER
22 LINE FILTER
23 SPIN FILTER
24 ACCUMULATOR
25 PRESSURE SWITCH
26 PRESSURE SWITCH
3-1
GROUP 2 MAIN CIRCUIT
The main hydraulic circuit consists of suction circuit, delivery circuit, return circuit and drain circuit.
The hydraulic system consists of one main pump, one control valve, one swing motor, four cylinders
and two travel motors.
The swash plate type variable displacement axial piston pump is used as the main pump and is
driven by the engine at ratio 1.0 of engine speed.
To cylinders To motors
Main pump
Suction filter
The pump receive oil from the hydraulic tank through a suction filter. The discharged oil from the
pump flows into the control valve and goes out the tank ports.
The oil discharged from the main pump flows to the actuators through the control valve.
The control valve controls the hydraulic functions.
The return oil from the actuators flows to the hydraulic tank through the control valve and the oil
cooler.
3-2
2. RETURN CIRCUIT
Check valve(1)
3.0kg/cm2
All oil from each actuator returns to the hydraulic tank through the control valve.
The bypass check valves are provided in the return circuit.
The setting pressure of bypass check valves are 1.5kg/cm2(21psi) and 3.0kg/cm2(43psi). Usually, oil
returns to the hydraulic tank from the left side of control valve through oil cooler.
When oil temperature is low, viscosity becomes higher and flow resistance increases when passing
through the oil cooler. The oil pressure exceeds 3.0kg/cm2(43psi) the oil returns directly to the hydraulic
tank, resulting in the oil temperature being raised quickly at an appropriate level.
When the oil cooler is clogged, the oil returns directly to the hydraulic tank through bypass check
valve(1).
The full-flow filter is provided in the hydraulic tank.
The oil from right and left side of control valve is combined and filtered by the full-flow filter. A bypass
relief valve is provided in the full-flow filter.
When the filter element is clogged, the bypass relief valve opens at 1.5kg/cm2(21psi) differential pressure.
3-3
3. DRAIN CIRCUIT
Main pump
Turning joint
Bypass valve
1.5kg/cm2
Drain filter
Hydraulic
oil tank
Besides internal leaks from the motors and main pump, the oil for lubrication circulates. These oil have
to be fed to the hydraulic tank passing through drain filter.
When the drain oil pressure exceed 1.5kg/cm2, the oil returns to the hydraulic tank directly.
3-4
GROUP 3 PILOT CIRCUIT
Pilot filter
Main pump
Relief valve
40kg/cm2
The pilot circuit consists of suction circuit, delivery circuit and return circuit.
The pilot pump is provide with relief valve, receives the oil from the hydraulic tank through the suction
filter.
The discharged oil from the pilot pump flows to the remote control valve through pilot filter, EPPR
valve, high speed solenoid valve, swing parking brake, main control valve and safety lock solenoid
valve.
3-5
1. SUCTION DELIVERY AND RETURN CIRCUIT
SAFETY
SOLENOID VALVE
PEDAL RCV LEVER(LH) RCV LEVER(RH)
OIL TANK
PILOT PUMP
SUCTION
FILTER
The pilot pump receive oil from the hydraulic tank. The discharged oil from the pilot pump flows to
the safety solenoid valve through the pilot filter. The oil is filtered by the pilot filter. The pilot relief
valve is provided in the pilot pump for limiting the pilot circuit pressure.
The oil filtered by pilot filter flows remote control valve through safety solenoid valve.
The return oil returned to hydraulic tank through the remote control valve.
3-6
2. SAFETY VALVE (SAFETY LEVER)
LEVER DOWN
LEVER UP
OIL TANK
PILOT PUMP
When the lever of the safety solenoid valve moved downward, oil flow remote control valve through
solenoid valve and pilot filter.
When the lever of the safety solenoid valve moved upward, oil does not flow remote control valve,
because of blocked by the spool.
3-7
3. SWING PARKING BRAKE RELEASE
P3
SWING
PILOT PUMP
When the swing control lever is tilted, the pilot oil go to SH port of shuttle valve, this pressure move
spool so, discharged oil from pilot pump go to P3 port.
This pressure is applied to swing motor disc cylinder, thus the brake released.
When the swing control lever is set neutral position, oil in the motor disc cylinder is drain, thus the
brake works.
3-8
4. SPEED CONTROL PRESSURE
SAFETY
TRAVEL MOTOR DEVICE SOLENOID VALVE
HI
PK
P3 LO
LO LO
HI HI
PK
PILOT PUMP
P3
When the travel speed solenoid valve was placed in the HI position, the pressure oil from pilot pump
flows to PK port of 2 speed change over valve, and the control piston is pushed up, thus minimizing
the displacement.
When the travel speed solenoid valve was placed in the LO position, the oil of PK port return to the
tank and the control piston is returned, thus maximizing the displacement.
3-9
GROUP 4 SINGLE OPERATION
RELIEF VALVE
MAKE UP VALVE
a4
OIL TANK
FRONT REAR PILOT
PUMP PUMP PUMP
When the right control lever is pulled to boom raise position. Then the oil from pilot pump through
the remote control valve to boom sections of the control valve.
Here, the spool positions are moved to the boom raise position, and the boom circuits are opened.
The oil flows from both main pumps through boom section of the control valve to the bottom end of
the boom cylinders, and to raise the boom.
The return oil flow from the rod end of the cylinders are directed to the tank through the boom section
of the control valve.
Cavitation and excessive pressure in the boom cylinder bottom end circuit is prevented by a overload
relief and make up valve in the control valve.
3 - 10
2. BOOM DOWN CIRCUIT OPERATION
BOOM CYLINDER
MAKE UP VALVE
RELIEF VALVE
b4
OIL TANK
FRONT PILOT
PUMP PUMP
When the right control lever is pushed forward to boom lower position. Then the oil from pilot pump
through the remote control valve to boom sections of the control valve. Here, the spool positions are
moved to the boom lower position, and the boom lower circuit is opened.
Oil flows from front pump through boom section of the control valve to the rod end of the boom
cylinders, and to lower the boom.
The return oil flows from the bottom end of the cylinders to the tank through the boom section of the
control valve.
Cavitation and excessive pressure in the boom cylinder rod end circuit is prevented by a overload
relief and make up valve in the control valve.
3 - 11
3. ARM ROLL IN CIRCUIT OPERATION
ARM CYLINDER
MAKE UP VALVE
RELIEF VALVE
a2
OIL TANK
FRONT REAR PILOT
PUMP PUMP PUMP
When the left control lever manually is placed in the arm roll in position.
Then the oil flows from pilot pump through the remote control valve to arm sections of the control
valve. Here, the spool positions are moved to arm roll in position.
The pilot pressure is not applied pilot port(a); the logic valve is blocked.
The oil flows from both main pump through arm section of the control valve to the bottom end of the
arm cylinder, and to roll in arm.
The return oil flows from the rod end of the cylinder through the arm section returned to the tank.
Then cavitation which will happen to the bottom of the arm cylinder is prevented by a make up valve,
on other hand. The excess pressure is also prevented by an overload relief valve in the control
valve.
3 - 12
4. ARM ROLL OUT CIRCUIT OPERATION
ARM CYLINDER
RELIEF VALVE
MAKE UP VALVE
b2
OIL TANK
FRONT REAR PILOT
PUMP PUMP PUMP
When the left control lever manually is placed in the arm roll out position.
Then the oil flows from pilot pump through the remote control valve to arm sections of the control
valve. Here, the spool positions are moved to arm roll out position.
The pilot pressure is not applied pilot port(a); the logic valve is blocked.
The oil flows from both pump through arm section of control valve to the bottom end of the arm
cylinder, and to roll out arm.
The return oil flows from the bottom end of the cylinder through the arm section returned to the tank.
The cavitation which will happen to the rod of the arm cylinder is prevented by a make up valve, on
other hand. The excess pressure is also prevented by an overload relief valve in the control valve.
3 - 13
5. BUCKET CIRCUIT OPERATION
BUCKET CYLINDER
RELIEF VALVE
MAKE UP VALVE
b5
a5
OIL TANK
FRONT REAR PILOT
PUMP PUMP PUMP
When the right control lever manually placed in the bucket roll in(roll out) position. Then the oil from
pilot pump through the pilot valve to bucket section of the control valve. Here the spool position is
moved to bucket roll in(roll out) position.
3 - 14
6. SWING CIRCUIT OPERATION
a1
p3
b1
A B
SWING
OIL TANK
FRONT REAR PILOT
PUMP PUMP PUMP
b1 SH a1
P3
When the left control lever manually is placed in the swing position. Then the oil flows from pilot
pump through the pilot valve to the swing section of the control valve. Here, the spool position is
moved to right or left swing position.
The oil flows from rear pump through swing section of the control valve to the swing motor and
swings the superstructure.
The motor brake valve, make up valve and swing parking brake are provided in the swing motor.
3 - 15
SWING CIRCUIT OPERATION
PARKING BRAKE
BRAKE OFF
SH
P3
BRAKE ON
MAKE UP VALVE
A B
3 - 16
7. SWING OPERATION
SWING MOTOR
a1
b1
LEVER DOWN
SWING
OIL TANK
REAR
PUMP PILOT PUMP
b1 SH a1
When the left control lever is manually placed in the left(right) swing position. Then the oil flows from
rear pump through the swing section of the control valve to swing motor to left(right) swing the
superstructure. The return oil flow from swing motor through the swing section of the control valve
returned to the tank.
When the control lever placed in the neutral position, the pressure of the pilot oil passage down.
Then the brake release valve returned to the neutral position and the oil is returned from the brake
piston to the tank. And the brake is set to "ON"
3 - 17
8. TRAVEL CIRCUIT OPERATION
PK
Low speed
P3
A B PK A B
b7
SELECT a7
VALVE
Pt
a3
b3
TRAVEL
OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP
b7 a7 a3 b3 Pt
P3
When the travel levers are manually placed to the forward or reverse position.
Then the oil flows from pilot pump through the pilot valve to travel sections of the control valve. Here,
spools position is moved to forward and reverse position. The oil flows from both main pumps
through the travel sections of the control valves to the travel motors, and move the machine forward
and reverse.
Brake valves are provided on travel motors to offer the following functions.
3 - 18
TRAVEL CIRCUIT OPERATION
A B A B
CHECK VALVE
OVERLOAD COUNTER
RELIEF BALANCE
VALVE VALVE
TURNING JOINT
1) CHECK VALVE
Stopping the motor, this valve sucks the oil from lower pressure passage for preventing the
negative pressure and the cavitation of the motor.
2) COUNTER BALANCE VALVE
When stopping the motor or slope descending, this valve to prevent the motor over run.
3) OVERLOAD RELIEF VALVE
Relief valve limit the circuit pressure below 350kgf/cm2 to prevent high pressure generated at a time
of stopping the machine.
3 - 19
9. TRAVEL FORWARD AND REVERSE OPERATION
TRAVEL MOTOR
Pt
SELECT VALVE b7
a7
a3
b3
LEVER DOWN
TRAVEL
OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP
b7 a7 a3 b3 Pt
P3
When the right and left travel levers are manually placed to the forward or reverse position. Then the
oil flows from rear pump through the travel(R) section of the control valve and turning joint to the right
travel motor and oil flows from front pump through the travel(L) section of the control valve and
turning joint to the left travel motor and move the machine forward and reverse.
The return oil flows from both travel motor through the turning joint and travel(R), (L) sections
returned to the tank.
3 - 20
GROUP 5 COMBINED OPERATION
1. OUTLINE
BUCKET BOOM
CYLINDER CYLINDER
TRAVEL MOTOR
SELECT VALVE
ARM CYLINDER
SWING MOTOR
OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP
SUCTION
FILTER
In case operation, the oil flows from both main pumps through the neutral oil passage, bypass oil
passage and confluence oil passage. Then the oil is supplied to each actuator and function them.
Check valves and orifices are provided with on these flow passage. These control the oil flows from
the pump corresponding to the each actuator's state of functioning and smooth the combined
operation.
SELECT VALVE
This select valve is provided in the control valve.
When the spool except travel is moved, the pilot oil from the pilot pump is closed by its spool.
Consequently, the pilot pressure port of the select valve rised and its spool is moved. Then the left
and right travel oil supply passage is opened, and the machine straight travelling.
3 - 21
2. COMBINED SWING AND BOOM OPERATION
BOOM
CYLINDER
SWING MOTOR
a1 b4
b1 a4
c
CENTER
BYPASS VALVE
OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP
SUCTION
FILTER
When the swing and boom functions are operated, simultaneously the swing spool and boom spools
changed. The oil flows from the front pump through boom section of the control valve to boom
cylinders and the boom functions.
The oil flows from rear pump through swing section to swing motor. At the same time the pressure in
the boom circuits can be high while the swing pressure is low therefore the oil flows from rear pump
to boom cylinders through boom confluence passage.
3 - 22
3. COMBINED SWING AND ARM OPERATION
ARM CYLINDER
a2
b2
SWING MOTOR
a1
b1
OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP
SUCTION
FILTER
When the swing and arm functions are operated, simultaneously the swing and arm spools changed.
The oil flows from the rear pump through arm and swing section of the control valve to arm cylinder
and swing motor, and the arm and swing function.
At the same time, the center bypass valve is blocked, the oil flows from the front pump through the
arm confluence oil passage to arm cylinder.
3 - 23
4. COMBINED SWING AND BUCKET OPERATION
BUCKET
CYLINDER
a5
b5
SWING MOTOR
a1
b1
OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP
SUCTION
FILTER
When the swing and bucket functions are operated, the swing and bucket spools changed. The oil
flows front pump through the bucket section of the right control valve to the bucket cylinder and the
bucket function. The oil flows from rear pump through swing section of the left control valve to the
swing motor and swing the superstructure.
3 - 24
5. COMBINED SWING, BOOM, ARM AND BUCKET OPERATION
BUCKET BOOM
CYLINDER CYLINDER
LOGIC VALVE
ARM CYLINDER
a2 b5
a5
b2
SWING MOTOR
a1 b4
b1 a4
c a b
ORIFICE
CENTER ORIFICE
BYPASS VALVE
LOGIC VALVE
OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP
SUCTION
FILTER
When the swing, boom, arm and bucket functions are operated, the each spools of the control valve
changed.
The oil flows from front pump through boom and bucket section to boom and bucket cylinders. The
oil flows from rear pump through the parallel oil passage and the swing and arm section to swing
motor and arm cylinder. Then the functions to each actuators.
According to the state of each actuators functioning, center bypass valve is blocked, the oil flows from
rear pump through the confluence oil passage to right control valve and the oil flows from rear pump
through logic valve to boom cylinders.
3 - 25
6. COMBINED SWING AND TRAVEL OPERATION
TRAVEL MOTOR
Pt
SELECT VALVE b7
a7
a3
b3
SWING MOTOR
a1
b1
ORIFICE
CENTER
BYPASS VALVE
OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP
SUCTION
FILTER
When the swing and right and left travel functions are operated, the swing and travel(R),(L) spools
and the select valve changed. The oil flows from front pump through the travel (R),(L) section of the
control valve to the right and left travel motor.
And the oil flows from rear pump through swing section of the right control valve to the swing motor.
Because of check valve the pressure in the travel circuit can be high while the swing pressure is low.
When the travel circuit pressure drops lower than swing pressure, as when traveling downhill, swing
priority and smoothness are maintained because of the orifice. In either case, the machine will
continue to travel straight.
3 - 26
7. COMBINED BOOM AND TRAVEL OPERATION
BOOM
CYLINDER
TRAVEL MOTOR
Pt
SELECT VALVE
b7
a7
a3
b3
b4
a4
c
CENTER ORIFICE
BYPASS VALVE
LOGIC VALVE
OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP
SUCTION
FILTER
When the boom and travel (R) (L) functions are operated, the boom and travel (R),(L) spools and the
select valve changed. The oil flows from front pump through the travel (R),(L)section of the control
valve to the right and left travel motor.
And the oil flows from front pump through boom section of the left control valve to the boom cylinder.
Because of check valve the pressure in the travel circuit can be high while the boom pressure is low.
When the travel circuit pressure drops lower than boom pressure, as when travelling downhill, boom
priority and smoothness are maintained because of the orifice. In either case, the machine will
continue to travel straight.
3 - 27
8. COMBINED ARM AND TRAVEL OPERATION
TRAVEL MOTOR
Pt
SELECT VALVE
b7
a7
a3
b3
ARM CYLINDER a2
b2
ORIFICE
CENTER
BYPASS VALVE
OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP
SUCTION
FILTER
When the arm and travel (R) (L) functions are operated, the arm and travel (R),(L) spools and the
select valve changed. The oil flows from front pump through the travel (R),(L) section of the control
valve to the right and left travel motor.
And the oil flows from rear pump through arm section of the right control valve to the arm cylinder.
Because of check valve the pressure in the travel circuit can be high while the arm pressure is low.
When the travel circuit pressure drops lower than arm pressure, as when traveling downhill, arm
priority and smoothness are maintained because of the orifice. In either case, the machine will
continue to travel straight.
3 - 28
9. COMBINED BUCKET AND TRAVEL OPERATION
BUCKET CYLINDER
TRAVEL MOTOR
Pt
SELECT VALVE
b7
a7
CHECK
VALVE
a3
b3
b5
a5
CENTER ORIFICE
BYPASS VALVE
OIL TANK
FRONT REAR
PUMP PUMP PILOT PUMP
SUCTION
FILTER
When the bucket and travel (R),(L) functions are operated, the bucket and travel (R),(L) spools and
the select valve changed. The oil flows from rear pump through the travel (R),(L) section of the
control valve to right and left travel motor and the machine travelling.
The oil flows from front pump through bucket section of the control valve to the bucket cylinder and
the bucket functions.
3 - 29
SECTION 4 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
10
11
12
1 13
2 14
15
16
17
18
20
21
22
7
19
8
4-1
2. LOCATION 2
16
1
2 15
3 14
4 11
12
5 13
17
6
8
9
10
7
18
4-2
GROUP 2 ELECTRICAL CIRCUIT
4-3
CE REGULATION NOT APPLIED
4-4
1. POWER CIRCUIT
The negative terminal of battery is grounded to the machine chassis.
When the start key switch is in the OFF position, the current flows from the positive battery terminal as
shown here.
1) OPERATING FLOW
Battery Battery relay Fusible linkŭCN-60(1)Ů I/connŭCN-5(1)Ů Start key switch
ŭCS-2(1)Ů
I/connŭCN-40(1)Ů
Fuse boxŭNo.19Ů I/connŭCN-38(8)Ů I/connŭCN-6(4)Ů Room lampŭCL-1(2)Ů
Fuse boxŭNo.18Ů I/connŭCN-38(7)Ů ClusterŭCN-8(6)Ů
CPU controllerŭCN-50(10)Ů
Fuse boxŭNo.17Ů I/connŭCN-38(6)Ů Cassette radioŭCN-27(7)Ů
2) CHECK POINT
Ɠ GND : Ground
4-5
POWER CIRCUIT
4-6
2. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Battery relay(M8, B+ terminal) Fusible linkŭCN-60(1)Ů
I/connŭCN-5(1)Ů Start key switchŭCS-2(1)Ů
2) CHECK POINT
Ɠ GND : Ground
4-7
STARTING CIRCUIT
4-8
3. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the key switch to the ON
position.
Charging current generated by operating alternator flows into the battery through the Battery
relay(CR-1).
The current also flows from alternator to each electrical component and controller through the fuse
box.
1) OPERATING FLOW
AlternatorūIŬterminal I/connŭCN-1(2)Ů CPU Alternator power level
ŭCN-51(18)Ů,
Charging lampŭCN-53(7)Ů I/connŭCN-7(7)Ů cluster charging warning lamp
ŭCN-56(7)Ů
2) CHECK POINT
Engine Key switch Check point Voltage
Ɠ GND : Ground
4-9
CHARGING CIRCUIT
4 - 10
CHARGING CIRCUIT(CE Regulation not applied)
When the starter is activated and the engine is started, the operator releases the key switch to the ON
position.
Charging current generated by operating alternator flows into the battery through the Battery
relay(CR-1).
The current also flows from alternator to each electrical component and controller through the fuse
box.
1) OPERATING FLOW
AlternatorūIŬterminal I/connŭCN-1(2)Ů CPU Alternator power level
ŭCN-51(18)Ů,
Charging lampŭCN-53(7)Ů I/connŭCN-7(7)Ů cluster charging warning lamp
ŭCN-56(7)Ů
2) CHECK POINT
Engine Key switch Check point Voltage
Ɠ GND : Ground
4 - 11
CHARGING CIRCUIT(CE Regulation not applied)
4 - 12
4. HEAD LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.8) I/connŭCN-37(1)Ů Head light switchŭCS-39(6)Ů
Head light relayŭCR-13(4)Ů
Ɠ When Light switch ON
Head light switch ONŭCS-39(2)Ů Head light relayŭCR-13(3) Ɗ (1)Ů Ground
ŭCR-13(4) Ɗ (2)Ů
Head light ONŭCL-3(2)Ů
I/connŭCN-4(7)Ů Head light ONŭCL-4(2)Ů
I/connŭCN-7(9)Ů Cluster illumination LampŭCN-56(9)Ů
2) CHECK POINT
Ɠ GND : Ground
4 - 13
HEAD LIGHT CIRCUIT
4 - 14
HEAD LIGHT CIRCUIT(CE Regulation not applied)
1) OPERATING FLOW
Fuse box (No.8) I/connŭCN-37(1)Ů Head light switchŭCS-39(6)Ů
Head light relayŭCR-13(4)Ů
Ɠ When Light switch ON
Head light switch ONŭCS-39(2)Ů Head light relayŭCR-13(3) Ɗ (1)Ů Ground
ŭCR-13(4) Ɗ (2)Ů
Head light ONŭCL-3(3)Ů
I/connŭCN-4(7)Ů Head light ONŭCL-4(3)Ů
I/connŭCN-7(9)Ů Cluster illumination LampŭCN-56(9)Ů
2) CHECK POINT
Ɠ GND : Ground
4 - 15
HEAD LIGHT CIRCUIT(CE Regulation not applied)
4 - 16
5. WORK LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.9) I/connŭCN-37(2)Ů Work light switchŭCS-36(6)Ů
Work light switchŭCR-3(4)Ů
Ɠ When Light switch ON
Work light switch ONŭCS-36(2)Ů Work light relayŭCR-3(3) (1)Ů Ground
ŭCR-3(4) (2)Ů
I/connŭCN-7(10)Ů Cluster Work light ONŭCN-56(10)Ů
I/connŭCN-4(4)Ů I/connŭCN-10(2)Ů Work light ONŭCL-6(2), CL-5(2)Ů
2) CHECK POINT
Ɠ GND : Ground
4 - 17
WORK LIGHT CIRCUIT
4 - 18
WORK LIGHT CIRCUIT(CE Regulation not applied)
1) OPERATING FLOW
Fuse box (No.9) I/connŭCN-37(2)Ů Work light switchŭCS-36(6)Ů
Work light switchŭCR-3(4)Ů
Ɠ When Light switch ON
Work light switch ONŭCS-36(2)Ů Work light relayŭCR-3(3) (1)Ů Ground
ŭCR-3(4) (2)Ů
I/connŭCN-7(10)Ů Cluster Work light ONŭCN-56(10)Ů
I/connŭCN-4(4)Ů I/connŭCN-10(3)Ů Work light ONŭCL-6(3), CL-5(3)Ů
2) CHECK POINT
Ɠ GND : Ground
4 - 19
WORK LIGHT CIRCUIT(CE Regulation not applied)
4 - 20
6. CAB LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.10) I/connŭCN-37(3)Ů Cab light switchŭCS-24(6)Ů
Cab light relayŭCR-9(4)Ů
Ɠ When Light switch ON
Cab light switch ONŭCS-24(2)Ů Cab light relayŭCR-9(3) (1)Ů Ground
ŭCR-9(4) (2)Ů
I/connŭCN-6(5)Ů I/connŭCN-14(4)Ů
Cab light ONŭCL-8(rear), CL-10(RH), CL-9(LH)Ů
2) CHECK POINT
Ɠ GND : Ground
4 - 21
CABIN LIGHT CIRCUIT
4 - 22
7. WIPER MOTOR CIRCUIT
1) OPERATING FLOW
(1) Wiper motor switch ON
Fuse box (No.1) I/connŭCN-36(6)Ů Wiper motor relayŭCR-4(2) ( 6)Ů
Wiper switchŭCS-3(6) ( 2)Ů Ground
Wiper motor relayŭCR-4(4) ( 1)Ů
I/connŭCN-6(1)Ů I/connŭCN-13(1)Ů
Wiper motor operatingŭCN-21(1)Ů
2) CHECK POINT
Ɠ GND : Ground
4 - 23
WIPER MOTOR CIRCUIT
4 - 24
WIPER MOTOR CIRCUIT(CE Regulation not applied)
1) OPERATING FLOW
(1) Wiper motor switch ON
Fuse box (No.1) I/connŭCN-36(6)Ů Wiper motor relayŭCR-4(2) ( 6)Ů
Wiper switchŭCS-3(6) ( 2)Ů Ground
Wiper motor relayŭCR-4(4) ( 1)Ů
I/connŭCN-6(1)Ů I/connŭCN-13(1)Ů
Wiper motor operatingŭCN-21(1)Ů
2) CHECK POINT
Ɠ GND : Ground
4 - 25
WIPER MOTOR CIRCUIT(CE Regulation not applied)
4 - 26
CONTROLLER CIRCUIT
4 - 27
ELECTRICAL CIRCUIT FOR HYDRAULIC
4-28
MONITORING CIRCUIT
4-29
GROUP 3 MONITORING SYSTEM
1. OUTLINE
Monitoring system consists of the monitor part and switch part.
The monitor part gives warnings when any abnormality occurs in the machine and informs the
condition of the machine.
Various select switches built into the monitor panel, and it acts as the control portion of the machine
control system.
Input Output
Alternator level signal Charge warning lamp
Engine oil pressure switch Engine oil warning lamp
Engine tacho signal Tachometer (or clock)
Work light Work light lamp
Air cleaner switch Air cleaner warning lamp
Coolant overheat sensor Coolant overheat warning lamp
Hydraulic oil temp. sensor Hydraulic oil temp warning lamp
Monitor
Coolant level sensor Coolant level lamp
Fuel sendor Fuel gauge
Coolant temp. sensor Fuel low level lamp
Coolant temperature gauge
Warming up lamp
Switch
Mode selection signal 1
ňMode selection switch Mode selection signal 2
Mode selection lamp 1 ňAuto idle selection switch Travel speed signal
Mode selection lamp 2 ňTravel speed switch Auto idle selection signal
Engine speedŜupŝsignal
Engine speedŜdownŝsignal
4 - 30
2. CLUSTER
1) Monitor panel
4 - 31
1) CLUSTER CHECK PROCEDURE
(1) Start key : ON
ڸCheck monitor initial 3 seconds
a. All lamps light up.
b. Buzzer sound.
ںSwitch portion
a. Mode selection : S mode
b. Auto decel LED : ON
c. Travel speed switch : Low(turtle)
4 - 32
3. CLUSTER CONNECTOR
1) CN-57 CONNECTOR
2) CN-56 CONNECTOR
Input/
No. Signal
output
1 Mode LED 1 input
2 Mode LED 2 input
3 Null -
4 Null -
5 Null -
6 Coolant level sensor input
Cluster
7 Battery charging warning input
8 Auto decel selection output
9 Head light input
10 Work light input
11 Null -
12 Hyd. oil overheat warning input CN-56
13 Engine oil pressure warning input
8 7 6 5 4 3 2 1
14 Air cleaner clog warning input
15 Coolant overheat warning input 16 15 14 13 12 11 10 9
16 Warming up output
4 - 33
4. CLUSTER FUNCTION
1) TACHOMETER
ڸTachometer displays the number of engine revolutions.
ڹRefer select switch for the selection and adjustment.
rpm
2) CLOCK
ڸClock displays the current time by electric digital timer(LCD).
ڹRefer select switch for the selection and adjustment.
TIME
3) FUEL GAUGE
Green D E ڸThis gauge indicates the amount of fuel in the fuel tank.
F
şSegment A : Approximately 33ֻ(Warning lamp display)
C F
şSegment B : Approximately 103ֻ
B şSegment C : Approximately 173ֻ
Red şSegment D : Approximately 246ֻ
A E şSegment E : Approximately 319ֻ
şSegment F : Approximately 392ֻ
şQuantity of fuel tank : Approximately 450ֻ.
4 - 34
5) COOLANT LEVEL WARNING LAMP
ڸThis lamp is turned ON when the coolant is below LOW in the
reservoir tank of radiator.
ڹCheck if the coolant level is between FULL and LOW in the reservoir
tank locating the side of radiator after opening the engine cover, and
check if there is mixture of oil and coolant.
4 - 35
10) AIR CLEANER WARNING LAMP
ڸThis lamp operates by the vacuum caused inside when the filter of
air cleaner is clogged which supply air to the engine.
ڹCheck the filter and wash or replace it when the lamp operates.
4 - 36
15) ENGINE SPEED CONTROL SWITCH
ڸThis switch is to control the engine speed which is increased by
ENGINE SPEED pressing switch and decreased the engine speed by pressing
switch.
17) BUZZER
ڸThe buzzer sounds when the warning lamp lights ON.
4 - 37
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specifications Check
Ɠ Check disconnection
Normal : 0ѻ
Fusible link 60A (connect ring terminal and
check resist between terminal
1 and 2)
4 - 38
Part name Symbol Specifications Check
Ɠ Check resist
Coolant 50Ƅ : 153.9ѻ
temperature 80Ƅ : 51.9ѻ
sensor 100Ƅ : 27.4ѻ
CD-8
Ɠ Check resist
Full : 3ѻ
5/6 : 25ѻ
2 4/6 : 35ѻ
Fuel sender
1 3/6 : 68ѻ
CD-2 2/6 : 95ѻ
1/6 : 110ѻ
Empty warning :180ѻ
1 N Ɠ Check resist
Tacho sensor Normal 9300ѻ
2 S
CD-17
4 - 39
Part name Symbol Specifications Check
4
Ɠ Check resist
3
Normal - About 200ѻ
Relay (for terminal 1-3)
2
1
- ſѻ
CR-2
(for terminal 2-4)
Ɠ Check resist
C 1 Normal - About 160ѻ
B 2 (for terminal 2-6)
Relay
E 4 - 0ѻ
D 6
(for terminal 1-3)
A 3
- ſѻ
CR-4
(for terminal 1-4)
Ɠ Check resist
3
R
POTEN GND
Normal - About 5ױ
Potentiometer W
(for terminal 1-3)
2 POTEN SIG
Y
1 POTEN 5V - 0.6~ױ5ױ
CN-77 (for terminal 2-3)
B
Ɠ Check resist
1 MOTOR A
G Normal - 5~6ѻ
Governor motor 2 MOTOR A'
3
R
MOTOR B (for terminal 1-2)
Y
4 MOTOR B' - 5~6ѻ
CN-76 (for terminal 3-4)
Ɠ Check resist
Solenoid valve 2
24V 1A Normal - 15~25ѻ
1
(for terminal 1-2)
CN-88
Ɠ Check resist
EPPR valve 24V Normal - 18~25ѻ
(for terminal 1-2)
CN-75
4 - 40
Part name Symbol Specifications Check
1 Ɠ Check resist
Resister 50ѻ 20W
2 Normal - 50ѻ
CN-47
Ɠ Check contact
10 9 8 7 6 5 4 3 2 1 Normal
Switch 10 6 5 ON - 0ѻ (for terminal 1-5,2-6)
24V 8A
(Looking type) - ſѻ (for terminal 5-7,6-8)
OFF - ſѻ (for terminal 1-5,2-6)
9 8 2 7 1
- 0ѻ (for terminal 5-7,6-8)
Ɠ Check contact
10 9 8 7 6 5 4 3 2 1 Normal
Switch 10 6 5 ON - 0ѻ (for terminal 1-5,2-6)
24V 8A
(Non-looking type) - ſѻ (for terminal 5-7,6-8)
OFF - ſѻ (for terminal 1-5,2-6)
9 2 1
- 0ѻ (for terminal 5-7,6-8)
Ɠ Check disconnection
Work lamp 24V 75W/70W Normal : a few ѻ
(H4 TYPE)
4 - 41
Part name Symbol Specifications Check
1
24V 10W Ɠ Check disconnection
Room light
Normal : a few ѻ
2
CL-1
Ɠ Check operation
ňSupply power(24V) to
P
Fuel filler pump terminal 1 pin
24V 35 ֻ/min
ňConnect ring terminal with
CN-61 ground and switch turn ON.
Ɠ Check operation
ňSupply power(24V) to
2
Ɠ Check operation
ňSupply power(24V) to each
Horn
24V 8A terminal and connect ground.
CN-20
Ɠ Check contact
Normal - 0ѻ (for terminal 1-3)
- ſѻ (for terminal 1-2)
Safety switch 24V Operating - ſѻ
(N.C TYPE) (for terminal 1-3)
- 0ѻ
(for terminal 1-2)
4 - 42
GROUP 5 CONNECTORS
1. CONNECTOR DESTINATION
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-1 SWP 12 I/conn(Engine harness-main harness) S814-012000 S814-112000
CN-2 SWP 12 I/conn(Engine harness-main harness) S814-012000 S814-112000
CN-3 SWP 12 I/conn(solenoid harness-main harness) S814-012000 S814-112000
CN-4 SWP 12 I/conn(R.H harness-main harness) S814-012000 S814-112000
CN-5 370FASTON 2 I/conn(R.H harness-main harness) S813-030200 S813-130200
CN-6 SWP 8 I/conn(Cabin harness-main harness) S814-008000 S814-108000
CN-7 SWP 12 I/conn(Cabin harness-main harness) S814-012000 S814-112000
CN-8 SWP 12 I/conn(Cabin harness-main harness) S814-012000 S814-112000
CN-9 SWP 4 I/conn(Cabin harness-main harness) S814-004000 S814-104000
CN-10 BS 3 I/conn(Boom harness-main harness) S812-003011 -
CN-13 CN 4 I/conn(Wiper harness-main harness) S810-004204 S810-104204
CN-14 CN 4 I/conn(Cabin harness-main harness) S810-004204 -
CN-20 MARK-н 1 Horn S819-010122 -
CN-21 CN 4 Wiper motor S810-004204 -
CN-22 CN 2 Washer tank S810-002202 -
CN-23 - 2 Speaker (LH) S819-020222 S819-120222
CN-24 - 2 Speaker (RH) S819-020222 S819-120222
CN-27 PA 9 Cassette & radio S811-009003 -
CN-28 CN 2 Compressor S810-002202 -
CN-29 - 4 R/dryer S812-002001 -
CN-30 CN 6 Fan speed switch S810-006202 -
CN-31 CN 4 Blower S810-004202 -
CN-32 PA 3 Air-con switch S811-003001 -
CN-36 SWP 12 Fuse box S814-012000 -
CN-37 AMP 3 Fuse box S810-003202 -
CN-38 SWP 8 Fuse box S814-008000 -
CN-40 58-L 2 Fuse box S813-030200 -
CN-45 RING-TERM - Start motor B+ S820-310000 -
CN-47 CN 2 Resistor S810-002202 -
CN-48 CN 2 Hour motor S810-002202 -
CN-50 LC 10 CPU & controller S815-010000 -
CN-51 LC 18 CPU & controller S815-018000 -
CN-52 LC 24 CPU & controller S815-024000 -
CN-53 PA 13 CPU & controller AMP,172498-1 -
CN-56 ML 16 Cluster AMP,174046-2 -
CN-57 ML 12 Cluster AMP,174045-2 -
CN-60 58-L 2 Fusible link - S813-130200
CN-61 - 1 Fuel filler pump S822-015000 -
4 - 43
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-65 - 1 Travel alarm S822-014000 -
CN-66 J 2 Breaker solenoid S816-002001 -
CN-68 J 2 Safety solenoid S816-002001 -
CN-70 J 2 Travel solenoid S-816-002001 -
CN-74 RING-TERM - Alternator "I" term S820-106000 -
CN-75 - 1 Eppr valve S822-014000 -
CN-76 58-X 4 Governor motor S813-060400 -
CN-77 58-X 3 Potentiometer S813-060300 -
CN-78 - 1 Cold start aid S822-014004 S822-114004
CN-79 - 3 Fuel cut-off solenoid S818-020311 -
ňRelay
CR-1 RING-TERM - Battery relay S820-104000 -
CR-2 CN 4 Horn relay S810-004202 -
CR-3 CN 4 Work lamp relay S810-004202 -
CR-4 CN 6 Wiper relay S810-006202 -
CR-7 CN 4 Air-con relay S810-004202 -
CR-9 CN 4 Cabin light relay S810-004202 -
CR-13 CN 4 Head lamp relay S810-004202 -
CR-23 CN 2 Start relay S816-002003 -
ňSwitch
CS-1 - 1 Door switch S810-014004 -
CS-2 SWP 6 Start key switch S814-006000 -
CS-3 SWF 10 Wiper switch SWF,593757 -
CS-4 CN 3 Safety switch S810-003202 -
CS-5 - 1 Horn switch S822-014000 S822-114000
CS-7 CN 6 Prolix switch S810-006202 -
CS-16 SWF 10 Travel alarm switch SWF,593757 -
CS-22 SWF 10 Cold start switch SWF,593757 -
CS-24 SWF 10 Cabin light switch SWF,593757 -
CS-26 - 1 Pedal switch S822-014000 S822-114000
CS-27 SWF 10 Breaker switch SWF,593757 -
CS-30 SWF 10 Washer switch SWF,593757 -
CS-36 SWF 10 Work lamp switch SWF,593757 -
CS-39 SWF 10 Head lamp switch SWF,593757 -
4 - 44
Connector No. of Connector part No.
Type Destination
number pin Female Male
ňLight
CL-1 CN 2 Room lamp YAZAKI,7123-8326 -
CL-2 - 1 Cigar lighter S822-014004 S822-114004
CL-4 BS 3 Head lamp S812-003011 -
CL-5 BS 3 Work lamp S812-003011 -
CL-6 BS 3 Work lamp S812-003011 -
CL-7 - 1 Beacon lamp S822-014000 S822-114000
CL-8 - 1 Cabin light (rear) S822-014000 S822-114000
CL-9 - 1 Cabin light (LH) S822-014000 S822-114000
CL-10 - 1 Cabin light (RH) S822-014000 S822-114000
ňSensor,sendor
CD-1 MARK-н 1 Hydraulic oil temp sendor S819-010112 -
CD-2 CN 3 Fuel sendor KET,MG 610320 -
CD-8 MARK-н 1 Water temp sendor S819-010122 -
CD-9 - 1 Over heat sensor S822-014000 -
CD-10 - 1 Air cleaner switch S822-014000 S822-114000
CD-11 - 1 Travel alarm press switch S822-014000 -
CD-12 - 1 Travel alarm press switch S822-014000 -
CD-13 - 1 Travel alarm press switch S822-014000 -
CD-14 - 1 Travel alarm press switch S822-014000 -
CD-16 CN 2 Water level sensor S810-002202 -
CD-17 TWP 2 Speed sensor - S818-120221
CD-18 CN 1 Engine oil press switch S810-001202 -
4 - 45
2. CONNECTION TABLE FOR CONNECTORS
1) 58-L TYPE CONNECTOR
1 1
S813-030100 S813-130100
1 2 1 2
S813-030200 S813-130200
4 - 46
2) MULTILOCK TYPE CONNECTOR
20 1 10
11 20
S817-020105
4 - 47
3) PA TYPE CONNECTOR
1 3
2 5
2 5
1 3
S811-005002 S811-105002
3 7 1 4
1 4 3 7
S811-007002 S811-107002
4 9 1 5
1 5 4 9
S811-009002 S811-109002
5 11 1 6
11
1 6 5 11
S811-011002 S811-111002
4 - 48
No. of Receptacle connector(Female) Plug connector(Male)
pin
6 1 7
13
13
1 7 6 13
S811-013002 S811-013002
1 9
8 17
17
1 9 8 17
S811-017002 S811-117002
10 21 1 11
21
1 10 21
11
S811-021002 S811-121002
4 - 49
4) 58-X TYPE CONNECTOR
1 1
S813-060100 S813-160100
2 1
1 2
S813-060200 S813-160200
2 1 3
1 3 2
S813-060200 S813-060200
2 4 1 3
1 3 2 4
S813-060200 S813-060200
4 - 50
5) J TYPE CONNECTOR
1 1
2 2
S816-002001 S816-102001
2 3 1
3 1 2
S816-003001 S816-103001
3 1 4 2
4 2 3 1
S816-004001 S816-104001
6 3 1 8 5 2
8 5 2 6 3 1
S816-008001 S816-108001
4 - 51
6) SWP TYPE CONNECTOR
1 1
S814-001000 S814-101000
2 1
1 2
S814-002000 S814-102000
3 1
2 1 23
S814-003000 S814-103000
2 4 1 3
1 3 2 4
S814-004000 S814-104000
4 - 52
No. of Receptacle connector(Female) Plug connector(Male)
pin
3 6
1 4
4 3 6
1
S814-006000 S814-106000
4 8 1 5
4 8
1 5
S814-008000 S814-108000
4 12 1 9
12
1 9 4 12
S814-012000 S814-112000
3 14 1 11
14
3 14
1 11
S814-014000 S814-114000
4 - 53
7) CN TYPE CONNECTOR
1 1
S810-00120 S810-10120
2 2
1 1
S810-002202 S810-102202
3 2
1 2 1 3
S810-003202 S810-103202
2 4 1 4
1 3 2 3
S810-004202 S810-104202
4 - 54
No. of Receptacle connector(Female) Plug connector(Male)
pin
3 6 1 4
1 4 3 6
S810-006202 S810-106202
1 5
4 8
1 5 4 8
S810-008203 S810-108203
4 - 55
8) BS TYPE CONNECTOR
2 1
1 2
S812-002001 S812-102001
1 3 1 2
2 3
S812-003001 S812-103001
2 4 1 3
1 3 2 4
S812-004001 S812-104001
3 6 1 4
1 4 3 6
S812-006001 S812-106001
4 - 56
9) LC TYPE CONNECTOR
5 10
1 6
S815-010000
6 12
12
1 7
S815-012000
8 16
16
1 9
S815-016000
9 18
18
1 10
S815-018000
4 - 57
No. of Receptacle connector(Female) Plug connector(Male)
pin
12 24
24
1 13
S815-024000
4 - 58
10) 375 FASTEN TYPE CONNECTOR
2
1 2
1 2
S810-002402 S810-102402
4 - 59
SECTION 5 MECHATRONICS SYSTEM
GROUP 1 OUTLINE
K'6/$(
2. GENERAL STANDARD MODE : "S' MODE
When "S" mode is set, CPU controller moves E'4/$(
the engine governor motor lever to the full pressure'kgf.cm2(
position.
And it also sends out more currents into the
EPPR valve than those of "H" mode, which
reduces the discharge amount. So, it is
possible to work swift and soft controllability.
5-1
3. ENERGY(FUEL) SAVING AND FINISHING WORK : "L", "F" MODE
1) When "L" mode is set, CPU controller
moves the engine governor motor lever to Pump input torque
(kg/HPňhr)
the partial position and it also sends out Pump input torque
much more currents into the EPPR valve
than those of "S" mode, which reduces the
pump absorption power largely. So, at this
mode it is useful for light work and for Engine fuel
energy saving. consumption
F L H,S Engine
speed(rpm)
5-2
GROUP 2 OPERATION OF CAPO SYSTEM
CAPO : Computer Aided power optimization system, is the name of mode selection system, developed
by HYUNDAI
Engine rpm
Item Mode Application
Idle rpm Rated rpm
H Heavy duty operation 2050+50 1900
POWER S General operation 2050+50 1900
MODE L Light duty operation 1850+50 1700
F Finishing operation 1550+50 1400
TRAVEL LO Low speed travelling ӧ ӧ
MODE HI High speed travelling ӧ ӧ
KEY STARTING ӧ Key switch start position 1000Ţ100 ӧ
ONE TOUCH
ӧ Engine deceleration 1000Ţ100 ӧ
DECEL MODE
When engine start, S mode, One Touch Decel and Travel Lo(Turtle) mode are selected automatically.
POWER MODE
H S L F
AUTO SELECT
DECEL
H M
5-3
GROUP 3 SYSTEM DIAGRAM
This system is combined system of electronics, hydraulics and mechanics designed with four power
modes to have maximum performance and economical operation.
MCV
Engine
Coolant
temp. Sensor
Hydraulic
Throttle lever
EPPR valve
Governr
motor Speed sensor
CPU
Controller
(Micro computer)
Resistor Battery
Emergency switch
Electric Line
Hydraulic Line
5-4
GROUP 4 ENGINE CONTROL SYSTEM
5-5
3. ENGINE GOVERNOR MOTOR AND EMERGENCY CABLE MOUNTING
Governor motor
5-6
3) ENGINE THROTTLE LEVER
4 5
9
Section A-A
1 Potentiometer
2 Cover
3 Shaft for connecting rod
4 Dust seal
5 Bearing
6 Motor
7 Gear
8 Connector(3 P)
8
9 Connector(4 P)
2 1 2 1
Connector 3 4 3
5-7
4. ENGINE SPEED SENSOR
1) DETECT ACTUAL ENGINE RPM AND SEND SIGNAL TO TACHOMETER
3 2
2) INSTALLATION
(1) Clean contacting point of sensor.
(2) Loosen lock nut.
(3) Screw in speed sensor to flywheel housing.
(4) Turn it back 135Ňwhen it contact gear teeth.
(5) Tight lock nut and connect wiring.
5-8
GROUP 5 EPPR(Electro Proportional Pressure Reducing) VALVE
Pressure
Mode Electric current (mA) Engine rpm
kg/cm 2
psi
H 11 Ţ 3 160 Ţ 40 (350 Ţ 30) 2050 + 50
S 15 Ţ 3 220 Ţ 40 (400 Ţ 30) 2050 + 50
L 20 Ţ 3 290 Ţ 40 (450Ţ 30) 1850 + 50
F 33 Ţ 3 480 Ţ 40 (600 Ţ 30) 1550 + 50
ƕ 13 Ţ 3 190 Ţ 40 (375 Ţ 30)
ƕ Manually operated condition when prolix switch is selected emergency position.
5-9
2. OPERATING PRINCIPLE
1) STRUCTURE
1 Sleeve
2 Spool
3 Piston
4 Bushing
5 Spring
6 9 2 8 10 6 Ball
7 Spring
8 O-ring
9 O-ring
A 10 O-ring
11 Solenoid valve
12 Lock nut
13 Adjusting screw
11 4 3 1 7 5
2) AT H MODE
Pressure line blocked so, A oil return to tank.
A
P A
T
3) AT S, L, F MODE
Secondary pressure enter to A.
P A
5 - 10
3. EPPR VALVE CHECK PROCEDURE Spec : 270~450mA
1) CHECK ELECTRIC VALUE AT EPPR VALVE
(1) Start engine.
(2) Set S-mode and cancel quick decel
mode. CN-75
mode.
CN-75
(4) If tachometer show approx 2050+50rpm. Pressure adjusting
screw
locknut
(5) Check pressure at relief position of bucket
circuit by operating bucket control lever.
(6) If pressure is not correct, adjust it.
(7) After adjust, test the machine.
5 - 11
GROUP 6 PROLIX SWITCH
Is the conversion switch to manual control temporarily when the electronic control system get out of
order, until repair work be done.
EMERGENCY
NORMAL
Ɠ Normal :
Emergency :
2
1
CN-47
6 PROLIX S.W
5
4
9 3
8 2
6 1
CN-50 CS-7
11 1
2 EPPR V/V
CN-75
CN-51 CN-2
1) NORMAL POSITION
- EPPR valve supply specified amount of pilot pressure to flow regulator at hydraulic pump and
regulate hydraulic pump delivery amount depend upon the signal of CPU controller by selected
mode.
2) EMERGENCY POSITION
- If prolix switch set emergency position when any abnormality occurs in CAPO system, constant
electric current of prolix resistor from battery flow to EPPR valve so that EPPR valve fixed
predetermined position.
- In this case excavator can be operated equivalent to S mode.
5 - 12
GROUP 7 FUNCTION AND ELECTRICAL CIRCUIT
5 - 13
2. TRAVEL SPEED HI/LO FUNCTION ňCircuit diagram
1) When the travel speed switch is switched
ON/OFF, the lamp on the cluster changes
from rabbit(HI)to turtle(Lo) and the CPU
controller receives the signal.
CPU
2) When the CPU controller receives the Cluster controller
switch signal of ON(rabbit), it activates the Travel solenoid
valve
travel speed solenoid valve to change the
travel speed onto high.
3) Logic table
Travel speed switch
ON OFF
Signal Low High
Voltage(V) 0(GND) 5
Lamp Rabbit Turtle
Ɠ Default : Travel speed lamp lights at Lo(turtle)
on the cluster.
5 - 14
4. ENGINE SPEED SENSING FUNCTION ňCircuit diagram
1) Engine speed sensor mounted on the
engine sends AC voltage signals to CPU Engine speed
CPU
controller, after being rectified into Cluster
controller
rectangular pulse signals by the CPU
controller, they are displayed as engine rpm
counter on the 7-segment displays of the
cluster.
EPPR valve
2) When the engine speed drops below the ş Engine speed signal
reference rpm of each mode, the CPU 5V
controller reduces the pump discharge 0V
amount through engine speed feedback to
match engine output power with pump Ɠ Vpp = 5V
absorption power in the optimal condition.
5 - 15
6. HYDRAULIC OIL TEMP WARNING FUNCTION ňCircuit diagram
1) When the CPU controller receives hydraulic
oil temperature signals(analog voltage
signal) from the hydraulic oil temperature
Hydraulic oil temp sensor
sensor, it converts them into digital signals. Cluster
CPU
controller
If the temperature increases above 100Ƅ,
the CPU controller sends hydraulic oil
temperature warning buzzer signal and
lamp signal to cluster.
So the warning buzzer and lamp ON the
cluster work in condition of that the
temperature is above 100Ƅ
2) Logic table
5 - 16
4) Logic table(1)
Condition Function
Warming-up
lamp Coolant temperature : above 30Ƅ Warming-up lamp : OFF
5) Logic table(2)
5 - 17
8. ENGINE OVERHEAT PREVENTION FUNCTION ňCircuit diagram
1) When the engine coolant boils upto 110Ƅ,
the overheat switch is ON. and if the
Overheat switch
temperature drops to 100Ƅ, the switch is
OFF.
2) When the overheat switch is ON, engine CPU
Cluster controller
overheat warning buzzer and lamp work
and mode set is changed to "F" mode
Governor motor
automatically on the cluster.
3) If the coolant temperature drops to 100Ƅ or
mode set is changed among the function,
the cluster sends the overheat prevention
cancel signal to the CPU controller.
Thereby the CPU controller returns the
mode to the mode set before.
Ɠ Even if the overheat prevention function is
canceled by mode change, the overheat
warning lamp turns OFF only when the
overheat switch is OFF, that is, the coolant
temperature is less than 100Ƅ
4) Logic table(1)
Actuated - Coolant temperature : above 110Ƅ - Mode : "H", "S", "L" Ɗ "F"
- Overheat warning lamp & buzzer : ON
- Coolant temperature : less than 100Ƅ - Return to the mode set before
- Changed mode by operator - Hold on the changed mode
Canceled Ɠ If any of the above conditions is
applicable, engine overheat prevention
function is canceled
Overheat - Coolant temperature : less than 100Ƅ - Lamp OFF
warning lamp
5) Logic table(2)
Overheat switch
ON OFF
Condition Coolant temp : above 110Ƅ Coolant temp : less than 100Ƅ
Signal Low(GND) High(5V)
Lamp & buzzer ON OFF
(cluster)
Mode set F Default
(CPU controller)
5 - 18
SECTION 6 TROUBLESHOOTING
GROUP 1 HYDRAULIC AND MECHANICAL SYSTEM
1. INTRODUCTION
1) MACHINE IN GENERAL
(1) If even a minor fault is left intact and operation is continued, a fatal failure may be caused,
entailing a large sum of expenses and long hours of restoration.
Therefore when even a small trouble occurs, do not rely on your intuition and experience, but
look for the cause based on the troubleshooting principle and perform maintenance and
adjustment to prevent major failure from occurring. Keep in mind that a fault results from a
combination of different causes.
(2) The following lists up commonly occurring faults and possible causes with this machine. For the
troubleshooting of the engine, refer to the cummings troubleshooting and repair.
(3) When carrying out troubleshooting, do not hurry to disassemble the components.
It will become impossible to find the cause of the problem.
(4) Ask user or operator the following.
ڸWas the any strange thing about machine before failure occurred?
ڹUnder what conditions did the failure occur?
ںHave any repairs been carried out before the failure?
(5) Check before troubleshooting.
ڸCheck oil and fuel level.
ڹCheck for any external leakage of oil from components.
ںCheck for loose or damage of wiring and connections.
6-1
2. DRIVE SYSTEM
1) UNUSUAL NOISE COMES OUT OF PUMP CONNECTION
Cause Remedy
YES
Coupling element Disassemble and
is broken. repair.
Remove dust plug
under engine
flywheel and check YES
if rubber pieces or Replace hub or
particles are not retighten
present. Coupling hub setscrew.
spline is worn or
NO hub fastening
setscrew is slack.
If hydraulic pump or engine is suspected as
NO
a culprit refer also to shop manuals
"hydraulic components" and"engine"
6-2
2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL
Cause Remedy
NO
Replenish
specified oil to the
Is oil level in Abnormal noise standard level.
YES YES
hydraulic oil tank comes out of Hydraulic pump is Disassemble and
within standard hydraulic pump broken. repair.
level?
Do not hydraulic
Abnormal noise
pump and pump YES YES
comes out of See item 1).
YES connections make
pump connection
abnormal noise?
Is primary pilot
pressure within ڞ
NO standard level?
YES
Clean pilot piping
Is not pilot piping interior or repair
YES clogged or is not
piping.
oil leakage present
on pilot piping?
Pilot valve is faulty. Disassemble and
NO
ڞ repair.
YES
Pilot relief valve is Repair of replace.
Is gear pump faulty.
NO delivering oil?
Gear pump is Disassemble and
NO
broken. repair.
6-3
3. HYDRAULIC SYSTEM
1) HYDRAULIC OIL IS CLOUDY
Cause Remedy
YES
Water is mixed. Put hydraulic oil
still, separate
Drop hydraulic oil water and
sample on hot
dispose it or
plate and check if
foams come up. replace hydraulic
oil.
Air is intruded. Check suction
NO
line and return
line and eliminate
the air intruding
source.
Cause Remedy
NO Replenish
specified oil to the
standard level.
Is hydraulic oil
volume proper? YES
Clean oil cooler.
In not oil cooler Secure air
clogged and is circulation route.
YES anything blocking YES ڞ
air circulation?
Is fan belt tension
NO proper?
Adjust belt
NO
tension or
replace belt.
6-4
3) CAVITATION OCCURS WITH PUMP
Cause Remedy
NO
Replenish
specified oil to the
standard level.
Is hydraulic oil
YES
volume proper? Replace oil with
one of proper
Is not viscosity of viscosity.
YES hydraulic oil too YES
high? Clean suction
strainer.
Is not suction
NO Is not air intruding
strainer clogged?
Check for air
NO from pump suction
line? intrusion in
suction line and
retighten or
replace parts.
Cause Remedy
YES
Replace
Has not hydraulic hydraulic oil to be
oil passed specified.
specified replace-
ment hours? Has return filter
NO
been replaced at Flush with
NO
proper intervals? hydraulic oil and
replace return
filter.
6-5
4. SWING SYSTEM
1) BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE
Cause Remedy
NO
Replenish
YES
ڞ specified oil to the
Is safety valve standard level.
YES
pressure within
Gear is gear pump standard?
pressure within Safety valve faulty Repair or replace.
NO
Is oil in hydraulic standard level?
YES
tank within Gear pump faulty Repair or replace.
standard level? NO
YES
Are broken pieces Pump connection Disassemble and
of coupling present coupling is broken. repair.
ڞ when dust plug
under engine fly Is not main relief
NO Hydraulic pump is Disassemble and
Are attachment wheel is removed? valve faulty?
NO
and travel motions out of order. repair.
impossible at all?
NO
Swing control valve Disassemble and
YES Does swing control
valve spool move spool is stuck. repair.
Is MCV pilot ڟ
YES YES
pressure within
standard level?
Is RH travel NO
ڠ
NO function? Does not symptom
change when front
and rear pump Hydraulic pump is Disassemble and
NO
discharge hoses broken. repair.
are exchanged?
YES
Swing brake Disassemble and
release valve is repair.
Is swing brake broken.
ڟ release valve
faulty? YES Swing reduction Disassemble and
Does swing motor unit is broken. repair.
NO rotate?
Swing motor is Disassemble and
NO
broken. repair.
YES
Pilot relief valve is Disassemble and
NO Is gear pump faulty. repair or replace.
delivering oil?
Gear pump is out Disassemble and
Is gear pump pilot NO
of order. repair.
ڠ pressure within
standard level? YES
Is not there oil Clean pilot piping
leakage from pilot interior or repair
YES piping or is not it piping.
clogged?
Pilot valve is Disassemble and
NO
broken. repair.
6-6
2) SWING SPEED IS LOW
Cause Remedy
YES
Swing port relief Disassemble and
Does swing control
YES valve is faulty. repair or replace.
valve spool move
smoothly by hand?
Swing control valve Disassemble and
NO
Is secondary pilot spool is stuck. repair.
pressure same on
LH and RH sides? YES
Clogged or oil leak. Clean pilot piping
Is not pilot piping
interior or repair
Single direction clogged or is not it
NO piping.
leaking oil?
Is the trouble in NO Pilot valve or Disassemble and
one direction or in shuttle valve is repair.
both direction? faulty.
YES ڞ
YES
Pilot relief valve is Disassemble and
Is gear pump
defective. repair or replace.
NO delivering oil?
NO
Gear pump is Disassemble and
broken. repair.
NO
Main relief valve Main relief valve
faulty. pressure
resetting or repair.
Is main relief valve Does the symptom YES Hydraulic pump is Disassemble and
ڠ setting pressure change when front
YES broken. repair.
normal and rear pump
discharge hoses
Is safety valve pilot are exchanged? Shuttle valve faulty. Repair or replace.
NO
pressure within
YES YES
standard level? Pilot relief faulty. Repair or replace.
Is gear pump
output pressure
NO within standard
level Gear pump faulty. Repair or replace.
NO
6-7
3) SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION
Cause Remedy
YES
Does symptom Swing port relief Disassemble and
change when LH valve is faulty. repair.
YES
and RH port relief
Does swing valves are
exchanged Shuttle valve is Disassemble and
YES control valve spool NO
move smoothly by faulty repair.
hand?
Is MCV pilot Swing control valve Disassemble and
pressure same for NO
spool is stuck. repair.
LH and RH? Check if pilot piping
is not clogged or YES
Pilot valve is Disassemble and
NO does not have oil
leakage. broken. repair.
Clogged or oil
Clean pilot piping
leak.
interior or repair
piping.
Cause Remedy
YES
Pilot relief valve is Disassemble and
Is MCV pilot Is gear pump pilot
YES YES faulty. repair or replace.
pressure within pressure within
standard value? standard level?
NO
Gear pump is Disassemble and
broken. repair.
YES Does swing
control valve spool
move smoothly by Pilot valve is faulty. Disassemble and
NO
hand? repair.
Is swing control
valve's return
Swing control valve Disassemble and
spring normal? NO
spool is stuck. repair.
6-8
5) THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE
Cause Remedy
YES
Shuttle valve is Disassemble and
YES Is brake spring faulty. replace.
normal?
YES Is brake spring
ڞ
NO
normal?
Is return spring of
swing control Brake spring is Disassemble and
valve normal? NO
faulty replace.
Return spring of Disassemble and
NO
swing control valve replace.
is faulty.
YES
Swing relief valve Disassemble and
YES Is drain rate of is faulty. repair or replace.
swing motor within
standard value?
Is swing relief Swing motor is Disassemble and
NO
ڞ pressure within broken. repair.
standard level?
Adjust swing relief
NO
valve pressure or
replace swing
relief valve.
6-9
5. TRAVEL SYSTEM
1) TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE
Cause Remedy
YES ڇ
Does counterbalance
YES spool in travel brake
valve move lightly by
Is travel brake hand?
YES valve pressure Counter spool in
NO
Disassemble and
within standard Does the symptom travel brake valve repair or replace.
Has travel control level? change when relief is stuck.
YES valve spool valves in travel YES
Relief valve built in Disassemble and
changed over NO motor are
exchanged? travel motor is repair.
positively?
faulty.
YES
Does spool move Control system is Disassemble
lightly when hand defective. inspect and
NO is let free from repair.
control cable?
Is bucket or arm NO
Travel control valve Disassemble and
operation spool is stuck. repair.
possible?
YES
Travel reduction Disassemble and
Do not metallic
particles come out unit is faulty. repair.
ڞ of drain port in
travel reduction
unit?
NO Travel motor is out Disassemble and
of order. repair.
Does the symptom
change when front
and rear pump YES
Hydraulic pump is Disassemble and
NO discharge hoses
broken. repair.
are exchanged?
6 - 10
2) SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES
Cause Remedy
YES
Brake valve is Disassemble and
Do LH and RH defective. repair or replace.
travel speeds
YES change when LH
YES
and RH travel Does the symptom Relief valve built in Disassemble and
brake valves are change when relief travel motor is repair.
valves in LH and
NO faulty.
Has control valve RH travel motors
YES ڇ
spool changed are exchanged? NO
over positively?
YES
Control system is Disassemble,
Does spool move faulty . inspect and
lightly when it is cut repair.
Is the lower speed
NO off from control
(bucket or arm) spool?
within standard Control valve spool Disassemble and
level? NO
is stuck. repair.
YES
Travel relief valve is Disassemble and
Do LH and RH
faulty. repair or replace.
travel speeds Does the symptom
change over when YES
change when front YES
NO travel relief valves and rear pump Hydraulic pump is Disassemble and
are exchanged? Is external pilot discharge hoses broken. repair.
pressure within are exchanged?
NO
standard level?
NO External pilot piping Disassemble and
is clogged or oil is clean.
leaking from it.
Does travel speed
change when
YES parking brake YES Travel motor's Disassemble and
Is leak rate of spring in the slower parking brake is not clean pilot piping.
ڞ travel motor within travel motor is
released properly.
standard level?
Travel motor is Disassemble and
NO
faulty. repair.
6 - 11
3) MACHINE DOES NOT STOP ON A SLOPE
Machine is pulled forward as sprocket rotates during digging operation.
Cause Remedy
None Is parking brake YES
Friction plate is Disassemble and
Check if parking friction plate worn?
YES faulty. repair.
brake pilot line is
not clogged.
clogged Disassemble and
Is travel brake clean pilot piping.
pressure within Is drain rate of NO
standard level? travel motor within Travel motor is Disassemble and
standard value? defective. repair.
Cause Remedy
YES
Inspect according
to the procedure
"Travel does not
function at all on
one side."
However, a case
where both LH
and RH travel
motions are
disabled is
extremely
seldom
Is bucket or arm
statistically.
operation
possible? OK Hydraulic pump is Disassemble and
Disassemble both
travel relief valves faulty. repair.
OK and inspect for
Remove dust plug any fault.
under engine
OK flywheel and Travel relief valve is Disassemble and
Faulty
check that there is faulty. repair or replace.
no coupling
Check oil volume element particles.
Particles present. Coupling at pump Disassemble and
in hydraulic oil
NO connection is repair.
tank.
broken.
Short Replenish
hydraulic oil.
6 - 12
5) TRAVEL ACTION IS POWERLESS(travel only)
Cause Remedy
YES
ڇ
YES Is travel motor's
drain rate within
standard level?
YES Is travel brake NO
Travel motor is Disassemble and
pressure within faulty. repair.
standard level?
Is travel relief valve Travel brake valve Disassemble and
pressure within NO
is defective. repair or replace.
standard level?
YES
Hydraulic circuit Disassemble and
Does parking that releases travel clean.
Remove parking Increases brake piston move parking brake is
brake spring in lightly by hand? clogged with dirt.
travel motor, draw
out piston Parking brake Disassemble and
ڞ NO
completely, refit piston in travel repair.
cover and check if motor is stuck.
travel power Remains
Travel reduction Disassemble and
changes. unchanged
unit is defective. repair.
Cause Remedy
Travel brake valve
(counterbalance Disassemble and
valve) is faulty. repair or replace.
6 - 13
7) MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL AND
ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME
6 - 14
6. ATTACHMENT SYSTEM
1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL
Cause Remedy
Does the symptom YES Port relief valve is Disassemble and
change when port faulty. repair or replace.
YES
relief valve is
replaced with other
Is MCV pilot valve? ڇ
YES NO
pressure within
standard level? Inspect if pilot
piping is not OK
YES Are other clogged or oil is not Pilot valve is faulty. Disassemble and
attachments NO
leaking from the repair.
operable? piping.
YES
Pilot relief valve is Disassemble and
Is gear pump pilot NO
Is gear pump faulty. repair or replace.
pressure within
NO delivering oil?
standard level?
Gear pump is Disassemble and
NO
Are LH/RH broken. repair.
operations
possible? OK Hydraulic pump is Disassemble and
Disassemble main broken. repair.
YES relief valve and
Remove dust plug check if it is not
under engine irregular.
OK flywheel and check Main relief valve is Disassemble and
Faulty
if coupling element defective. repair or replace.
particles are not
Inspect oil volume present. Particles present
NO
in hydraulic oil Coupling at pump Disassemble and
tank. connection is repair.
broken.
Short
Replenish
hydraulic oil
YES
Does control valve Cylinder interior is Disassemble and
ڞ spool move lightly broken. repair.
by hand?
NO Control valve spool Disassemble and
is stuck. repair.
6 - 15
2) BOOM, ARM OR BUCKET SPEED IS LOW
Cause Remedy
YES
Normal
YES ڞ
Are other
YES attachment speeds
Is speed low only Is combination of within standard
oil streams normal levels? ڟ
in composite YES NO
operation? at boom hoisting YES Logic valve is faulty
and at arm Repair or replace.
extrusion? Logic valve
Are LH/RH travel NO normal.
speeds within Replace spring.
NO NO
standard levels?
YES
Hydraulic pump is Disassemble and
Are both LH/RH faulty. repair.
YES ڠ
NO travel speeds low?
Is MCV pilot
pressure within
NO
standard?
NO
ڡ
Does the symptom OK Port relief valve is Disassemble and
YES change when port faulty. repair or replace.
relief valve is
replaced with other
Does control valve valve? Cylinder is faulty. Disassemble and
YES spool move lightly NO
repair.
by hand?
NO
Control valve spool Disassemble and
Is MCV pilot
ڞ pressure within is stuck. repair.
standard level?
YES
Is not secondary Clean pilot piping
pilot pressure interior or repair
piping clogged or
NO piping.
is not there oil
leakage? Pilot valve is Disassemble and
NO
defective. repair.
YES
Pilot relief valve is Disassemble and
Is primary pilot
NO Is gear pump faulty. repair or replace.
ڟ pressure within
delivering oil?
standard level?
Gear pump is Disassemble and
NO
broken. repair.
Is engine
NO
ڠ revolution within Adjust engine
standard level? revolution.
YES
Clean orifice in
control valve.
Is not orifice in
ڡ control valve YES
clogged? Is pilot piping not Clean pilot piping
clogged or is oil not interior or repair
NO leaking from the piping
piping? Is pilot valve
Pilot valve is faulty. Disassemble and
NO normal? NO
repair.
6 - 16
3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS
Cause Remedy
YES
Port relief valve is Disassemble and
Does the
faulty repair or replace.
symptom change
Normal
when port relief
valve is replaced YES ڇ
with normal valve? Is control valve
YES Is not hydraulic oil NO return spring
normal?
temperature high? Control valves Disassemble and
NO
return spring is replace.
faulty.
Is genuine Abnormally high. Locate the cause
hydraulic oil or of hydraulic oil
equivalent being
used? temperature rise
and lower it to
proper level.
NO Replace with
genuine hydraulic
oil or equivalent.
OK
Disassemble and Pressure tightness Disassemble and
inspect check between control repair.
YES
valve in hydraulic valve casing and
circuit and check spool is poor.
Is cylinder internal for any fault.
Abnormal Contact surface Disassemble and
ڞ leakage within
between poppet repair.
standard level?
and seat is poor.
NO
Cylinder is faulty. Disassemble and
repair.
Cause Remedy
YES
Check according
Is cylinder internal to the procedure
YES leakage within in Item "Speed is
standard level? low"
Is relief pressure in
YES port relief valve Cylinder is faulty. Disassemble and
NO
within standard repair.
level?
Is relief pressure in
main relief valve Port relief valve is Adjust pressure,
within standard NO
faulty. repair or replace.
level?
6 - 17
5) ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE
Cause Remedy
YES
Port relief valve is Disassemble and
Does the
defective. repair or replace.
symptom change
YES when port relief
valve is replaced YES
Cylinder interior is Disassemble and
with other valve? Does control valve broken. repair.
Is secondary pilot NO spool move
YES smoothly by hand?
pressure within Control valve spool Disassemble and
standard level? NO
is stuck. repair.
YES
Does the Main relief valve is Adjust pressure,
symptom change faulty. repair or replace.
when LH/RH main Does the symptom
NO
relief valves are change when YES
exchanged? Hydraulic pump is Disassemble and
NO hydraulic pump's
discharge hoses broken. repair.
are exchanged?
6 - 18
6) BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED
Cause Remedy
YES
Frictional noise
occurs between
the sliding faces
of boom
cylinder's oil seal
and boom
Is boom foot pin
greased proper.
sufficiently? Ɠ Frictional
noise will
disappear if
they are kept
used.
6 - 19
Ɠ HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE
6 - 20
GROUP 2 ELECTRICAL SYSTEM
1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No. 14.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective cluster Replace
Check voltage
YES
between CN-57
(5) and chassis
Short circuit or poor Repair or replace
NO
Check voltage connection (after clean)
YES
between CN-8(5) between CN-57 (5)
and chassis
and chassis
FUSE
3
NO.14
CN-38
CLUSTER
9
5 5 7
11 11
CN-50
12 12
CPU CONTROLLER
CN-57 CN-8
11
CN-51
6 - 21
2. BATTERY CHARGING LAMP LIGHTS UP(Starting switch : ON)
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
ڞ
Check voltage
YES
between CN-53
(7) and chassis
Check voltage Defective controller Replace
YES NO
between CN-51
(18) and chassis
Short circuit or poor Repair or replace
YES Check voltage NO
between CN-1 (2) connection (after clean)
and chassis between CN-51
(18) and chassis
Check voltage Short circuit or poor Repair or replace
between alternator NO
connection (after clean)
terminal "I" and
chassis between CN-1(2)
Voltage : 20~30V and alternator
Starting switch : ON terminal "I"
Defective alternator Replace
NO
YES
Defective cluster Replace
Check voltage
ڞ between CN-
7(7) and chassis
Short circuit or poor Repair or replace
NO
connection (after clean)
between
CN-7(7) and
chassis
7 7 7
18
CN-51
ALTERNATOR
2
check voltage value "I" TERMINAL
XDR 1/}2/U CN-1
MN /U
6 - 22
3. WHEN COOLANT OVERHEAT LAMP LIGHTS UP(Engine is started)
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Coolant overheat Check engine
(110ƄŹ2Ƅ) system
YES
Check resistance ڞ
YES between CN-1(3) -
Does display go chassis and CN-
off when 51 (1) -chassis Short circuit or Repair or replace
disconnect CD-9 NO
and connector?
Starting switch : OFF poor connection (after clean)
Check resistance
YES
Starting switch : ON between CN-9(3)
Engine : start and chassis
Starting switch : OFF
Check resistance Short circuit or Repair or replace
NO
between CN-56 (after clean)
NO poor connection
(15) and chassis
YES
Defective sensor Replace
Check resistance
between CD-9 -
ڞ chassis and
sensor-chassis
Starting switch : OFF NO Short circuit or Repair or replace
poor connection (after clean)
15 3 1
3
check resistance value CN-1 CD-9
XDR L@W0װ
MN LHM0ײ
6 - 23
4. WHEN AIR CLEANER LAMP LIGHTS UP(Engine is started)
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Check air filter Repair or replace
(after clean)
YES
Short circuit or Repair or replace
Check resistance poor connection (after clean)
Does display go off YES between CN-1(9)
when disconnect
CD-10 and and chassis
connector? Short circuit or Repair or replace
Check resistance Starting switch : OFF NO
Starting switch : ON YES between CN-9(2) poor connection (after clean)
Engine : start
and chassis
Starting switch : OFF
Check resistance NO
Short circuit or Repair or replace
between CN-56 poor connection (after clean)
NO
(14) and chassis
Starting switch : OFF
Before checking,
disconnect CD-10 Defective cluster Replace
NO
14 2 9
6 - 24
5. WHEN ENGINE OIL PRESSURE LAMP LIGHTS UP(Engine is started)
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Engine oil leakage, Check engine oil
or defective switch level or replace
switch
YES
Short circuit or Repair or replace
Does display go off Check resistance
when disconnect YES between CN-1 (5) poor connection (after clean)
CD-18 and
and chassis
connector?
Short circuit or Repair or replace
Starting switch : ON Check resistance NO
Engine : start YES between CN-9 (1) poor connection (after clean)
and chassis
Starting switch : OFF
Check resistance NO Short circuit or Repair or replace
between CN-56 poor connection (after clean)
NO
(13) and chassis
Starting switch : OFF
Before checking,
disconnect CD-18
NO
Defective cluster Replace
13 1 5
6 - 25
6. WHEN HYDRAULIC OIL TEMPERATURE LAMP LIGHTS UP(Engine is started)
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective switch Check hydraulic
oil temperature
(105ƄŹ2Ƅ) ,
YES
ڞ Replace
Check resistance
Does display go YES
between CN-53 (8)
off when
disconnect CD-1 and chassis
and connector? Short circuit or Repair or replace
Check resistance Starting switch : OFF
Starting switch : ON YES between CN-7 (12) poor connection (after clean)
Engine : start
and chassis
Starting switch : OFF
Check resistance NO
Short circuit or Repair or replace
between CN-56 poor connection (after clean)
NO
(13) and chassis
Starting switch : OFF
Before checking,
disconnect CD-1 Defective cluster Replace
NO
HYDRAULIC
check resistance value OIL TEMPERATURE SENDER
XDR L@W0װ
MN LHM0ײ
CD-1
21
CN-52
CLUSTER CPU CONTROLLER
13 12 8
6 - 26
7. WHEN COOLANT LEVEL LAMP LIGHTS UP(Engine is started)
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Insufficient Refill coolant
coolant or
Defective switch Replace
YES
Short circuit or Repair or replace
Does display go Check resistance poor connection (after clean)
off when YES between CN-1 (11)
disconnect CD-16 and chassis
and connector?
Starting switch : ON Check resistance Starting switch : OFF NO Short circuit or Repair or replace
Engine : start YES between CN-7 (6) poor connection (after clean)
and chassis
Starting switch : OFF
Check resistance
NO Short circuit or Repair or replace
between CN-56
NO poor connection (after clean)
(6) and chassis
Starting switch : OFF
Before checking,
disconnect CD-16
NO Defective cluster Replace
WATER LEVEL
CLUSTER
6 6 11 2
CD-16
6 - 27
8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE
(Check coolant temperature lamp ON/OFF)
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted, and
short of fuse N0. 14.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Coolant overheat Check coolant
or Defective switch temperature or
replace
YES
Short circuit or Repair or replace
3 3 6
6 - 28
9. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective cluster Replace
Check resistance
value between YES
CN-57(4) and Short circuit Repair or replace
chassis between CN-57 (after clean)
Starting switch : OFF Check resistance
(4) and CN-8(4)
See : TABLE value between
YES Repair or replace
NO CN-8(4) and Short circuit
chassis between CN-8(4) (after clean)
See : TABLE Check resistance and CN-4(6)
value between
YES Short circuit Repair or replace
NO CN-4(6) and
chassis Check resistance between CN-4(6) (after clean)
See : TABLE value between
NO CD-2(2) and and CD-2(2)
chassis ڞ
See : TABLE NO
Check Table
F
Kdudk Dlosx '0.1( Etkk
Hsdl
TmhsQdrhrs`mbd'(װ 00/ '21-4( 2
E Snkdq`mbd Ź2 Ź1
FUEL SENDER
CLUSTER
4 4 6 2
CD-2
6 - 29
10. WHEN SAFETY SOLENOID DOES NOT OPERATE
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No. 4.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES Check hydraulic
YES Check operation system
of solenoid
Defective solenoid Replace
Safety lever : ON-OFF NO
Check resistance
value between
CN-68(1)-(2) with YES
chassis Check chassis Replace
Starting switch : ON contact
Voltage : 20~30v Check resistance
Safety state
value between YES
NO CN-68(1) with Short circuit Repair or replace
chassis between CN-3(6)
Safety lever : ON Check resistance
value between and CN-68(1)
NO CN-3(6) and YES Repair or replace
Short circuit
chassis
between CS-4(1)
Starting switch : ON Check operation
Voltage : 20~30v NO of safety switch and fuse
Defective switch Replace
Voltage : 20~30v NO
Connector(male)
SAFETY SWITCH
FUSE
1 COM.
NO.4 2
NC
3
NO
CS-4 SAFETY SOLENOID
1
3 6 2
6 - 30
11. WHEN TRAVEL SPEED 1,2 DOES NOT OPERATE
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No. 2.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES Short circuit Repair or replace
13 9 1
8 2
CN-52
CN-3 CN-70
5
CN-51 CLUSTER
7 7
CN-8 CN-57
6 - 31
12. WHEN ENGINE DOES NOT START
ňCheck supply of the power at engine stop solenoid while starting switch is ON.
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted.
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified. START KEY S.W
1 B+
3 IG
Cause Remedy
5 START
YES
Check engine
CS-2
system
Defective battery Charge(after
checking specific 24V
1
gravity of battery)
or replace CN-38
Check operation YES
Defective magnet Replace
Check voltage 24V
of start motor 1
YES between starter
of start motor
magnet coil CN-40
Starting switch : start
and chassis Replace
Defective start
Starting switch : start NO
relay FUEL CUT-OFF
10
Check operation YES Defective start Repair or replace 1
NO of start relay Check voltage switch CN-1
YES between CS-2
CN-79
Starting switch : start (1) and chassis
Short circuit Repair or replace
Starting switch : ON NO ENGINE STOP SOLENOID
between CS-2(1)
Check voltage and CN-40(1)
1 STARTER
between CR-23
NO 2
(1)-(2) YES
Short circuit Repair or replace
Starting switch : start CR-23
between CN-1(1) M
Check voltage and CR-23
between CN-1
NO (start relay)
(1) and chassis
Starting switch : OFF
ڞ
NO
6 - 32
13. WHEN STARTING SWITCH "ON" DOES NOT OPERATE
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted.
START KEY SWITCH
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
1 B+
3 IG
Cause Remedy 5 START
YES CS-2
Defective cable Repair or replace
Check voltage assembly (after clean)
YES between
CN-60(1)-(2)
Check voltage Short circuit or Replace
YES Voltage : 20~30V NO
between defective of
CN-4(2)-(9) fusible link 1
Check voltage
YES Voltage : 20~30V Short circuit or Replace CN-39
between NO
CS-2(1)-(3) defective of
battery relay IG POWER
Check voltage Voltage : 20~30V 1
CONTINUOUS POWER 24V
and specific Short circuit or Replace 2
NO
gravity of battery defective of start CN-40
Specific gravity : MIN 1.28 switch
Voltage : MIN 24V BATTERY(12VX2)
Battery capacity Charge or replace
NO
too low (after clean)
FUSIBLE LINK
2 2
1 1
CN-5 CN-60
M4 M8
2
9 CR-1
CN-4 M4 M8
BATTERY RELAY
1
2
TO STARTER
6 - 33
14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse NO.14.
WIPER MOTOR
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
S1
3 4 4
Cause Remedy B
2 3 3
YES
ڞ 7 2 2 E M
Check voltage 1 1 S2
YES 1
between CN-13
(1) and chassis CN-6 CN-13 CN-21
Voltage : 20~30V NO Short circuit or poor Repair or replace
Check voltage
YES between CN-6 (1) Starting switch : ON connection between (after clean)
Wiper switch : ON
and chassis CN-13(1) - CN-6
Voltage : 20~30V (1) with chassis
Starting switch : ON Short circuit or poor Repair or replace
Wiper switch : ON NO
Check voltage connection between (after clean)
YES WIPER RELAY
between CR-4 (1)
CR-4(1) - CN-6(1) WIPER SWITCH
and chassis 1
with chassis LAMP
Voltage : 20~30V YES 2 9
Starting switch : ON Defective relay Replace
Wiper switch : ON 4 10
Check voltage YES Short circuit or poor Repair or replace
6 2
NO between CR-4 (4) connection between (after clean)
and chassis Check voltage 3 6
SWITCH
Voltage : 20~30V between CN-36 CR-4(4) - CN-36(6)
NO CR-4 CS-3
Starting switch : ON (6) and chassis with chassis
Replace WASHER SWITCH
NO Short circuit of
Voltage : 20~30V
Check operation Starting switch : ON LAMP
of wiper relay fuse 10
YES Defective relay Replace 9
Starting switch : ON 2
Wiper switch : ON-OFF Check connection
YES
between CR-4(6) 6
and chassis 5
Short circuit or Repair or replace
Check connection Wiper switch : OFF NO 1
YES poor connection (after clean) SWITCH
between CS-3(2) CS-30
and chassis between CR-4(6)
Check voltage and chassis 1
between CR-4 (2)
Wiper switch : OFF
Defective wiper Replace switch 2
W WASHER TANK
and chassis NO
switch CN-22
Voltage : 20~30V
Starting switch : ON Short circuit of Replace
NO FUSE
fuse 6
CN-36 NO.1
YES Defective wiper Replace
Check voltage motor
ڞ between CN-21(1)
and chassis
Short circuit or Repair or replace
NO
Starting switch : ON
Wiper switch : ON-OFF
poor connection (after clean)
between CN-13
(1) and CN-21(1)
6 - 34
15. WHEN STARTING SWITCH IS TURNED ON, CAB LAMP DOES NOT LIGHT UP
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.10
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
CN-10
Cause Remedy
YES
Short circuit or Repair or replace
poor connection (after clean)
Check voltage
YES between lamps CL-9
between CN-14
(4) and chassis
Voltage : 20~30V Short circuit or Repair or replace 5 4
Check voltage Starting switch : ON NO
YES between CN-6 (5) (after clean) 7 1
cab lamp switch : ON poor connection
and chassis CL-8
between CN-6(5) CN-6 CN-14
CABIN LIGHT
Voltage : 20~30V and CN-14(4)
Starting switch : ON
cab lamp switch : ON Short circuit or Repair or replace
NO
Check voltage poor connection (after clean)
YES
between CR-9 (2) between CR-9(2)
and chassis
and CN-6(5)
Voltage : 20~30V YES
Defective relay Replace
Starting switch : ON
cab lamp switch : ON CABIN LIGHT
Check voltage CABIN LIGHT SWITCH
4
between CR-9(4) YES LAMP
NO Short circuit or Repair or replace 3 10
and chassis
poor connection (after clean) 1 9
Voltage : 20~30V Check voltage 2 2
Starting switch : ON between CN-37 between CR-9(4)
NO 6
(3) and chassis and CN-37(3) CR-9 SWITCH
Voltage : 20~30V Replace CS-24
Starting switch : ON NO Short circuit of fuse
6 - 35
16. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted and
HEAD LIGHT
short of fuse No.8
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective bulb Replace
Check voltage
YES between CL-4(3)
and chassis
NO Short circuit or Repair or replace
Check voltage Voltage : 20~30V 1 2
YES between CN-4 (7) Starting switch : ON poor connection (after clean) CL-3
Head lamp switch : ON
and chassis between CL-4(3)
and chassis
Voltage : 20~30V 7 2
Starting switch : ON
NO Short circuit or Repair or replace
Head lamp switch : ON 9 1
Check voltage poor connection (after clean)
YES CN-4 CL-4
between CR-13 between CL-4(3) HEAD LIGHT
(2) and chassis
and CN-4(7)
Voltage : 20~30V YES
Defective relay Replace
Starting switch : ON
Head lamp switch : ON
Check voltage 9 9
YES
NO between CR-13 Short circuit or Repair or replace CN-7 CN-56
(4) and chassis
poor connection (after clean)
Voltage : 20~30V Check voltage HEAD LIGHT RELAY
Starting switch : ON between CR-13(4)
NO between CN-37 HEAD LIGHT SWITCH
(1) and chassis and CN-37(1) 4
LAMP
3 10
Voltage : 20~30V
NO Short circuit of
Replace
Starting switch : ON 1 9
fuse 2
2
YES
Short circuit or Repair or replace 6
CR-13 SWITCH
Check voltage poor connection (after clean)
Check operation CS-39
YES
of head lamp relay between CS-39 between CR-13(3)
(2) and chassis CS-39(2)
Starting switch : ON Head lamp switch : ON
Head lamp switch : Defective head Replace switch FUSE
NO
ON-OFF Check voltage lamp switch
NO between CS-39 (6) NO.8
and chassis CN-37
YES
Short circuit or Repair or replace
Voltage : 20~30V
Starting switch : ON
Check voltage poor connection (after clean)
between CN-37 between CN-37(1)
NO
(1) and chassis and CS-39(6)
Short circuit of Replace
NO
fuse
6 - 36
17. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
ňBefore disconnecting the connector, always turn the starting switch OFF.
ňBefore carrying out below procedure, check all the related connectors are properly inserted and
short of fuse No.9. WORK LIGHT
ňAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
1
Cause Remedy 2
YES CL-6
Short circuit or Repair or replace
poor connection (after clean)
Check voltage berweenCL-5(3) 9 1 1
YES 4 2 2
between CN-10
(2) and chassis and CL-6(3)
CN-4 CN-10 CL-5
Voltage : 20~30V
Check voltage Starting switch : ON Short circuit or Repair or replace
YES Work lamp switch : ON NO
between CN-4(4) poor connection (after clean)
and chassis CLUSTER
between CN-4(4)
Voltage : 20~30V and CN-10(2)
Starting switch : ON
10 10
Work lamp switch : ON Short circuit or Repair or replace CN-7 CN-56
NO
Check voltage poor connection (after clean)
YES
between CR-3 (2) WORK LIGHT
between CR-3(2)
and chassis WORK LIGHT SWITCH
and CN-4(4) 4
Voltage : 20~30V YES
LAMP
Starting switch : ON Defective relay Replace 3 10
Work lamp switch : ON 1 9
2 2
Check voltage
between CR-3(4) 6
NO YES Short circuit or CR-3 SWITCH
and chassis Repair or replace
CS-36
poor connection (after clean)
Voltage : 20~30V Check voltage
Starting switch : ON between CN-37 between CR-3(4)
NO
(2) and chassis and CN-37(2) FUSE
Voltage : 20~30V Short circuit of Replace 2
Starting switch : ON NO
fuse CN-37 NO.9
6 - 37
GROUP 3 MECHATRONICS SYSTEM
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective
YES Check pressure hydraulic system.
at EPPR valve
Wiring diagram
2 Ɠ Normal :
1
CN-47 Emergency :
PROLIX S.W
6
5
4
9 3
8 2
6 1
CN-50 CS-7
11 1
EPPR V/V
2
CN-75
CN-51 CN-2
6 - 38
2) TEST PROCEDURE
SPEC : 24 Ţ 1ѻ(20Ƅ)
(1) Test 1 : Check resistance value (6)-(8) at
connector CN-50.
ڸStarting key OFF. CN-50
ڹRemove CPU controller and disconnect CPU 1 2 3 4 5
connector CN-50. CONTROLLER 6 7 8 9 10
ںCheck resistance value between pin No. CN53 CN52 CN51 CN-50
Multimeter
Multimeter
Multimeter
6 - 39
(2) Test 4 : Check pressure at EPPR valve.
ڸRemove plug and connect pressure SPEC : 4~20 kg/cm2(58~290 psi)
gauge as Fig.
Gauge capacity : 0 to 40~50 kg/cm2
(0 to 580~730 psi)
ڹStart engine.
ںSet S-mode and cancel auto decel Supply line, pilot press
mode.
CN-75
ڻIf tachometer show approx. 2350+50rpm,
Pressure adjusting
check pressure at relief position of screw
locknut
bucket circuit by operating bucket control
lever.
ڼIf pressure is not correct, adjust it.
ڽAfter adjust, test the machine.
6 - 40
2. ENGINE SPEED IS SLOW AT ALL MODE
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
If test 7 is good
Check tachometer Check TEST 1~4
YES work properly or
YES
not by changing Check resistance Misalignment Clean speed
the mode. value between between speed sensor and adjust.
Check resistance
SEE : TEST 6 CN-52(14) - CN- sensor and fly SEE: 5-8page
YES value between NO 51(12)
CN-50(2) - (3) and wheel
(4) - (5) SPEC:0.2~0.4ױ ڞ
SEE : TEST 7 NO
SPEC:5~6י
Replace governor
Check linkage SEE : TEST 5 Defective governor motor or harness.
NO
between governor motor or short circuit assembly.
motor - injection or poor connection
pump. between CN-50 -
CN-2 and CN-2 -
CN-76 Adjust or repair.
Improper operation
NO
by loosening or
interference of Check and repair.
linkage.
YES
Short circuit or poor
Check resistance connection between
ڞ value between CN-51(12) - CD- Replace.
CD-17(1) - (2) 17(2) or CN-52(14) -
CD-17(1)
SPEC:0.2~0.4ױ NO
SEE : TEST 8 Defective
speed sensor.
Wiring diagram
2 Ɠ Mnql`k9
1
CN-47 Dldqfdmbx9
5 PROLIX S.W
4 6
3 5
2 4
9 3
8 2
6 1
CN-50 CS-7
11 1
12
2 EPPR V/V
10
CN-51 CN-2 CN-75 SPEED SENSOR
24 2
23 1
14 CD-17
CN-52 5 1
4 2 POT(POTENTIOMETER)
3 3
7
6 CN-77
9
10 1 A
11 2 A-
12 3 B
4 B-
CN-2
CN-76 GOVERNOR MOTOR
6 - 41
2) TEST PROCEDURE
(1) Test 5 : Check resistance value between CPU
(2)-(3) and (4)-(5) at connector CONTROLLER
CN-50. CN53 CN52 CN51 CN-50
ڸStarting key OFF.
ڹRemove CPU controller and disconnect
connector CN-50 from CPU controller.
ںCheck resistance value as below.
CN-50 CN-50
1 2 3 4 5 1 2 3 4 5
6 7 8 9 10 6 7 8 9 10
Multimeter Multimeter
unit : rpm
(2) Test 6 : Check tachometer
Spec Remark
(Work properly or not.)
ڸStart engine. H-mode 2050+50rpm
ڹCheck tachometer reading. S-mode 2050+50rpm Check rpm after
cancel the one touch
L-mode 1850+50rpm decel mode.
F-mode 1550+50rpm
CN-52 CN-51
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
13 14 1516 17 18 19 20 2122 23 24 10 11 12 13 14 1516 17 18
Multimeter
6 - 42
(4) Test 8 : Check resistance value at speed
SPEC : 0.2 - 0.4ױ
sensor.
ڸStarting key OFF.
ڹDisconnect connector CD-17 of speed Speed sensor
Engine flywheel
Multimeter
6 - 43
3. ENGINE STALL
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Not enough engine Contact cummins
YES Check pressure at power. engine dealer.
EPPR valve.
NO
Defective EPPR Replace.
SPEC:30~33 kg/cm2 valve.
Check electric SEE:TEST 10
current value at YES
EPPR valve. Defective CPU Replace.
controller.
SPEC:570~600 mA
SEE:TEST 9 Check resistance
value between YES
Short circuit or poor Check and
NO CN-50(6) - (8)
connection repair.
SPEC:24Ţ1Ѥ(20Ƅ) Check resistance between
SEE : TEST 1 value at EPPR CN-50 - CN-2 or
NO
valve. CN-50 - CN-75
SPEC:24Ţ1Ѥ(20Ƅ)
SEE : TEST 2 Defective EPPR Replace.
NO
valve.
Wiring diagram
Ɠ Mnql`k9
Dldqfdmbx9
2
1
CN-47
PROLIX S.W
6
5
4
9 3
8 2
6 1
CN-50 CS-7
11 1
EPPR V/V
2
CN-75
CN-51 CN-2
6 - 44
2) TEST PROCEDURE
SPEC : 570~600mA
(1) Test 9 : Check electric current value at
EPPR valve at F-mode
ڸStart engine. CN-75
ڹSet F-mode with 1550 +50rpm
ںInstall multimeter as below.
ڻCheck electric current value at bucket
circuit relief position.
EPPR VALVE
Multimeter
pull. CN-75
ڼHold arm lever at the end of stroke. Pressure adjusting
screw
ڽCheck pressure at relief position. locknut
6 - 45
4. CLUSTER LAMPS ARE OFF IMMEDIATELY AFTER KEY SWITCH OFF
Ɠ Before carrying out below procedure, check all the related connector are properly inserted.
Normal condition : Lamps "ON" approx. 3-12 second after key switch OFF.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective Replace.
CPU controller.
SEE : TEST 12
Defective fuse. Replace.
NO
Wiring diagram
FUSE BOX
BATTERY
10 1 17 2 2 2
CN-40 CN-5 CN-60
CN-39
CN-50
6 - 46
2) TEST PROCEDURE
SPEC : 24 Ţ 1Volt
(1) Test 11 : Check voltage at (10) of CN-50.
ڸStarting key OFF. CN-50
Ground
Multimeter
20A
10A
12
1
CONTROLLER WASHER
20A
20A
CLUSTER
2
13
SOL. B+
20A
20A
3
WORK LAMP
14
RADIO
CIGAR &
20A
20A
15
SPARE
4
ETHER SOL.
20A
10A
16
5
CLOCK B+ SAFETY
MONITOR &
20A
20A
17
6
HEAD LAMP
CPU B+
F/PUMP &
10A
10A
18
ROOM LAMP
7
T/ALARM
AIR-CON
30A
20A
SPARE
8
BREAKER
30A
30A
SPARE
9
CABIN LIGHT
10A
30A
10
SPARE SPARE
10A
SPARE
11
FUSE
20A
12
PULLER SPARE
SPEC : 20A
6 - 47
5. CLUSTER LAMPS ARE STILL ON AFTER STARTING KEY OFF
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Improper Check and
operation of repair.
governor motor.
Check interference So, governor
YES of connecting rod motor supply
when governor
signal to
motor move to low
rpm side. cluster panel
continuously.
Replace.
Check voltage at Defective
CN-50(9). NO
CPU controller. Replace.
SPEC : YES
Key ON : 24Ţ1 VOLT Defective battery
Key OFF : 0 VOLT
SEE : TEST 13 Is the voltage 24V relay.
Replace.
NO between CN-50(4)
and GND?
NO
Defective CPU
TEST :
Repeat key switch controller
ON and OFF
SEE : TEST 14
Wiring diagram
FUSE BOX
9 3 3 START
14
1 IGNITION
CN-38 CS-2
CN-50 START KEY SWITCH
6 - 48
2) TEST PROCEDURE
SPEC :
(1) Test 13 : Check voltage at(9) of CN-50. Key ON : 24Ţ1 Volt
ڸStarting key "ON". Key OFF : 0 Volt
ڹDisconnect connector CN-50 from CPU
CN-50
controller. CPU 1 2 3 4 5
ںCheck voltage as below. CONTROLLER 6 7 8 9 10
CN53 CN52 CN51 CN-50
Ground
Multimeter
Multimeter
6 - 49
6. CLUSTER LAMPS ARE ON WHEN ENGINE RUN OR MALFUNCTION OF MODE SELECTION
SYSTEM
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective lamps or Repair or Replace
Check voltage for cluster
YES
between CN-50(7)
- CN-57(5).
SPEC : 24Ţ1V NO
Defective CPU Replace.
Check resistance SEE : TEST 16 controller.
value for switches. Poor connection Check and repair.
between CN-50 -
SPEC :
Switch ON : 0י CN-57.
Switch OFF : Ũי
SEE : TEST 15 NO
Defective switch at Replace.
cluster.
Wiring diagram
8 8
4
CN-56 CN-7
5
6
7
8
9
7 7
CN-51
1 1
2 2
9 9
8 8
5 5 7
CN-57 CN-8
CN-50
6 - 50
2) TEST PROCEDURE
(1) Test 15 : Check resistance value for CPU
switches. CONTROLLER
ڸStarting key OFF. CN53 CN52 CN51 CN-50
ڹDisconnect connector CN-51 from CPU
controller.
ںCheck resistance value as below.
CN-51
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
Ground
Multimeter
CN-57
1 2 3 4 5 6
7 8 9 10 11 12
Ground
Multimeter
6 - 51
7. SLOW ACTION OF ENGINE SPEED CHANGE WHEN CHANGE THE MODE
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Slow action of Check and repair.
engine speed
control due to
interference.
Check interference Replace.
Check voltage YES
between between CN- Defective CPU
connecting rod 52(24) - CN-51(10) controller.
and governor YES
and check
resistance value Replace.
Check resistance between CN- Defective governor
value between CN- 52(23) - CN-51(10). NO
motor.
NO 50(2) - (3) and CN- SPEC : (24)-(10) : 5Ţ1 volt
50(4) - (5) (23)-(10) : 0-5ױ
SEE : TEST 18 Replace.
SPEC : 5~6י
SEE : TEST 17 Defective governor
NO
motor.
Wiring diagram
2
3
4
5
CN-50
5 1
4 2 POT(POTENTIOMETER)
10 3 3
CN-77
CN-51
12 4 B-
11 3 B
10 2 A-
24 9 1 A
23
CN-2 CN-76 GOVERNOR MOTOR
CN-52
6 - 52
2) TEST PROCEDURE
Test - a
(1) Test 17 : Check resistance value
ڸStarting key OFF.
ڹDisconnect connector CN-50 from CPU CN-50
CPU
controller. 1 2 3 4 5
CONTROLLER
ںCheck resistance value between (2) and 6 7 8 9 10
CN53 CN52 CN51 CN-50
(3), (4) and (5) of CN-50 as below.
Multimeter
Test - b
CN-50
CPU
1 2 3 4 5
CONTROLLER
6 7 8 9 10
CN53 CN52 CN51 CN-50
Multimeter
6 - 53
(2) Test 18 : Check voltage and resistance
SPEC : 0 ~ 5 ױ
value.
ڸCheck resistance value between (23) of
CN-52 and (10) of CN-51. CPU
CONTROLLER
Ť Starting key OFF.
CN53 CN52 CN51 CN-50
Ť Disconnect connector CN-52 and CN-51
from CPU controller.
Ť Check resistance value with multimeter
as below.
CN-52 CN-51
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
13 14 1516 17 18 19 20 2122 23 24 10 11 12 13 14 1516 17 18
Multimeter
Multimeter
6 - 54
8. ONE TOUCH DECEL SYSTEM DOES NOT WORK
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective CPU Replace.
controller.
Short circuit or poor Replace or repair.
connection
Check resistance
between CN-51(3)
value between
CN-51(4) - GND. - (4)
SPEC :
Switch ON : 0װ
Switch OFF : ſװ
SEE : TEST 19
NO
Defective cluster. Replace.
Wiring diagram
11 11 2
CS-29
8 8 CN-36
3
4
CN-56 CN-7 5
6
7
8
9
7 7
1 1 CN-51
2 2
9 9
8 8
5 5 7
CN-57 CN-8
CN-50
6 - 55
2) TEST PROCEDURE
SPEC :
(1) Test 19 : Check resistance value at One touch decel switch ON(Light ON) : 0װ
CN-51(4) and ground. One touch decel switch OFF(Light OFF) : ſװ
ڸStarting key OFF.
ڹDisconnect connector CN-51 from CPU
CPU controller. CONTROLLER
ںTurn start key ON. CN53 CN52 CN51 CN-50
Check resistance value as Fig.
CN-51
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
Ground
Multimeter
6 - 56
9. MALFUNCTION OF WARMING UP
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective cluster or Repair or
Check resistance CPU controller or Replace.
YES
value between CN- CD8(sensor)
57(3) - CD-8
Check resistance SPEC : 0ѻ Poor connection Repair.
NO
value between CN SEE : TEST 21 between CN-57(3)
-51(20) - CN-56(16) - CD-8.
SPEC : 0ѻ
SEE : TEST 20
Poor connection Repair.
NO
between CN-
52(20) - CN-56(16).
Wiring diagram
CN-56
3 6
CN-1
CN-57
6 - 57
2) TEST PROCEDURE
SPEC : 0ѻ
(1) Test 20 : Check resistance value between
connector (20) of CN-52- (16) of
CN-56. CPU
ڸStarting key OFF. CONTROLLER
ڹRemove CPU controller and disconnect CN53 CN52 CN51 CN50
from cluster.
ڻCheck resistance value as Fig.
CN-56
9 10 1112 1314 15 16
1 2 3 4 5 6 7 8
CN-52
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
Multimeter
from cluster. 6 5 4 3 2 1
ںDisconnect connector CD-8 of water
temp sensor at engine head.
ڻCheck resistance value as Fig.
Cluster
CD-8 Water temp sensor
Multimeter
6 - 58
10. MALFUNCTION OF OVERHEAT
Ɠ Before carrying out below procedure, check all the related connectors are properly inserted.
1) INSPECTION PROCEDURE
Cause Remedy
YES
Defective overheat Replace
switch
Check resistance
value between YES
CD-9 - GND. Defective CPU Replace
SPEC : Check resistance controller
Region мƊſѻ value between CN-
(Fig.) нƊſѻ NO
51(1) - CD-9
оƊſѻ
SEE : TEST 22 Short circuit or poor Check or Repair
SPEC : 0ѻ NO
SEE : TEST 23 connection between
CN-51(1) - CD-9.
coolant
temperature
110Ƅ
Time
Region ѓ Region є Region ѕ
Temperature curve
Wiring diagram
Overheat switch
1 3
CD-9
CN-51 CN-1
15 3
CN-59
CN-56
6 - 59
2) TEST PROCEDURE
SPEC : 0ѻ
(1) Test 22 : Check resistance value between
connector CD-9 - GND. CD-9 Overtheat switch
ڸStarting key OFF.
ڹDisconnect connector CD-9 of overheat
switch at engine head.
ںCheck resistance value as Fig.
Ground
Multimeter
CN-51
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
CD-9
Overtheat switch
Multimeter
6 - 60
SECTION 7 MAINTENANCE
GROUP 1 OPERATIONAL PERFORMANCE TEST
1. PURPOSE
Performance tests are used to check:
1) OPERATIONAL PERFORMANCE OF A NEW
MACHINE
Whenever a new machine is delivered in Working
parts and reassembled at a customer's site, condition
it must be tested to confirm that the
operational performance of the machine Maintenance
meets HYUNDAI SPEC. record
2) OPERATIONAL PERFORMANCE OF A
WORKING MACHINE
With the passage of time, the machine's
operational performance deteriorates, so
that the machine needs to be serviced
periodically to restore it to its original Operating
time
performance level.
Before servicing the machine, conduct
performance tests to check the extent of
deterioration, and to decide what kind of
service needs to be done(by referring to the
"Service Limits" in this manual).
3) OPERATIONAL PERFORMANCE OF A
REPAIRED MACHINE
After the machine is repaired or serviced, it
must be tested to confirm that its
operational performance was restored by
the repair and/or service work done.
7-2
2. TERMINOLOGY
1) STANDARD
Specifications applied to the brand-new
machine, components and parts.
2) SERVICE LIMIT
The lowest acceptable performance level.
When the performance level of the machine
falls below this level, the machine must be
removed from work and repaired.
Necessary parts and components must be
replaced.
7-3
3. OPERATION FOR PERFORMANCE TESTS
1) Observe the following rules in order to carry
out performance tests accurately and
safely.
(1) The machine
Repair any defects and damage found,
such as oil or water leaks, loose bolts,
cracks and so on, before starting to test.
(2) Test area
ڸSelect a hard, flat surface.
Secure enough space to allow the
ڹmachine to run straight more than 20m,
and to make a full swing with the front
attachment extended.
ںIf required, rope off the test area and
provide signboards to keep unauthorized
personnel away.
(3) Precautions
ڸBefore starting to test, agree upon the
signals to be employed for communication
among coworkers. Once the test is
started, be sure to communicate with
each other using these signals, and to
follow them without fail.
ڹOperate the machine carefully and
always give first priority to safety.
ںWhile testing, always take care to avoid
accidents due to landslides or contact
with high voltage power lines. Always
confirm that there is sufficient space for
full swings.
ڻAvoid polluting the machine and the
ground with leaking oil. Use oil pans to
catch escaping oil. Pay special attention
to this when removing hydraulic pipings.
7-4
(4) Make precise measurements
ڸAccurately calibrate test instruments in
advance to obtain correct data.
ڹCarry out tests under the exact test
conditions prescribed for each test item.
ںRepeat the same test and confirm that
the test data obtained can be procured
repeatedly. Use mean values of
measurements if necessary.
7-5
2) ENGINE SPEED
(1) Measure the engine speed at each power
mode
Ɠ The engine speed at each power mode
must meet standard RPM; if not, all other
operational performance data will be
unreliable. It is essential to perform this
test first.
(2) Preparation
ڸWarm up the machine, until the engine
coolant temperature reaches 50Ƅor
Ź5Ƅ.
more, and the hydraulic oil is 50Ň
ڹPush the H-mode switch and confirm
that the fuel injection pump governor
lever comes into contact with the high-
idle stopper.
ںTo measure engine RPM:
(3) Measurement
ڸStart the engine. The engine will run at
start idle speed. Measure engine speed
with a tachometer.
ڹMeasure and record the engine speed at
each mode(H.S.L.F)
ںSelect the H-mode.
ڻLightly operate the bucket control lever a
few times, then return the control lever to
neutral; the engine will automatically
enter the auto-idle speed after 4seconds.
ڼMeasure and record the one touch
deceleration speed.
7-6
(4) Evaluation
The measured speeds should meet the following specifications.
Unit : rpm
Model Engine speed Standard Remarks
Start idle 1000 Ź100
H mode 2050 + 50
S mode 2050 + 50
R290LC-3
L mode 1850 + 50
F mode 1550 + 50
One touch decel 1000Ź 100
7-7
1) TRAVEL-SPEED
(1) Measure the time required for the
excavator to travel a 20m test track.
(2) Preparation
ڸAdjust the tension of both tracks to be
equal.
ڹPrepare a flat and solid test track 20m in
length, with extra length of 3 to 5m on
both ends for machine acceleration and 0.3~0.5m
deceleration.
ںHold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
ڻKeep the hydraulic oil temperature at 50Ň
Ź5Ƅ.
(3) Measurement
ڸMeasure both the medium and fast
speeds of the machine.
ڹBefore starting either the medium or fast
speed tests, adjust the travel mode
switch to the speed to be tested, then
select the following switch positions: 20m 3~5m
3~5m
ş Mode selector : H mode
ںStart traveling the machine in the
acceleration zone with the travel levers
at full stroke.
ڻMeasure the time required to travel 20m.
ڼAfter measuring the forward travel
speed, turn the upperstructure 180Ňand
measure the reverse travel speed.
ڽRepeat steps(4) and (5) three times in
each direction and calculate the average
values.
(4) Evaluation
The average measured time should meet the following specifications:
Unit : seconds/20m
Model Travel speed Standard Maximum allowable Remarks
1 speed 21.9Ź2.0 28.5
R290LC-3
2 speed 14.8Ź1.0 18.5
7-8
4) TRACK REVOLUTION SPEED
(1) Measure the track revolution cycle time
with the track raised off ground.
(2) Preparation
ڸAdjust the tension of both side tracks to
be equal.
ڹOn the track to be measured, mark one
90~110Ň
shoe with chalk.
ںSwing the upperstructure 90Ňand lower
the bucket to raise the track off ground. Mark
Keep the boom-arm angle between 90
to 110Ňas shown. Place blocks under
machine frame.
ڻKeep the hydraulic oil temperature at
50Ň Ź5Ƅ.
(3) Measurement
ڸSelect the following switch positions:
ş Travel mode switch : 2 speed
ş Mode selector : H mode
ş Auto idle switch : OFF
ڹOperate the travel control lever of the
raised track in full forward and reverse.
ںRotate 1 turn, then measure time taken
for next 3 revolutions.
ڻRaise the other side of machine and
repeat the procedure.
ڼRepeat steps ںand ڻthree times and
calculate the average values.
(4) Evaluation
The revolution cycle time of each track should meet the following specifications:
Unit : Seconds / 3 revolutions
Model Travel speed Standard Maximum allowable
R290LC-3 2 speed 23.0Ź2.0 30
7-9
5) TRAVEL DEVIATION
(1) Measure the deviation by the tracks from
a 20m straight line.
(2) Preparation
ڸAdjust the tension of both tracks to be
equal.
ڹProvide a flat, solid test yard 20m in
0.3~0.5m
length, with extra length of 3 to 5m on
both ends for machine acceleration and
deceleration.
ںHold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
ڻKeep the hydraulic oil temperature at 50Ň
Ź5Ƅ.
(3) Measurement
ڸMeasure the amount of mistracking at
fast, medium and slow travel speeds.
ڹBefore beginning each test, select the
following switch positions: 3~5m extra length
M
20
ںStart traveling the machine in the
acceleration zone with the travel levers
at full stroke. 3~5m extra length
ڻMeasure the distance between a straight
20m line and the track made by the
machine.(dimension a)
ڼAfter measuring the tracking in forward
travel, turn the upperstructure 180Ňand
measure that in reverse travel.
ڽRepeat steps ڻand ڼthree times and
calculate the average values.
(4) Evaluation
Mistrack should be within the following specifications:
Unit : mm/20m
Model Standard Maximum allowable Remarks
R290LC-3 200 240
7 - 10
6) SWING SPEED
(1) Measure the time required to swing three
complete turns.
(2) Preparation
ڸCheck the lubrication of the swing gear
and swing bearing.
ڹPlace the machine of flat, solid ground
with ample space for swinging. Do not 1m
conduct this test on slopes.
ںWith the arm rolled out and bucket rolled
in, hold the bucket so that the height of
the bucket pin is the same as the boom
foot pin. The bucket must be empty.
ڻKeep the hydraulic oil temperature at
50Ň Ź5Ƅ.
(3) Measurement
ڸSelect the following switch positions:
ş MODE selector : H mode
ڹOperate swing control lever fully.
ںSwing 1 turn, and measure time taken to
swing next 3 revolutions.
ڻRepeat steps(3) and (4) three time and
calculate the average values.
(4) Evaluation
The time required for 5 swings should meet the following specifications:
7 - 11
7) SWING FUNCTION DRIFT CHECK
(1) Measure the swing drift on the bearing
outer circumference when stopping after
a 90Ňfull speed swing.
(2) Preparation
ڸCheck the lubrication of the swing gear
and swing bearing.
ڹPlace the machine on flat, solid ground
with ample space for swinging. Do not 1.5m
conduct this test on slopes.
ںWith the arm rolled out and bucket rolled
in, hold the bucket so that the height of
the bucket pin is the same as the boom
foot pin. The bucket must be empty.
ڻMake two chalk marks: one on the swing
bearing and one directly below it on the
track frame.
ڼSwing the upperstructure 90Ş
ڽKeep the hydraulic oil temperature at
50Ş Ź5Ƅ.
(3) Measurement
ڸConduct this test in the H mode.
ڹSelect the following switch positions:
ş MODE selector : H mode
ںOperate the swing control lever fully and Drift angle
return it to the neutral position when the Swing stop
mark on the upperstructure aligns with
that on track frame after swinging 90Ň
ڻMeasure the distance between the two 90Ňswing
marks.
ڼAlign the marks again, swing 90Ň, then Swing start
7 - 12
8) SWING BEARING PLAY
(1) Measure the swing bearing play using a
dial gauge to check the wear of bearing
races and balls.
(2) Preparation
ڸCheck swing bearing mounting cap
screws for loosening.
ڹCheck the lubrication of the swing
bearing. Confirm that bearing rotation is
smooth and without noise.
ںInstall a dial gauge on the track frame as
shown, using a magnetic base.
ڻPosition the upperstructure so that the
boom aligns with the tracks facing
towards the front idlers.
ڼPosition the dial gauge so that its needle
point comes into contact with the bottom
face of the bearing outer race.
ڽBucket should be empty.
(3) Measurement Measurement :(h1)
ڸWith the arm rolled out and bucket rolled
in, hold the bucket so that the height of
the bucket pin is the same as the boom
foot pin. Record the dial gauge
reading(h1)
ڹLower the bucket to the ground and use Measurement :(h2)
it to raise the front idler 50 cm. Record
the dial gauge reading(h2)
ںCalculate bearing play(H) from this
data(h1 and h2) as follows:
H=h2-h1
(4) Evaluation
The measured drift should be within the following specifications:
1. PURPOSE Unit : mm
Model Standard Maximum allowable Remarks
R290LC-3 0.5}1.5 3.0
7 - 13
9) HYDRAULIC CYLINDER CYCLE TIME
(1) Measure the cycle time of the boom,
(standard) arm, and(standard) bucket
cylinders.
(2) Preparation şBoom cylinder
Raise
ڸTo measure the cycle time of the boom
cylinders:
With the arm rolled out and the empty
bucket rolled in, lower the bucket to the Lower
ground, as shown.
ڹTo measure the cycle time of the arm
cylinder: şArm cylinder
With the empty bucket rolled in, position Roll out
Roll in
the arm so that it is vertical to the ground.
Ň
Lower the boom until the bucket is 0.5m
90
above the ground. 0.5m
ںTo measure the cycle time of the bucket
cylinder:
The empty bucket should be positioned şBucket cylinder
at midstroke between roll-in and roll-out,
so that the sideplate edges are vertical to
the ground.
ڻKeep the hydraulic oil temperature at Roll in Roll out
7 - 14
- Bucket cylinders
Measure the time it takes to roll in the
bucket, and the time it takes to roll out
the bucket. To do so, position the
bucket at one stroke end, then move the
control lever to the other stroke end as
quickly as possible.
- Repeat each measurement 3 times and
calculate the average values.
(4) Evaluation
The average measured time should meet the following specifications:
1) 1. PURPOSE Unit : seconds
Model Function Standard Maximum allowable Remarks
Boom raise 3.6Ź0.4 4.7
Boom lower 2.5Ź0.3 3.3
R290LC-3 Arm in 4.0Ź0.4 5.2
Arm out 3.4Ź0.3 4.4
Bucket load 4.4Ź0.4 5.7
Bucket dump 2.6Ź0.3 3.4
7 - 15
10) DIG FUNCTION DRIFT CHECK
(1) Measure dig function drift, which can be
caused by oil leakage in the control valve
and boom, (standard) arm, and
(standard) bucket cylinders, with the
loaded bucket.
When testing the dig function drift just
after cylinder replacement, slowly operate
each cylinder to its stroke end to purge
air.
(2) Preparation
ڸLoad bucket fully. In lieu of loading the
bucket, weight(W) of the following
specification can be used.
şW=M3ź1.5
1.5m
Where :
M3 =Bucket heaped capacity (m3)
1.5=Soil specific gravity
ڹPosition the arm cylinder with the rod 20
to 30mm extended from the fully retracted
position.
ںPosition the bucket cylinder with the rod
20 to 30mm retracted from the fully
extended position.
ڻWith the arm rolled out and bucket rolled
in, hold the bucket so that the height of
the bucket pin is the same as the boom
foot pin.
ڼKeep the hydraulic oil temperature at
50Ş Ź5Ƅ
(3) Measurement
ڸStop the engine.
ڹFive minutes after the engine has been
stopped, measure the changes in the
positions of the bottom of the bucket, as
well as the boom, arm and bucket
cylinders.
ںRepeat step(2) three times and calculate
the average values.
7 - 16
(4) The measured drift should be within the following specifications:
Unit : mm/5min
Model Drift to be measured Standard Maximum allowable Remarks
Boom cylinder 40Ź7 55
R290LC-3 Arm cylinder 60Ź7 75
Bucket cylinder 60
7 - 17
11) CONTROL LEVER OPERATING FORCE
(1) Use a spring scale to measure the
maximum resistance of each control lever
at the middle of the grip.
(2) Preparation
ڸKeep the hydraulic oil temperature at
50ŞŹ5Ƅ
(3) Measurement
ڸStart the engine.
ڹSelect the following switch positions:
şMODE H mode
ںOperate each boom, arm, bucket and
swing lever at full stroke and measure
the maximum operating force for each.
ڻLower the bucket to the ground to raise
one track off the ground. Operate the
travel lever at full stroke and measure
the maximum operating force required.
When finished, lower the track and then
jack-up the other track.
ڼRepeat steps(3) and (4) three times and
calculate the average values.
(4) Evaluation
The measured operating should be within the following specifications
Unit : kgf
Model Kind of lever Standard Maximum allowable Remarks
Boom lever 1 or below 1.2
Arm lever 1 or below 1.2
R290LC-3 Bucket lever 1 or below 1.2
Swing lever 1 or below 1.2
Travel lever 1.8 or below 2.5
7 - 18
12) CONTROL LEVER STROKE
(1) Measure each lever stroke at the lever
top using a ruler.
Ɠ When the lever has play, take a half of
this value and add it to the measured
stroke.
(2) Preparation
Keep the hydraulic oil temperature at
50ŇŹ5Ƅ.
(3) Measurement
ڸStop the engine.
ڹMeasure each lever stroke at the lever
top from neutral to the stroke end using
a ruler.
ںRepeat step(2) three times and calculate
the average values.
(4) Evaluation
The measured drift should be within the following specifications:
Unit : mm
Model Kind of lever Standard Maximum allowable Remarks
Boom lever 60Ź10 78
Arm lever 60Ź10 78
R290LC-3 Bucket lever 60Ź10 78
Swing lever 60Ź10 78
Travel lever 150Ź10 195
7 - 19
13) PILOT PRIMARY PRESSURE
(1) Preparation
ڸStop the engine.
ڹRemove the top cover of the hydraulic
tank oil supply port with a wrench.
Loosen and remove plug on the pilot
ںpump delivery port and connect pressure
gauge.
ڻStart the engine and check for oil
leakage from the port.
ڼKeep the hydraulic oil temperature at
50Ş Ź5Ƅ.
(2) Measurement
ڸSelect the following switch positions:
şMODE selector : H mode
şAuto-idle switch : OFF
ڹMeasure the primary pilot pressure in the
H mode.
(3) Evaluation
The average measured pressure should meet the following specifications:
Unit : kgf / ֲ
Model Engine speed Standard Allowable limits Remarks
R290LC-3 H mode 40Ź5 -
7 - 20
14) FOR TRAVEL SPEED SELECTING PRESSURE:
(1) Preparation
ڸStop the engine.
ڹRemove the top cover of the hydraulic
tank oil supply port with a wrench.
ںPush the pressure release button to
bleed air.
ڻTo measure the speed selecting pressure:
Install a connector and pressure gauge
assembly to turning joint E port as shown.
ڼStart the engine and check for on
leakage from the adapter.
ڽKeep the hydraulic oil temperature at
50Ş Ź5Ƅ.
(2) Measurement
ڸSelect the following switch positions:
Travel mode switch : 1 speed
2 speed
ş MODE selector : H mode
ڹMeasure the travel speed selecting
pressure in the Hi or Low mode.
ںLower the bucket to the ground to raise
the track off the ground. Operate the
travel lever at full stroke and measure
the fast speed pressure.
ڻRepeat steps(2) and (3) three times and
calculate the average values.
(3) Evaluation
The measured drift should be within the following specifications:
Unit : kgf / ֲ
Model Travel speed mode Standard Allowable limits Remarks
1 speed 0 -
R290LC-3
2 speed 40 Ţ5 -
7 - 21
15) SWING PARKING BRAKE RELEASING PRESSURE
(1) Preparation
ڸStop the engine.
ڹRemove the top cover of the hydraulic
tank oil supply port with a wrench.
ںThe pressure release L wrench to bleed
air.
ڻInstall a connector and pressure gauge
assembly to swing motor SH port, as
shown.
ڼStart the engine and check for oil
leakage from the adapter.
ڽKeep the hydraulic oil temperature at
50Ş Ź5Ƅ.
(2) Measurement
ڸSelect the following switch positions:
şMODE selector : H mode
ڹOperate the swing function or arm roll in
function and measure the swing brake
control pressure with the brake
disengaged. Release the control lever
to return to neutral and measure the
control pressure when the brake is
applied.
Repeat step(2) three times and calculate
the average values.
(3) Evaluation
The measured drift should be within the following specifications:
Unit : kgf / ֲ
Model Standard Allowable limits Remarks
Brake disengaged 26 -
R290LC-3
Brake applied Less than 2 -
7 - 22
16) MAIN PUMP DELIVERY PRESSURE
(1) Preparation
ڸStop the engine.
ڹRemove the top cover of the hydraulic
tank oil supply port with a (+) driver.
ںPush the pressure release button to
bleed air.
ڻTo measure the main pump pressure :
Install a connector and pressure gauge
assembly main pump gauge port as
shown.
ڼStart the engine and check for oil
leakage from the port.
ڽKeep the hydraulic oil temperature at
50Ň Ź5Ƅ.
(2) Measurement
ڸSelect the following switch positions:
ş MODE selector : H mode
ڹMeasure the main pump delivery
pressure in the H mode(fast idle).
(3) Evaluation
The average measured pressure should meet the following specifications:
Unit : kgf / ֲ
Model Engine speed Standard Allowable limits Remarks
R290LC-3 fast idle 30Ź5 -
7 - 23
17) SYSTEM PRESSURE REGULATOR RELIEF SETTING
(1) Preparation
ڸStop the engine.
ڹRemove the top cover of the hydraulic
tank oil supply port with a wrench.
ںPush the pressure release button to
bleed air.
ڻTo measure the system relief pressure :
Install a connector and pressure gauge
assembly main pump gauge port, as
shown.
ڼStart the engine and check for oil
leakage from the port.
ڽKeep the hydraulic oil temperature at
50Ň Ź5Ƅ.
(2) Measurement
ڸSelect the following switch positions:
şMODE selector : H mode
ڹSlowly operate each control lever of
boom, arm and bucket functions at full
stroke over relief and measure the
pressure.
ںIn the swing function, place bucket
against an immovable object and
measure the relief pressure.
ڻIn the travel function, lock undercarriage
with an immovable object and measure
the relief pressure.
(3) Evaluation
The measured drift should be within the following specifications:
Unit : kgf / ֲ
Model Function to be tested Normal Over load
Boom, Arm, Bucket 320+5 350
R290LC-3 Travel 320+5 -
Swing 270 -
7 - 24
GROUP 2 MAJOR COMPONENT
1. MAIN PUMP
3 1 2
9 6 5 4 7
Standard Recommended
Part name & inspection item replacement Countermeasures
dimension value
Clearance
between piston(1) & Replace
d D 0.043 0.070 piston or
cylinder bore(2)
(D-d) cylinder.
Play between
piston(1) & shoe caulking 0-0.1 0.3
section(3)
(҇) Replace
assembly of
Thickness of shoe ҇ piston & shoe.
(t) t 5.4 5.0
7 - 24
2. MAIN CONTROL VALVE
Casing ňScratch, rust and corrosion ňReplace parts that have damage on
the following areas:
- Sliding surface between casing hole
and spool, particularly the land area.
- Seal pocket section into which spool
enters.
- Sealing area to which O-ring contact.
- Sealing area of main, travel and port
relief valves.
- Other areas which may be deemed
to mar normal functions.
Spool ňScratch, binding, rust and corrosion ňReplace a spool with a scratch that
may be caught by your nail
(particularly on an area in contact with
seals).
ňO-ring seals on both ends ňReplace such a spool having a
scratch on its sliding surface.
ňInsert spool into casing hole, rotate ňCorrect or replace such a spool that
and stroke it. may damage O-rings or that does it
operate smoothly.
Poppet ňDamage of poppet and spring ňCorrect or replace such a poppet that
gives incomplete sealing effect.
ňInsert poppet into casing and function ňPoppet is normal if it functions lightly
it. without binding.
Spring and ňInspect that spring, spring seat, plugs ňReplace those showing excessive
associated parts and covers are not rusted, corroded, damage.
deformed and broken.
7 - 25
3. SWING MOTOR
Standard Recommended
Part name & inspection item replacement Countermeasures
dimension value
Clearance
between piston & Replace
d D 0.028 0.058 piston or
cylinder bore
(D-d) cylinder.
Play between
piston & shoe caulking 0 0.3
section
(҇) Replace
assembly of
Thickness of shoe ҇ piston & shoe.
(t) t 5.5 5.3
Friction plate
4.0 3.6 Replace
SURFACE ROUGHNESS
7 - 26
4. TRAVEL MOTOR
Replace parts in accordance with the following standards. However, if a part is damaged
significantly in terms of its appearance, replace it irrespective of the standards.
1) Hydraulic Motor
Standard Recommended
Part name ˕ inspection item dimension value for Remedy
replacement
Clearance between piston ˕
0.044 mm 0.065 mm Replacement
cylinder bore
7 - 27
Standard Recommended
Part name ˕ inspection item dimension vaue for Remedy
replacement
Replacement if elongation
Screw
is found.
Replacement if such
Piston ring abnormality as seizure,
deformation, etc, is found.
d D
҇
h H
t
7 - 28
2) Reduction Gear
Standard Recommended
Part name ˕ inspection item dimension value for Remedy
replacement
Pitting area Replacement pitting
Pitting or crack of gear -
rate : 10$ or crack is found
Overpin
No. 1 sun gar internal spline 30.85 mm Replacement (Z=14)
30.25(ܵ5)
Displacement
No. 1 sun gear 42.60 mm Do. (Z=28)
42.90(4teeth)
Reduction
Displacement
ratio No. 1 planetary gear 43.28 m Do. (Z=24)
43.58(4teeth)
i = 67.57
Overpin
Ring gear(1st stage) 302.44 mm Do. (Z=77)
301.84(ܵ7)
Displacement
No. 2 sun gear 39.57 mm Do. (Z=21)
39.87(3teeth)
Displacement
No. 2 planetary gear 54.71 mm Do. (Z=26)
55.01(4teeth)
Overpin
No. 2 carrier internal spline 112.84 mm Do. (Z=25)
112.24(ܵ10)
Displacement
No. 3 sun gear 39.86 mm Do. (Z=25)
40.16(3teeth)
Displacement
No. 3 planetary gear 39.76 mm Do. (Z=24)
40.09(3teeth)
Overpin
No. 3 carrier internal spline 158.13 mm Do. (Z=52)
157.53(ܵ5.486)
Overpin
Casing external spline 173.88 mm Replacement. (Z=52)
174.48(ܵ6.096)
Overpin
Ring gears (2nd ˕ 3rd stages) 373.19 mm Do. (Z=75)
372.59(ܵ7.2)
7 - 29
Standard Recommended
Part name ˕ inspection item dimension value for Remedy
replacement
Radial clearance of needle Replacement of abnormal
0.01-0.04 mm 0.07 mm
bearing parts as a set.
Replacement if such
Crack of spline coupling area - - damage as crack, crevice
of chipping is found.
Replacement of scratch
or rust is found in sliding
Floating seal - - surface.
Replacement if O-ring is
deformed of damaged.
7 - 30
5. RCV LEVER
Spool This is to be replaced when the sliding surface The leakage at the left condition
has worn more than 10֭compared with the is estimated to be nearly equal
non-sliding surface. to the above leakage.
Push rod
ٻ7
1ׅ
Play at operating The pin, shaft, and joint of the operating section
When a play is due to looseness
section are to be replaced when their plays become
of a tightened section, adjust it.
more than 2mm due to wears or so on.
Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However,
they may be reused, after being confirmed to be free of damage.
2. When loosening the hexagon socket head cap screw(125), replace the seal washers(121)
without fail.
7 - 31
6. RCV PEDAL
Spool This is to be replaced when the sliding surface The leakage at the left condition
has worn more than 10֭, compared with the is estimated to be nearly equal
non-sliding surface. to the above leakage.
Push rod
ٻ7
1ׅ
Play at operating The pin, shaft, and joint of the operating section When a play is due to looseness
section are to be replaced when their plays become of a tightened section, adjust it.
more than 2mm due to wears or so on.
Notes 1. It is desirable to replace seal materials, such as O-rings, every disassembling. However,
they may be reused, after being confirmed to be free of damage.
7 - 32
7. TURNING JOINT
Cover Sliding surface ňWorn more than 0.5mm (0.02in) or abnormality. Replace
with thrust plate. ňWorn less than 0.5mm (0.02in). Smooth
ňDamage due to seizure or contamination
remediable within wear limit (0.5mm(0.02in).
- Extrusion
Square ring
Seal set -
1.5mm(max.)
(0.059in)
7 - 33
8. CYLINDER
7 - 34
GROUP 3 TRACK AND WORK EQUIPMENT
1. TRACK
1) TRACK ROLLER
2
6
1
3 4
Unit :mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Outside diameter of flange
ٻ216
Rebuild or
2 Outside diameter of tread ٻ180 ٻ168
replace
3 Width of tread 49 55
4 Width of flange 27 -
Standard Tolerance Standard Clearance
Clearance between shaft size Shaft Hole clearance limit
5
and bushing -0.215 +0.127 0.140
ٻ65 1.5 Replace
-0.315 +0.075 to 0.442
Standard Tolerance Standard Interference bushing
Interference between roller size Shaft Hole Interference limit
6
and bushing +0.108 +0.006 0.014
ٻ72 -
+0.008 -0.036 to 0.144
Standard clearance Clearance limit
7 Side clearance of roller Replace
0.2 to 0.6 1.5
7 - 35
2) CARRIER ROLLER
4 3
5
6
1
2
Unit :mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Outside diameter of flange
ٻ200
Rebuild or
2 Outside diameter of tread ٻ168 ٻ158
replace
3 Width of tread 54 62
4 Width of flange 18.25 -
Standard size &Tolerance Standard Clearance
Clearance between shaft Shaft Hole clearance limit Replace
5
and support +0.085 +0.370 +0.396 bushing
ٻ55 +0.066
ٻ55 +0.330
1.5
to +0.455
Interference between shaft +0.125 +0.03 0.06
6 ٻ65 ٻ65 - Replace
and seal guard +0.090 0 to 0.155
7 - 36
3) IDLER
7
1
2
3 5
4
Unit :mm
No. Check item Criteria Remedy
Outside diameter of Standard size Repair limit
1
protrusion ٻ646
2 Outside diameter of tread ٻ594 ٻ575 Rebuild or
3 Width of protrusion 104 - replace
4 Total width 203 -
5 Width of tread 50.5 55.5
Standard size &Tolerance Standard Clearance
Clearance between shaft Shaft Hole clearance limit Replace
6
and bushing 0 +0.35 0.35 bushing
ٻ85 ٻ85 1.5
-0.035 0.40 to 0.435
Clearance between shaft 0 +0.090 0.036
7 ٻ85 -0.035
ٻ85 +0.036 to 0.125
0.15 Replace
and support
Side clearance of idler Standard clearance Clearance limit
8 Replace
(both side) 0.4 to 1.0 2.0
7 - 37
4) TRACK
2 1 6
5
4
3
Unit :mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Link pitch Turn or
203.2 207.2
replace
2 Outside diameter of bushing 66.9 61.65
3 Height of grouser 26 19 Rebuild or
4 Height of link 116.4 108.4 replace
Standard size &Tolerance Standard Interference
Interference between Shaft Hole interference limit
5
bushing and link +0.05 +0.07 0.020
ٻ66.65 -0 ٻ66.27 -0 to
0.015
0.120
Replace
Interference between +0.1 +0.03 0.070 0.05
6 ٻ44.45 ٻ44.13
regular pin and link 0 0 to 0.130
7 - 38
5) TRACK FRAME AND RECOIL SPRING
2
1
Unit :mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
+2
1 Vertical width of idler guide Track frame 123 -1 127
0
Idler support 120 -1.5 116 Rebuild or
replace
+3
Track frame 292 -1 297
2 Horizontal width of idler guide
Idler support 290 - 288
Standard size Repair limit
7 - 39
2. WORK EQUIPMENT
A C D E F
B K J I H G
Unit :mm
Criteria Criteria
Remedy
Measuring point Normal Recomm. Limit Recomm. Limit &
Mark value service
(Pin and Bushing) of service of Remark
limit use limit use
A Boom Rear 100 99 98.5 100.5 101 Replace
B Boom Cylinder Head 90 89 88.5 90.5 91 ţ
C Boom Cylinder Rod 100 99 98.5 100.5 101 ţ
D Arm Cylinder Head 90 89 88.5 90.5 91 ţ
E Boom Front 100 99 98.5 100.5 101 ţ
F Arm Cylinder Rod 90 89 88.5 90.5 91 ţ
G Bucket Cylinder Head 90 89 88.5 90.5 91 ţ
H Arm Link 80 79 78.5 80.5 81 ţ
I Bucket and Arm Link 80 79 78.5 80.5 81 ţ
J Bucket Cylinder Rod 80 79 78.5 80.5 81 ţ
K Bucket Link 80 79 78.5 80.5 81 ţ
7 - 40
SECTION 8 DISASSEMBLY AND ASSEMBLY
GROUP 1 PRECAUTIONS
1. REMOVAL WORK
1) Lower the work equipment completely to the ground.
If the coolant contains antifreeze, dispose of it correctly.
2) After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
3) When draining oil, prepare a container of adequate size to catch the oil.
4) Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
5) To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors.
6) Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
7) Check the number and thickness of the shims, and keep in a safe place.
8) When raising components, be sure to use lifting equipment of ample strength.
9) When using forcing screws to remove any components, tighten the forcing screws alternately.
10) Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
11) When removing hydraulic equipment, first release the remaining pressure inside the hydraulic tank
and the hydraulic piping.
12) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
number D A L
06 6 5 8
08 8 6.5 11
10 10 8.5 12
12 12 10 15
14 14 11.5 18 Taper 1/8
ܵD ܵd
16 16 13.5 20
18 18 15 22
20 20 17 25
L
22 22 18.5 28
24 24 20 30
27 27 22.5 34
8-1
2. INSTALL WORK
1) Tighten all bolts and nuts(sleeve nuts) to the specified torque.
2) Install the hoses without twisting or interference.
3) Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
4) Bend the cotter pin or lock plate securely.
5) When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2-3 drops of adhesive.
6) When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
7) Clean all parts, and correct any damage, dents, burrs, or rust.
8) Coat rotating parts and sliding parts with engine oil.
9) When press fitting parts, coat the surface with antifriction compound (LM-P)
10) After installing snap rings, check that the snap ring is fitted securely in the ring groove(check that the
snap ring moves in the direction of rotation).
11) When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
12) When using eyebolts, check that there is no deformation or deterioration, and screw them in fully.
13) When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
14) When operating the hydraulic cylinders for the first time after repairing and reassembling the
hydraulic cylinders, pumps, or other hydraulic equipment or piping, always bleed the air from the
hydraulic cylinders as follows:
(1) Start the engine and run at low idling.
(2) Operate the control lever and actuate the hydraulic cylinder 4-5 times, stopping 100mm
(3) before the end of the stroke.
(4) Next, operate the piston rod to the end of its stroke to relieve the circuit. (The air bleed valve is
actuated to bleed the air.)
After completing this operation, raise the engine speed to the normal operating condition.
Ɠ If the hydraulic cylinder has been replaced, carry out this procedure before assembling the rod to
the work equipment.
Ɠ Carry out the same operation on machines that have been in storage for a long time after
completion of repairs.
8-2
3. COMPLETING WORK
1) If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
2) If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
3) If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been
removed for repair, always bleed the air from the system after reassembling the parts.
4) Add the specified amount of grease(molybdenum disulphied grease) to the work equipment related
parts.
8-3
GROUP 2 TIGHTENING TORQUE
1. MAJOR COMPONENT
Torque
No. Descriptions Bolt size
Ɠ For tightening torque of engine and hydraulic components, see each components disassembly and
assembly.
8-4
2. TORQUE CHART
The torques given are standard figures. Any figures specifically described in this manual has priority.
1) METRIC BOLT-coarse thread
8T 10T
Bolt size
kgfşm lbfşft kgfşm lbfşft
M 6 ź 1.0 0.9 ~ 1.3 6.5 ~ 9.4 1.1 ~ 1.7 A8.0 ~ 12.3
M 8 ź 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7
M10 ź 1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60.0
M12 ź 1.75 7.4 ~ 11.2 53.5 ~ 81.0 9.8 ~ 15.8 70.9 ~ 114.3
M14 ź 2.0 12.2 ~ 16.6 88.2 ~ 120.0 16.7 ~ 22.5 120.8 ~ 162.7
M16 ź 2.0 18.6 ~ 25.2 134.5 ~ 182.3 25.2 ~ 34.2 182.3 ~ 247.4
M18 ź 2.0 25.8 ~ 35.0 186.6 ~ 253.2 35.1 ~ 47.5 253.9 ~ 343.6
M20 ź 2.5 36.2 ~ 49.0 261.8 ~ 354.4 49.2 ~ 66.6 355.9 ~ 481.7
M22 ź 2.5 48.3 ~ 63.3 349.4 ~ 457.8 65.8 ~ 98.0 475.9 ~ 708.8
M24 ź 3.0 62.5 ~ 84.5 452.1 ~ 611.2 85.0 ~ 115.0 614.8 ~ 831.8
M30 ź 3.0 124.1 ~ 167.9 897.6 ~ 1214.4 169.1 ~ 228.9 1223.1 ~ 1655.6
M36 ź 4.0 174.3 ~ 235.6 1260.7 ~ 1704.0 250.0 ~ 310.0 1808.3 ~ 2242.2
8T 10T
Bolt size
kgfşm lbfşft kgfşm lbfşft
M 8 ź 10 2.2 ~ 3.4 15.9 ~ 24.6 3.0 ~ 4.4 21.7 ~ 31.8
M10 ź 1.2 4.5 ~ 6.7 32.5 ~ 48.5 5.9 ~ 8.9 42.7 ~ 64.4
M12 ź 1.25 7.8 ~ 11.6 56.4 ~ 83.9 10.6 ~ 16.0 76.7 ~ 115.7
M14 ź 1.5 13.3 ~ 18.1 96.2 ~ 130.9 17.9 ~ 21.1 129.5 ~ 174.3
M16 ź 1.5 19.9 ~ 26.9 143.9 ~ 194.6 26.6 ~ 36.0 192.4 ~ 260.4
M18 ź 1.5 28.6 ~ 43.6 206.9 ~ 315.4 38.4 ~ 52.0 277.7 ~ 376.1
M20 ź 1.5 40.0 ~ 54.0 289.3 ~ 390.6 53.4 ~ 72.2 386.2 ~ 522.2
M22 ź 1.5 52.7 ~ 71.3 381.2 ~ 515.7 70.7 ~ 95.7 511.4 ~ 692.2
M24 ź 2.0 67.9 ~ 91.9 491.1 ~ 664.7 90.9 ~ 123.1 657.5 ~ 890.4
M30 ź 2.0 136.9 ~ 185.1 990.2 ~ 1338.8 181.7 ~ 248.3 1314.2 ~ 1796.0
M36 ź 3.0 192.1 ~ 259.9 1389.5 ~ 1879.9 261.8 ~ 354.2 1893.6 ~ 2561.9
8-5
3) PIPE & HOSE
1/4" 19 3 21.7
3/8" 22 4 28.9
1/2" 27 5 36.2
3/4" 36 12 86.8
1" 41 14 101.3
4) FITTING
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 6 43.4
3/4" 36 13 94.0
1" 41 15 108.5
8-6
GROUP 3 PUMP DEVICE
8-7
2) INSTALL
(1) Carry out installation in the reverse order
to removal
(2) Remove the suction strainer and clean it.
(3) Replace return filter with new.
(4) Remove breather and clean it.
(5) After adding oil to the hydraulic tank to the
specified level.
(6) Bleed the air from the hydraulic pump.
ڸRemove the air vent plug(2EA)
ڹTighten plug lightly
ںStart the engine, run at low idling, and
check oil come out from plug.
ڻTighten plug.
(7) Start the engine, run at low idling (3~5
minutes) to circulate the oil through the
system.
(8) Confirmed the hydraulic oil level and
check the hydraulic oil leak or not.
8-8
2. MAIN PUMP(1/2)
1) STRUCTURE
A
789 532 548 724 792 954
732 214 531 702 534 901 719
535
808
953
886
717
406
261
824
111
774
127
710
123 251 401 211 156 157 313 312 725 314 468 141 152 113
490 212 153 158 114 124 466 885 728 151 271
8-9
MAIN PUMP(2/2)
544
542
543
545
541 (079)
725
726
466
725
325
407
VIEW A
8-10
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.
8-11
(2) Tightening torque
8-12
3. REGULATOR
1) STRUCTURE(1/2)
615
613
A 611
B
A
KR3H - 9N29
P2
438 Pf
801 Pi
924
413 438
438
656
Pi
735
8-19
REGULATOR(2/2)
734 653 654 836 651 652 601 624 629 630 628
655
641 801
C
814 925
898
631 627
732
733
732
622
8-20
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
The tools necessary to disassemble/reassemble the pump are shown in the follow list.
B 5 M 6 BP-1/ 8 - M10
6 M 8 BP-1/ 4 PO-1/4 M12, M14
socket wrench, Hexagon Headed VP plug
double(single) open end - Hexagon nut
bolt (PF thread)
B
6 M8 M8 -
Adjustable angle wrench Small size, Max 36mm
Screw driver Minus type screw driver, Medium size, 2 sets
Hammer Plastic hammer, 1 set
Pliers For snap ring, TSR-160
Steel bar Steel bar of key material approx. 10x8x200
Torque wrench Capable of tightening with the specified torques.
Pincers -
Bolt M4, Length : 50mm
8-21
(2) Tightening torque
8-22
GROUP 4 MAIN CONTROL VALVE
2) INSTALL
8-30
2. STRUCTURE(1/3)
42
39
39 80
52
6 53
2 39 41
17 3
7 46 9 57 13
2728 58 14
11 47
26 8 59
4 29
25 11 32
23 4 30
2728 25
33
31
51 30
23
5049
9
10
40
18 39
34
35
14
13
39 54 56
42
79
39
80
8-31
STRUCLTURE(2/3)
64
49
50 55 62
60
55
48
47
60 55
50
49
61 55
55 60
75
74 63
73
61
55
78
65
66 47
76
68 48
69 77
67
71
70
39
72
8-32
STRUCTLURE(3/3)
13
1 29 14
2
3
47 81 32
46 11
30 1615
33 13
30 31 14
12
4 32 29
5 30
33
30 31
9 42 40
39 39
10 8 37 38
7 3 36
2
6
25
18 4 26
19 11
35 28
34 27 17
20 25
14 4 11
13 53 49 28
39 27
50 23 22
52
21 45 3
1516 40 39 44
42 43 2
38
39 24
40 36
37
39
41
8-33
3. DISASSEMBLY AND ASSEMBLY
1) PRECAUTION
(1) Disassembly
ڸHandle the components carefully not to
drop them or bump them with each other
as they are made with precision.
ڹDo not force the work by hitting or
twisting as burred or damaged
component may not be assembled or
result in oil leakaged or low performance.
ںWhen disassembled, tag the
components for identification so that they
can be re-assembled correctly.
ڻOnce disassembled, O-rings and backup
rings are usually not to be used again.
(Remove them using a wire with its end
made like a shoehorn. Be careful not to
damaged the slot.)
ڼIf the components are left disassembled
or half-disassembled, they may get rust
from moisture or dust. If the work has to
be interrupted, take measures to prevent
rust and dust.
(2) Assembly
ڸTake the same precautions as for
disassembly.
ڹWhen assembling the components,
remove any metal chips or foreign
objects and check them for any burrs
or dents. Remove burrs and dents with
oil-stone, if any.
ںO-rings and backup rings are to be
replaced with new ones, as a rule.
ڻWhen installing O-rings and backup
rings, be careful not to damage them.
(Apply a little amount of grease for
smoothness.)
ڼTighten the bolts and caps with specified
torque.
8-34
2) MOUNTING AND DISMOUNTING VALVES
1 2 4 3
(1) Disassembly
ڸRemove socket bolts (1, 2) and separate
3-spool valve(ѓ) from block(є)
ڹRemove socket bolts (3, 4) and separate
4-spool valve(ѕ) from block(є)
(2) Assembly
ڸIn the reverse manner of disassembly,
reassemble 4-spool valve(ѕ).
ڹreassemble 3-spool valve(ѓ).
ںTighten the bolts to the torque of 10kgfň
m (72.3lbfňft)
Ɠ Before reassembly, see if the O-Rings ѓ є ѕ
are fitted in between the blocks.
Tools
ňHexagon socket : 10mm
ňTorque wrench
8-35
3) OPERATING SECTION OF HYDRAULIC PACK
(1) Disassembling
ڸLoosen socket bolt (1) to remove cover
(2). 2 1
(2) Assembling
ڸPlace the plunger between holders and
clamp the holders with the vise.
ڹMount guide (4), spring (5) and plunger
cap (3) to the plunger.
ںTighten plunger cap (3) at the specified
torque.
ڻTightening torque : 6kgfňm (43.4lbfňft)
Restore the plunger to the valve while
holding the spring section.
Ɠ Insert the plunger into the valve hole
while turning it slowly so that it is well
aligned with the HG hole. In particular,
be careful not to hit it against the first
round corner.
ڼInstall cover (2) after making sure that O-
ring is placed on the edge of the valve
hole and tighten socket bolt (1) with the
specified torque.
Tightening torque : 5kgfňm (36.2lbfňft)
8-36
4) LOGIC ASSEMBLY(Boom, Arm)
(1) Disassembling
1
ڸRemove cap (1)
ڹRemove spring (3) and poppet (2).
3
(2) Assembling
2
ڸMount poppet (2) and spring (3) to the
valve housing.
ڹTighten cap (1) at the specified torque.
Ɠ Be careful for the backup ring not
to protrude.
Tightening torque : 8kgfňm (57.9lbfňft)
Tools
ňHexagon socket : 30mm
ňTorque wrench
8-37
5) LOGIC CHECK ASSEMBLY(Boom Operation)
(1) Disassembling 11 10 9
Tools
ňHexagon socket : 32mm
ňTorque wrench
(2) Assembling
ڸReassemble the check valve(11) and the
spring(10).
ڹTighten the plug(9) to the specified
torque of 2kgfňm(14.5lbňft)
ںReassemble sleeve(4) with cap(1) after
inserting spring(3) and piston(2) to the
sleeve(4)
ڻReassemble poppet(8), check valve(7)
and spring(6)
ڼReassemble the cap assembly(1) and
tighten it to specified torque of
6kgf.m(43.4lbfňft)
8-38
6) FOOT RELIEF ASSEMBLY
1 2
(1) Disassembling
ڸRemove valve(1) from valve block.
Ɠ Do not disassemble internal part of valve
assembly because it is not easy to adjust
them.
(2) Assembling
Reassemble valve(1) and tighten the
cap(2) to the specified torque of
6kgf.m(43.4lbňft) Tools
ňHexagon socket : 30mm
ňTorque wrench
8-39
GROUP 5 SWING DEVICE
2) INSTALL
(1) Carry out installation in the reverse order 6
to removal
(2) Bleed the air from the swing motor. 8
ڸRemove the air vent plug. 7
ڹPour in hydraulic oil until it over flows
from the port.
ںTighten plug lightly.
ڻStart the engine, run at low idling, and
check oil come out from plug.
ڼTighten plug fully.
(3) Confirmed the hydraulic oil level and
check the hydraulic oil leak or not.
8-40
2. SWING MOTOR
1) STRUCTURE
993 117 121 118 114 706 707 702 712 472 488 355 351 469 051
106
438
432 444
106 303
443
471
304
101
491
437
124
468
487
433
401
301 994 122 123 113 116 111 742 743 031 131 451
464 485
Section A-A
8-41
3. REMOVAL AND INSTALL OF REDUCTION GEAR
1) REMOVAL
(1) Remove the swing motor assembly.
For details, see removal of swing motor
assembly
(2) Slide reduction gear assembly(1) and
remove mounting bolts(2)
(3) Remove the reduction gear assembly
ş Reduction gear device weight :
260kg(573lb)
2) INSTALL
(1) Carry out installation in the reverse order
to removal.
şMounting bolt : 58.4kgfşm(422.4lbşft)
1
2
8-53
4. REDUCTION GEAR
1) STRUCTURE
102
401
231 312 311
801
911
201
288
211
287
912
286
204 285
403
284
210
282
8-54
2) Inspections
(1) Precautions
This assembly is designed to balance the life time of each part. Therefore, when replacing the
parts, some parts could require another part's replacement at the same time because of their
structural or functional correlations.
(2) Inspections replacement
ڸWhen the pitting happens on a tooth of sun gear, planetary gear or ring gear, replace the
gear.(When a pit size is bigger than ܵ1mm(0.04") or the pits are more than 5 percent of the
tooth.)
ڹReplace the lock pin when loosely installed in the pin groove because of the wearing.
ںReplace the oil seal when damaged or weared. Replace the oil seal when reassembling the
reduction gear assembly.
ڻReplace the No.1 carrier assembly when flaking happens on the sliding surfaces of the No.1
planetary gear.
ڼReplace the No.2 planetary gear assembly when radial clearance of bearing is more than
0.6mm(0.02").
Replace the No.2 planetary gear assembly when removing the output shaft.
ڽReplace the thrust button when the sliding surface of the sun gear is badly damaged.
ھReplace the thrust washer only when it was damaged.
ڿReplace the shaft support bearing when it was damaged. Do not reuse the disassemble shaft
support bearing.
Ɠ Inspect the No.2 planetary gear, thrust button, thrust washer, and shaft support bearing as
in assembly.
3) Disassembly.
(1) Remove the level bar(311) and pipe(312) installed in the swing motor.
(2) Loosen the drain plug in the swing gear box to discharge the gear oil.
Ɠ Check the gear oil for contamination.
(3) Release the bolt(702) and remove the swing motor from is reduction gear assembly.
(4) Release the No.1 sun gear(211).
(5) Release the No.1 carrier assembly including No.1 planetary gear.
(6) Disassemble the No.1 carrier assembly, if necessary.
(7) Release the No.2 sun gear(204) and if necessary, remove the stop ring(915).
(8) Remove the No.1 ring gear(209).
(9) Remove the middle, casing(103).
(10) Remove the output shaft(201) assembly.
(11) Remove the No.2 ring gear(202) front the casing(102).
(12) Remove the oil seal(801) from the front casing(102).
(13) Remove the self-aligning roller bearing(402).
(14) Remove the pin(282).
(15) Remove the spring pin from the output shaft.
(16) Remove the No.2 planetary gear(203) and thrust washer(283).
Ɠ Remove that the above articles(13~16) are applied for only special inspections or
maintenance.
8-55
4) Assembly
(1) Reassemble the output shaft assembly.
ڸInstall the self-aligning roller bearing(4010 in the output shaft(201) after warming it up for about
10 minutes in the oil can at 80Ƅ ~ 100Ƅ(176Ȫ ~ 212Ȫ).
ڹInsert the thrust button(284) in the groove of the output shaft.
ںInsert the thrust plate(283) of No.2 planetary gear(203) in the output shaft(201).
ڻInsert the pin(282) with spring(901) in the pin hole of output shaft.
(2) Insert the oil seal(801) in the front casing(102).
(3) Reassemble the output shaft assembly in the front casing(102).
(4) Insert the 4 lock pins(351) in the front casing(102).
(5) Reassemble the No.2 ring gear(202) after applying grease to the front casing(102).
(6) Reassemble the middle casing(103) after applying grease to the No.2 ring gear.
(7) Reassemble No.2 sun gear(204) with the stop ring(915).
(8) Reassemble the No.1 ring gear(209) after applying grease to the middle casing(103).
(9) Reassemble the No.1 carrier assembly.
ڸInsert the No.1 pin(285)with the spring pin(910) in the No.1 carrier(231).
ڹInsert the spring pin(910) in the No.1 carrier.
ںInsert the side plate(288) in the center of No.1 carrier.
ڻInsert the side plate(286).
ڼInsert the side plate(287) with stop ring(912).
Ɠ See the Table for the sizes of side plates.
(10) Install the No.1 carrier assembly in the No.2 sun gear.
(11) Install the No.1 sun gear(211).
(12) Install the swing motor with stop ring(911) in the No.1 ring fear(209) with grease.
(13) Insert the pin(902) in the drain plug of the gear.
(14) Reassemble the level bar(311) and pipe(312).
(15) Give gear oil.
8-56
GROUP 6 TRAVEL DEVICE
2) INSTALL
(1) Carry out installation in the reverse order
to removal
(2) Bleed the air from the travel motor.
ڸRemove the air vent plug.
ڹPour in hydraulic oil until it over flows
from the port.
ںTighten plug lightly.
ڻStart the engine, run at low idling, and
check oil come out from plug.
ڼTighten plug fully.
(3) Confirmed the hydraulic oil level and
check the hydraulic oil leak or not.
8-57
2. TRAVEL MOTOR
1) STRUCTURE(1/2)
111 742 741 709 707 702 708 461 545 547 472 705 461 303
121
568
123
567
122
116
131
202
452 568
113 567
272
107 464
485
101
491 103
304 451
435 507
471
102 506
105 505
506 511
507
504
510
509 461 501 114 201 502 503 508 512 546 509 461 533 531 572 571
8-58
STRUCTURE(2/2)
366
364
365
711 712
485 713
464
710
350
E
714
702
Section E- E
E
401
567
568
022 C/B Spool sub assy 402 Hex socket screw 568 O - ring
350 Relief valve 464 VP plug 702 Brake piston
361 Washer 485 O - ring 710 Spring guide
362 C/B spring 541 Seat 711 Spool
364 C/B cover 542 Stopper 712 Bushing
365 O - ring 543 Steel ball 713 Spring
366 Hex socket screw 567 VP plug 714 RO plug
401 Hex socket screw
8-59
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
Allen wrench 4
6
B
8
10
14
Socket for socket wrench, spanner 24
27
Torque wrench Capable of tightening with the specified torques.
Pliers -
( - ) Driver 6 ź 100
Plastic and iron hammer Wooden hammer allowed. Nominal 1 or so
Steel rod approx 7 ź 7 ź 200mm
Monkey wrench -
Oil seal inserting jig -
Bearing pliers -
Seal tape -
8-60
3. TRAVEL REDUCTION GEAR
1) STRUCTURE
30 6 27 7 1 31
4
26
46
11
5
45
10
24
32
42
9
25
12
21
15
44
19
18
36
32
16
20 41 22 13 20 36 17 14 23 20 37 8 35 33 2 29 34
8-61
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
Allen wrench 5
8 B
10
17
Socket for socket wrench 19
Spanner 27
Torque wrench Capable of tightening with the specified torques.
Pliers For shaft
( - ) Driver 6 ź 100, For removing floating seal
Hammer Steel and plastic
Eye bolt M10, M20, For lifting-up
Press(1 ton) -
Depth gauge straight edge 100mm depth
Taps M 20, M 12
Oil stone -
Seal tape -
screw lock Three bond 1303B
Liquid packing Three bond 1104
Bearing assembling jig -
8-62
4. DISASSEMBLING
1) General Precautions
(1) Pay attention to not damaging contact surfaces for O-ring, oil seals, etc. and contact/sliding
surfaces for gears, pins, bearings, etc.
(2) This motor can be disassembled even in a state fitted on a machine.
However, in that case, pay full attention to preventing mud, dust, etc. from entering in it.
(3) The numeral in parentheses following each part name indicates its part number shown in the
attached assembly drawings.
(4) The piping side of the motor is referred to as the rear side and the output side, as the front side.
2) Disassembling Procedures
For disassembling, follow the procedures shown below. The procedures are shown for the case
where disassembling is carried out in the order of
A : Reduction Gear and then
B : Hydraulic motor.
8-63
GROUP 7 RCV LEVER
2) INSTALL
3
(1) Carry out installation in the reverse order
to removal.
2
(2) Confirmed the hydraulic oil level and
check the hydraulic oil leak or not.
8-95
2. DISASSEMBLY AND ASSEMBLY
1) STRUCTURE(RH - LEVER)(1/2)
451
402
421
422
453
454
452
401
455
431
458
411 456
457 412
413
501
323
301
459 315
302
312
213
212
211
151
214
215
121
125 216
241
217
221
201
126
101
122
111
8-96
101 Casing 216 spring seat 421 Screw 2
111 Port plate 217 Washer 2 422 Nut
121 Seal washer 221 spring 431 Screw 3
122 O-ring 241 Spring 451 Roller
125 Hexagon socket bolt 301 Joint 452 Lever
126 Spring pin 302 Plate 453 Switch seat 1
131 Bushing 312 Adjusting nut 454 Switch seat 2
151 Plate 315 Lock nut 455 Switch
201 Spool 323 Handle bar 456 Cord
211 Plug 401 Handle 457 Bushing
212 Push rod 402 Handle cap 458 Tube
213 Seal 411 Screw 1 459 Terminal
214 O-ring 412 Nut 501 Bellows
215 washer 1 413 Washer
8-97
2) STRUCTURE(LH - LEVER)(2/2)
451
402
421
422
453
454
452
401
455
431
458
411 456
457 412
413
501
323
301
459 315
302
312
213
212
211
151
214
215
216
241
121
217
125
221
201
126
101
122
292
293
294
111 291
8-98
101 Casing 221 spring 421 Screw 2
111 Port plate 241 Spring 422 Nut
121 Seal washer 291 Seat 431 Screw 3
122 O-ring 292 Steel ball 451 Roller
125 Hexagon socket bolt 293 Plug 452 Lever
126 Spring pin 294 O-ring 453 Switch seat 1
131 Bushing 301 Joint 454 Switch seat 2
151 Plate 302 Plate 455 Switch
201 Spool 312 Adjusting nut 456 Cord
211 Plug 315 Lock nut 457 Bushing
212 Push rod 323 Handle bar 458 Tube
213 Seal 401 Handle 459 Terminal
214 O-ring 402 Handle cap 471 Insulation cap
215 washer 1 411 Screw 1 472 Rubber tube
216 spring seat 412 Nut 501 Bellows
217 Washer 2 413 Washer
8-99
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
Allen wrench 6 B
Spanner 22
27
( + ) Driver Length 150
( - ) Driver wide 4 ~ 5
Torque wrench Capable of tightening with the specified torques.
Torque
Part name Item Size
fşm lbfşft
Port plate 111 PF 1/4 0.37 2.7
Socket head bolt 125 M8 3.0 Ź 0.3 21.7 Ź 2.2
Joint 301 M 14 3.5 Ź 0.25 25.3 Ź 1.8
Adjusting nut 312 M 14 5.0 Ź 0.35 36.2 Ź 2.5
Lock nut 315 M 14 5.2 Ź 0.35 36.2 Ź 2.5
Screw 1 411 M4 0.05 0.36
Screw 2 421 M4 0.01 0.07
Screw 3 431 M5 0.09 Ź 0.01 0.65 Ź 0.07
Plug(For LH) 293 M 12 1.1 Ź 0.1 7.96 Ź 0.7
8-100
GROUP 8 TURNING JOINT
2) INSTALL
1 2
(1) Carry out installation in the reverse
order to removal.
Ɠ Take care of turning joint direction.
Ɠ Assemble hoses to their original positions.
Confirmed the hydraulic oil level and
Ɠ check the hydraulic oil leak or not.
8-116
2. DISASSEMBLY AND ASSEMBLY
1) STRUCTURE
3 6 10
14
15
13
9
8
12
11
8-117
2) DISASSEMBLY
Ɠ Before the disassembly, clean the turning 14
joint. 15
3
(1) Remove bolts(14), washer(15) and cover
(3).
8-118
3) ASSEMBLY
Ɠ Clean all parts.
Ɠ As a general rule, replace oil seals and
O-ring.
Ɠ Coat the sliding surfaces of all parts with
engine oil or grease before installing.
8-119
(7) Install cover(3) to body(1) and tighten
bolts(14). 14
şTorque : 10 ~ 12.5 kgfşm 15
3
8-120
GROUP 9 BOOM, ARM AND BUCKET CYLINDER
Wooden block
8-121
ڻSling bucket cylinder assembly, and
remove nut(7), bolt(6), then pull out 8
pin(5). 6
ڼRemove bucket cylinder assembly(8)
şWeight : 228kg(503lb)
5
(2) Install
ڸCarry out installation in the reverse order
to removal.
When aligning the mounting position of
the pin, do not insert your fingers in the
pin hole.
Ɠ Bleed the air from the bucket cylinder.
Ɠ Confirmed the hydraulic oil level and
check the hydraulic oil leak or not.
8-122
2) ARM CYLINDER
(1) Removal
Ɠ Expand the arm and bucket fully, lower
the work equipment to the ground and
stop the engine.
Ɠ Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious in
injury.
Ɠ Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or
dust from entering. Block
8-123
ڼSling bucket arm assembly(9), and
remove nut(8), bolt(7), then pull out 9 7
pin(6).
6
ڽRemove arm cylinder assembly(9)
8
şWeight : 350kg(772lb)
(2) Install
ڸCarry out installation in the reverse
order to removal.
When aligning the mounting position of
the pin, do not insert your fingers in the
pin hole.
Ɠ Bleed the air from the arm cylinder.
Ɠ Confirmed the hydraulic oil level and
check the hydraulic oil leak or not.
8-124
3) BOOM CYLINDER
(1) Removal
Ɠ Expand the arm and bucket fully, lower
the work equipment to the ground and
stop the engine.
Ɠ Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrate the skin causing serious in
injury.
Ɠ Fit blind plugs in the hoses after
disconnecting them, to prevent dirt or
dust from entering.
8-125
ڼDisconnect boom cylinder hoses(6), and
put plugs on cylinder pipe.
(2) Install
ڸCarry out installation in the reverse
order to removal.
When aligning the mounting position of
the pin, do not insert your fingers in the
pin hole.
Ɠ Bleed the air from the boom cylinder.
Ɠ Conformed the hydraulic oil level and
check the hydraulic oil leak or not.
8-126
2. DISASSEMBLY AND ASSEMBLY
1) STRUCTURE
(1) Bucket cylinder
13
7, 8
4 19
20
5
Internal detail
8-127
(2) Arm cylinder
13
7, 8
4 24
25
19
5, 6 20
21
22
Internal detail
27 30, 32, 33
8-128
(3) Boom cylinder
4 19
20
5, 6
Internal detail
8-129
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
Allen wrench 14
B
Spanner 13
17
19
( - ) Driver Small and large sizes
Torque wrench Capable of tightening with the specified torques.
Torque
Part name Item Size
fşm lbfşft
Socket head bolt bucket cylinder
21 M16 62Ź6.2 448.4Ź44.8
boom cylinder
arm cylinder 26 M18 80Ź8 578.6Ź57.9
Hexagon head bolt bucker cylinder 32
M10
arm cylinder 10Ź1 72.3Ź7.2
31
boom cylinder M8
bucker cylinder 27, 29 M10 2.3Ź0.23 16.6Ź1.7
arm cylinder 32 M10 4Ź0.4 28.9Ź2.9
boom cylinder 27, 29 M10 2.3Ź0.23 16.6Ź1.7
bucker cylinder 33 M12 4Ź0.4 28.9Ź2.9
Lock nut bucker cylinder 65Ź6.5 470.1Ź47
19 -
boom cylinder 70Ź7 506.3Ź50.6
arm cylinder 24 - 75Ź7.5 542.5Ź54.2
Piston bucker cylinder 70Ź7 506.3Ź50.6
arm cylinder 13 - 80Ź8 578.6Ź57.9
8-130
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
ڸHold the clevis section of the tube in a
vise.
Ɠ Use mouth pieces so as not to damage
the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.
Cover here
2 with rag
8-131
Note that the plated surface of piston
rod(2) is to be lifted. For this reason, do
not use a wire sling and others that may
damage it, but use a strong cloth belt or
a rope.
Wooden block
8-132
(3) Disassemble the piston assembly
ڸRemove wear ring(15). 16 15 14 15 16
ڹRemove dust ring(16) and piston
seal(14).
Ɠ Exercise care in this operation not to
damage the grooves.
8-133
4) ASSEMBLY
(1) Assemble cylinder head assembly
Ɠ Check for scratches or rough surfaces if
found smooth with an oil stone.
ڸCoat the inner face of cylinder head(3)
with hydraulic oil.
ڹCoat dust seal(5) with grease and fit dust Press here
seal(5) to the bottom of the hole of dust (Straight down)
5
seal. Metal
At this time, press a pad metal to the
metal ring of dust seal.
ںFit snap ring(6) to the stop face.
8-134
ڼFit back up ring(11,41) to cylinder head
(3).
Ɠ Put the backup ring in the warm water of 10
30}50Ƅ
41
ڽFit O-ring(10) to cylinder head(3).
10
11
3
17
8-135
(3) Install piston and cylinder head
ڸFix the piston rod assembly to the work
Cylinder head assy
bench.
ڹApply hydraulic oil to the outer surface of Piston rod
piston rod(2), the inner surface of piston
and cylinder head.
ںInsert cylinder head assembly to piston
rod.
8-136
(4) Overall assemble
Fix with a bar
ڸPlace a V-block on a rigid work bench.
Mount the cylinder tube assembly(1) on it
and fix the assembly by passing a bar Lift
through the clevis pin hole to lock the
assembly.
ڹInsert the piston rod assembly in to the Straight
cylinder tube assembly, while lifting and
moving the piston rod assembly with a Apply liquid packing
crane.
Ɠ Be careful not to damage piston seal by
thread of cylinder tube.
ںMatch the bolts holes in the cylinder Turn clockwise
head flange to the tapped holes in the
Apply loctite
cylinder tube assembly and tighten
socket bolts to a specified torque.
Ɠ Refer to the table of tightening torque.
Place rag
8-137
GROUP 10 UNDERCARRIAGE
1. TRACK LINK
1) REMOVAL
Block
2) INSTALL
8-138
2. CARRIER ROLLER Frame
1) REMOVAL
(1) Loosen tension of the track link. Grease
valve
2) INSTALL
(1) Carry out installation in the reverse order
to removal.
8-139
3. TRACK ROLLER
Frame
1) REMOVAL
90-110Ɓ
2) INSTALL
8-140
4. IDLER AND RECOIL SPRING
1) REMOVAL
2, 3
2) INSTALL
8-141
1) DISASSEMBLY AND ASSEMBLY OF IDLER
(1) Structure
5
1
2
5
7 6 7
4
4
6
3
8-142
(2) Disassembly
press
ڸRemove plug and drain oil.
ڹDraw out the spring pin(7), using a
press.
8-143
(3) Assembly
8-144
ڽInstall bracket(6) attached with seal(5).
8-145
4) DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING
(1) Structure
4 7 8 6 5 3 2 1 9 10 11 12
13
8-146
(2) Disassembly
13
8-147
(3) Assembly
ڸInstall rod packing(11), back up ring(10) 1 9 10 11
and dust seal(9)to body(1).
Ɠ When installing packing(11) and seal (9),
take full care so as not to damage the lip.
8-148
ڽLighten the press load and confirm the
set length of spring(3).
ھAfter the setting of spring(3), install 7
plate(6), spring washer(8) and bolt(7). 8
6
5
3
615
8-149
GROUP 11 WORK EQUIPMENT
1. STRUCTURE
B
C
8-150
2. REMOVAL AND INSTALL
1) BUCKER ASSEMBLY
(1) Removal
ڸLower the work equipment completely to
A
ground with back of bucket facing down.
B
B
3
(2) Install
ڸCarry out installation in the reverse
order to removal.
When aligning the mounting position of
the pin, do not insert your fingers in the
pin hole.
Ɠ Adjust the bucket clearance.
For detail, see operation manual
8-151
1) ARM ASSEMBLY
(1) Removal
Ɠ Loosen the breather slowly to release the
pressure inside the hydraulic tank.
Escaping fluid under pressure can
penetrated the skin causing serious in
jury.
ڸRemove bucket assembly.
For details, see removal of bucket
assembly.
ڹDisconnect bucket cylinder hose(1).
Fit blind plugs in the piping at the
chassis end securely to prevent oil from
spurting out when the engine is started.
ںSling arm cylinder assembly, remove
spring, pin stoper and pull out pin.
Ɠ Tie the rod with wire to prevent it from 1
coming out.
For details, see removal of arm
cylinder assembly.
ڻPlace a wooden block under the cylinder
and bring the cylinder down to it.
ڼRemove nut(3), bolt(2) and pull out the
pin(4) then remove the arm assembly.
Crane
şWeight : 373kg(822lb)
Ɠ When lifting the arm assembly, always lift
the center of gravity.
2, 3, 4
(2) Install
ڸCarry out installation in the reverse
order to removal.
When lifting the arm assembly, always lift
the center of gravity.
Ɠ Bleed the air from the cylinder.
8-152
3) BOOM CYLINDER
(1) Removal
ڸRemove arm and bucket assembly
For details, see removal of arm and
bucket assembly.
ڹRemove boom cylinder assembly from
boom.
For details, see removal of arm
cylinder assembly.
2
1
4, 5, 6
2
(2) Install
ڸCarry out in stallation in the reverse
order to removal.
When lifting the arm assembly, always lift
the center of gravity.
Ɠ Bleed the air from the cylinder.
8-153