SERVICE MANUALSER. NO. HY3570001~ INTRODUCTION To insure a long life for the machine and the engine and to prevent failure and problems, proper operation, maintenance and repairs are imperative. This service manual includes an “outline,” “structure and operation,” “inspection and ad- justment,” “disassembly and assembly,” “standard maintenance,” and “repair and replace- ment of parts” of the machine which are necessary to carry out the inspections and repairs in the repair shop. We trust that this manual will help you to effectively carry out the necessary. Repairs should they arise, also provide a accurate description of the product, and the correct repair procedures. . Pilot valve (2) (Swing. Pilot Valve (3) (Dozer) 12. Swivel Joint 16. Hydraulic Oil Filter 7. Attachment 4. Outline 3. Travel Motor 14. Spring Case and Grease Cylinder 18. Electrical Equipment 23. CONTENTS 1. Sprocket 20. Control Valve 8. Pilot Valve (1) (Travel) 10. Idler 19. Slew Motor 13. Carrier Roller 22. Precautions on Maintenance 2. Joystick (Pilot Valve) 9. Troubleshooting . Engine 5. Track Roller 21. Hydraulic Cylinder 15. PTO) 11. Crawler 17. Main Pump 6. 4) Repair of disassembled parts Keep the disassembled parts in order. NOTE: Electrical equipment. and what matters to attend to.). use of seal tape.” Procedure focuses on speed and accuracy of each job. check each part individually as it is disassembled.1 PRECAUTIONS ON MAINTENANCE 1. mount a dust cap on the connection. Also install the hose correctly. grease. rings. Clearly distinguish the parts to be replaced with new parts from those to be reused. rubbers and V belts (which are easily affected by water and oil) must be handled carefully in order to prevent soiling them. oil should be used. adjusted or disassembled. 2. how and which part should be checked. split pins must be replaced. 3. Precautions on operation 1. In the method. Preparation Prepare all of the tools and inspect and adjust the instruments. 5) Clean disassembled parts Thoroughly clean the disassembled parts. Hose mark Hose mark 1-1 . 6) Assembly Perform the assembly correctly (tightening torque. etc. 2. are addressed what type of facility. screw lock. For the electrical system. discon- nect the cable from the battery terminal. application of Three Bond. tools. seals. Correct operation Correct operation means to follow the correct “procedure” and “method. Safety check Check that stoppers and sleepers are correctly installed for the vehicle jack-up operation. When removing the hydraulic unit or the hoses. What is the problem? Is disassembly absolutely necessary? 2) Before disassembly Determine whether match marks are necessary. For efficiency 1) Understand the state before disassembly. 3) Precautions for disassembly In stead of checking all of the disassembled parts at once. Packings. materials. instruments. 2 OUTLINE CONTENTS 2-1 Location of serial No. 2-2 Name of each part 2-3 Dimensions and specification 2-3-1 H26C PTO flow 2-4 Weight list 2-5 Oil and grease supply points 2-6 List of supply oil and grease 2-7 When to repair 2-8 Hydraulic circuit diagram . Serial No. 2-1 .2-1 Location of Serial Number Model Name. Hour meter 4. Air filter lamp FUE L 8.O. Meter unit 6 2. Hearter switch (for cabin) 2 16.2-2 Name of each part 13 10 9 3 5 1. Left travel lever 15 11. Over drive switch 15. Left operation lever 7. Heater change lever (cold↔warm) 2 3 8 2-2 . Accelerator lever 1 8. Right travel lever 7 10. Charge lamp 7 5. P. Horn switch 4. Starter switch 8 3. Engine oil pressure lamp H 9 6. Manual boom lower lever 14 18. Fuel gauge 5 6 3. Wiper switch (for cabin) 17. Right operation lever 16 6. Glow lamp TER WA EMP C F T 7.T. Dozer lever 9. pedal 13. Cigarette lighter 18 4 17 1. Water temperature meter 4 2. Head light switch 1 E 00 00 UR 00 HO TER ME 9. Swing pedal 12. Fuse box 12 11 5. Operation lock lever 14. 2-3 Dimensions and Specifications 2-3 . digging reach mm 5180 5465 range Front 2060 2135 Min.31) kpa(kgf/cm2) pressure Cabin&rubber shoe 29.6(2710) Ground Canopy&rubber shoe 30.digging depth 3130 3425 Max.swing radius Swing 1700 1760 Rear end radius 1410 Boom swing angle deg Left80/Right50 Overall length 5010 Overall width 1580 Dimension mm Overall height 2420 Dozer(width × height) 1580×370 Travel speed km/hr 3.7 Gradeability deg(%) 30(58) Performance Bucket 27.2(210/175) Hydraulic oil tank 50.digging force Arm kN(kgf) 17.2 Hydraulic /min Auxiliary circuit oil flow 67. Description Unit Robex35-7 Rubber shoe 3320 Canopy Machine Steel shoe 3330 weight Kg Rubber shoe 3230 Cabin Steel shoe 3240 3 Standard Capacity m 0.5 -1 Swing speed min 8.5 Engine oil 4.9(2840) Max.) 1585(long) Max.9)/2400 Displacement cc 1318 Arm length 1285(std.5 Capacity Fuel tank 42 Cooling water 5.9(1830) Max.vertical digging depth 2290 2560 Max. drawbar pull 26.5 Noise Noise level(LwA/LpA) dB 96/80 2-4 . Tumbler distance × track gauge 1640×1280 mm carriage Track shoe width 300 Type of travelling motor Piston shoe-in type Crawler tension system Grease cylinder Type of hydraulic pump Piston×2.30) Under.0/4.10 bucket Width mm 590 Maker.6/17.1(0.5(0.digging height 5010 5215 Max. model MITSUBISHI S3L2 Engine Rated power ps(kW)/min -1 27(19. Gear×1 Pump oil flow 2×42+25.2 2 Relief valve setting pressure MPa(kgf/cm ) 20.dumping height 3540 3745 Working Max. 2-3-1 Robex 35-7 PTO Flow 2-5 . 5×2 Hydraulic oil tank 37 Sprocket 6.6 Steel crawler 182×2 Arm joint pin 2.5×2 Fuel tank 18 Turning motor 32 Engine cover(A) 31 Drive motor 43×2 Engine cover(B) 13.5 Battery 22 Tops roof 90 Battery cover 3 Operator cabin 165 Swivel joint 21 Boom cylinder 32 Control valve 27 Arm cylinder 32 Pump 25 Bucket cylinder 27 Seat plate 14 2-6 .5 Console box 9×2 Counter weight 300 Engine 135 Guard(R)(L) 35×2 Radiator 6 Guard(Center) 10.3 Rubber crawler 157×2 Bucket pin 2.2-4 Weight list Unit: kgf Part name Robex 35-7 Part name Robex 35-7 Boom 140 Swing cylinder 31 Arm 75 Dozer cylinder 23 Bucket 75 Turning bearing 42 Dump link 12 Track frame 339 Bucket link 4×2 Dozer 115 Boom joint pin 3.3×3 Idler 19×2 Swing post 75 Adjust cylinder 18×2 Swing post pin 7 Track roller 6.8×6 Swing frame 401 Carrier roller 2. 2-5 Oil and grease supply points Arm cylinder rod pin Bucket cylinder head pin Boom arm joint pin Fuel tank Arm cylinder head pin Hydraulic tank Bucket link pin Engine Bucket cylinder rod pin Bucket pin Boom cylinder rod pin Boom cylinder head pin Travel motor Dozer cylinder rod pin Track roller Dozer joint pin Adjust cylinder Boom joint pin Swing post pin Dozer cylinder head pin Front idler Slew gear Swing cylinder rod pin Swing cylinder Slew bearing head pin 2-7 . 8 2.8 5.6 3. LUBRICANT SHELL MOBIL 1 Engine Oil Myrina oil 15W-40 Delvac Super15W-40 2 Gear Oil Spirax Heavy Duty 140 Mobilub HD 85W-140 3 Hydraulic Oil ISO VG 46 (equivalent) ISO VG46 (equivalent) 4 Cup Grease Alvinia 2 Mobilux 2 5 Anti Freeze Anti Freeze Anti Freeze 6 Diesel Fuel — — *The engine oil SAE-CD 15W=40 or equivalent at the time of shipment is used for the lubricating oil for slewing and travelling speed reducer.3 2.5 0. *Use "Long-life coolant" for the antifreeze. Temperature -5°C -10°C -15°C -20°C -25°C -30°C antifreeze ratio 1. Table of recommended Lubricants No.5 Soft water (antifreeze is mixed in water) Fuel tank (effective capacity) 42 Diesel fuel with freezing point below -7°C Engine lubricating oil 4. because the effect will decrease.2-6 List of lubrication Type of oil according to ambient condition Name Quantity of oil/water -10°C~40°C -20°C~0°C Engine cooling water 5.5 ISO VG 46 Track roller (1 piece) 100 cc SAE 30-CD Front idler (1 piece) 80 cc SAE 30-CD Genuine oil Be sure to use Castrol Hyspin 46.5 SAE 10W-30 Travel motor 700 cc SAE 30-CD (reduction gear) Hydraulic tank 50. *Mixing ratio of antifreeze.4 1. Replace the cooling water after 1 year from its delivery.5 2-8 .1 3. add antifreeze to the cooling water.7 Engine inside capacity Radiator capacity Hose Reserve tank capacity Total 2. Cooling water (antifreeze) *To prevent the cooling system from freezing.5 1.6 0. 2-7 When to repair It is difficult to judge when to perform periodic inspections, maintenance and repairs. Although the wearing rate of each component differs depending on the grade of daily inspection, the skill in machine operation, the working conditions, the quality of used lubricating oil, the frequency of oil replacement, the quality of land to be dug, the digging rate, the schedule for maintenance and repairs should be decided considering the state of engine, the indication of the hour meter, the degree of wear in each part, the state of hydraulic system, your experience and data. 2-7-1 Category of maintenance Execute every day before beginning Prestart-up inspection operation Maintenance after the first Execute every 25 hours by the hour 25 service hours meter Maintenance after the first Execute once a week (every 50 50 service hours hours by the hour meter) Maintenance after the first Execute every 100 hours by the 100 service hours hour meter Maintenance after the first Execute every 250 hours by the 250 service hours hour meter Maintenance after the first Execute every 300 hours by the 300 service hours hour meter Maintenance after the first Execute every 500 hours by the 500 service hours hour meter Maintenance after the first Execute every 1,000 hours by the 1,000 service hours hour meter Maintenance after the first Execute every 2,000 hours by the 2,000 service hours hour meter 2-9 2-7-2 Maintenance procedure Inspection and Inspection and maintenance interval (hours) maintenance item 7 50 100 250 500 1,000 Engine oil pan Check oil Replace the Replace the Clean level engine oil engine oil (New 1 machine only) Engine oil filter Replace the Replace the cartridge cartridge (New machine only) 2 Fuel filter Check and Replace the clean element Engine valve Inspect and Inspect and 3 clearance adjust (New adjust machine only) Fan belt Check and 4 adjust Fuel tank Check oil Drain water 5 level and sediment, clean strainer Radiator (sub-tank) Check water Replace and level clean 6 Radiator fin Check and clean Air cleaner Check and Replace the 7 clean element 8 Hydraulic oil tank Check oil Drain water Replace oil level and sediment Hydraulic line filter Replace the Replace the cartridge cartridge 9 (New machine only) Hydraulic suction Clean the Replace the filter element element 10 (New machine only) 11 Bucket teeth and Inspect others Slew bearing Inspect and 12 grease Inspect crawler Check and 13 tension(grease adjust cylinder) and grease the crawler 14 Battery liquid Inspect, clean amount and and supply specific gravity distilled water Inspect each body Check and 15 part for loosening tighten and damage Each lever and Inspect 16 instrument Lubricating oil of Replace oil Replace oil slew/travelling (after the first reduction gear 500 service 17 hours only for a new machine) 18 Electrical wiring Inspect Water and oil Inspect 19 leakage in each body part 20 Inspect and grease Inspect attachment attachment PTO filter element Replace the 21 element 2-10 2-7-3 Prestart inspections (1)Prestart inspections Item Content Remarks 1 Engine oil pan Check oil level Before starting operation Check that the fuel level is 2 Fuel tank Check fuel level above the center of level gauge. Check that the amount of water 3 Radiator Check water level in sub-tank is within a specified level. 4 Each oil/grease supply point Oil and grease Refer to page 2-6 Inspect each body part for looseness Looseness, removal, Refer to tightening torque list. 5 water and oil leakage and damage Each lever and Whether abnormal operation 6 Operation check exists or not instrument Add oil if its level falls below the 7 Hydraulic oil tank Check oil level specified level. (Be careful of the position of machine.) Check whether the 8 Bucket teeth and Wear replacement of parts is others necessary or not. 9 Electrical wiring Loosened terminal, torn Looseness and tears covering, etc. 10 Fan belt Check and adjust 10mm(0.4”) to 12mm(0.5”) sag at the center (2)Post opertaion inspections Item Content Remarks Treatment of the part where Clean, check for water cleaning was not sufficient 1 Each body part and oil leaks. such as dirt sticking to the Looseness, failure, etc. body or muddy water remaining on the body. 2 Fuel tank Fuel supply Add fuel 3 Cooling water Drain Only when the danger of freezing exists 2-11 9 12.5 16 20 M8 30 39 45 M10 62 72 80 M12 100 120 130 M14 160 195 220 M16 250 305 340 N-m Tightening torque of the hydraulic pipings PT screw PF screw Torque Torque N. always check for loosened bolts or nuts and correctly tighten them according to the following tightening torque list.m N.m M6 12.m N.m N. N-m Tightening torque of the bolt and nut (Body) Material 8.8 10.Tightening torque list: In the present inspection.9 Size N.m Size Size 1 1 — 36 — 27-30 4 4 3 3 — 55 — 47-52 8 8 1 1 — 86 — 57-63 2 2 3 3 — 130 — 108-120 4 4 1 195 1 126-140 1 1— 300 4 1 1— 400 2 2-12 . 26 when fully charged. 2-7-4 Maintenance every 50 service hours Item Content Remarks 1 Engine oil pan Replace engine oil Only for a new machine. If short.20.20 Specific gravity when discharged (Recharge the battery when 1. After and filter this.) 14 Battery Clean each part. brush and Clean connect terminal and apply grease 20 Each oil/grease supply point Oil and grease Refer to page 2-7 2-13 . After 3 Inspect and adjust this. every 500 service hours clearance Drain sediment and Remove the drain plug on the Fuel tank water lower part of the tank Clean the strainer Wash strainer with diesel fuel 5 Dust sticking to the fin affects Radiator fin Clean the fins the cooling effect and causes overheating 6 Slew bearing Inspect and grease Always grease the machine after it is used in water Whether the liquid level is 12 Battery Liquid quantity proper or not. 1. every 250 service hours Engine valve Only for a new machine. add distilled water 1. every 500 service hours 2-7-6 Maintenance every 250 service hours Item Content Remarks Remove the drain plug on the Engine oil Replace the engine oil lower part of the tank. (After 50 service hours for a new 1 machine) Engine oil filter Replace the cartridge After 50 service hours for a new machine Drain water and After air is vent. After filter this. 2-7-5 Maintenance every 100 service hours Item Content Remarks 2 Fuel filter Clean the element After cleaning. 7 Air cleaner Replace the element 9 After 100 service hours for a Hydraulic line filter Replace the cartridge new machine 10 Hydraulic suction Clean the element filter 2-14 . Every 1. every 500 service hours 10 Hydraulic suction Clean the element Only for a new machine. After 9 Hydraulic line filter Replace the cartridge this. open the cock to vent air Clean the dust cover. loosen the 8 Hydraulic oil tank sediment drain plug Replace oil after the first 200 Lubricating oil of service hours. 7 Air cleaner clean or replace the Check also for a loosened band element Only for a new machine.000 17 slew and travelling Replace lubricating oil service hours after this (Refer reduction gears to Table of Oil/Grease Supply Points) 2-7-7 Maintenance every 500 service hours Item Content Remarks 2 Fuel filter Replace the element Clean the inside of bowl Engine valve Clearance between the valve 3 clearance Check valve clearance and the rocker Remove the drain plug. clean Replace cooling water the radiator and add water to 6 Radiator and clean the radiator the sub-tank up to the specified level. replace 700 cc after the first 500 API Classification service hours) CD Class SAE30 2 Track roller 100 cc Every 2.000 hours 2-15 .000 service hours Item Content Remarks 1 Engine oil pan Clean engine oil pan Replace the hydraulic 8 Hydraulic oil tank oil and clean the oil Clean the inside of the tank tank Lubricating oil of Refer to Table of Oil/Grease 12 Replace the lubricating Supply Points. (For new slew and travelling oil reduction gears machine. (genuine part) Quantity Time Point Every 1.000 service hours Item Content Remarks 15 Track roller Replace Table of Oil/Grease Supply Points Oil/Grease Supply Specified oil No. every 200 service hours) 2-7-9 Maintenance every 2.000 service 1 Travel motor hours (At first.000 hours 3 Front idler 80 cc Every 2. 2-7-8 Maintenance every 1. 2-8 Hydraulic circuit diagram 2-16 . 2 MPa Port relief 23.9 MPa Slew 15.2 /min Type S3L2 Engine Constant output 19.5 MPa Unload (pump) 2.400 min-1 Torque 85 N.6 MPa relief Pressure P3 17.800 min-1 2-17 .5 cc/rev P1 20.5 cc/rev Pump P3 10.5 cc/rev P4 4.7 MPa flow rate Q1 42 /min Pump Q2 42 /min Q3 25.9 kW (27 ps) Speed 2.5 cc/rev capacity P2 17.m/1.6 MPa Main P2 20. Item Robex 35-7 Boom cylinder ø80×ø45×609 st Arm cylinder ø80×ø45×600 st Bucket cylinder ø75×ø45×500 st Swing cylinder ø80×ø45×652 st Dozer cylinder ø90×ø50×125 st Slew motor PCR-2B-10A-P-8565Z Travel motor PHV-300-41-9R1-8855A Item Robex 35-7 P1 17. 3 ATTACHMENT CONTENTS 3-1 Standard of maintenance 3-1-1 Attachment 3-2 Inspection and adjustment 3-2-1 Measuring the fall of the attachment of its own weight 3-2-2 Measuring the speed of the attachment cylinder 3-1 Standard of maintenance 3-1-1 Attachment 8 9 7 10 13 11 14 6 12 4 5 1 15 16 17 3 2 A a b a b a b D B C E 1. Swing cylinder 2. Swing cylinder 3. S w i n g p o s t head rod bracket and swing post a b a b a b I F H G 4. Boom joint 5. Boom cylinder 6. Boom cylinder head rod 3-1 a b a L b a b J I M 7. A r m c y l i n d e r 8. A r m c y l i n d e r 9. Boom/arm joint head rod a b a b Q a b O N P R 10. Bucket cylinder 11. Bucket cylinder 12. B u c k e t / d u m p head rod link joint a b a b Q S a b U T R 13. Arm/bucket link 14. A r m / b u c k e t 15. Dozer joint joint joint a b a b V W 16. Dozer cylinder 17. Dozer cylinder rod head 3-2 0(0.04") R Bucket pin and bucket ø40(1.04") E Swing post pin and swing post bracket ø60(2.04") W Dozer cylinder head pin and dozer ø40(1.6") 1.6") 1.0(0.6") 1.04") N Bucket cylinder head pin and arm ø40(1.0(0.0(0.04") H Boom cylinder head pin and swing post ø40(1.6") 1.0(0.04") T Bucket link pin and bucket link ø40(1.0(0.4") 1.04") D Swing post pin and bush ø60(2.0(0.4") 1.04") G Boom joint pin and swing post ø45(1.04") J Arm cylinder head pin and boom ø40(1.8”) 1.6") 1.0(0.6") 1. Unit: mm(in) No.4”) 1.0(0.6") 1.0(0.6") 1.0(0.0(0.04") S Bucket link pin and bush ø40(1.04") B Swing cylinder head pin and the boss of head bracket ø35(1.04") F Boom joint pin and bush ø45(1.6") 1.0(0.0(0.04") K Arm cylinder rod pin and arm ø40(1.04") U Dozer joint pin and frame ø34.04") V Dozer cylinder rod pin and frame ø40(1.04") L Boom/ arm joint pin and bush ø40(1.4") 1.0(0.4”) 1.04") P Bucket cylinder rod pin and bucket link ø40(1. Item Basic Dimension Allowable Clearance A Swing cylinder head pin and head bracket ø35(1.8(1.0(0.0(0.6") 1.0(0.04") I Boom cylinder rod pin and boom ø40(1.8”) 1.6") 1.6") 1.0(0.0(0.04") C Swing cylinder rod pin and swing post ø35(1.6") 1.6") 1.0(0.04") M Boom/ arm joint pin and boom ø40(1.6") 1.0(0.04") Q Bucket pin and bush ø40(1.0(0.4") 1.04") 3-3 .04") O Bucket cylinder rod pin and dump link ø40(1. 1”~0.0(0.1") MBU3-00022 ø41×t0.08"~0.14") cylinder rod and frame MBU3-00023 ø41×t1.1”) 〃 〃 cylinder head and boom Clearance between arm 8 51(2.0(0.0 Clearance between dozer 17 57(2.5(0.88") 0.31") 134.5(0.16") 2.46") 213(8.96") 2.62") 0.16”) NBU3-00021 ø36×t1.1”) Clearance between swing 3 post and frame 215(8.04"~0.5(0.1”) MBU3-00024 ø46×t0.0 Clearance between boom 5 51(2.5(0.02”~0.5(5.0") 50(1.04") 〃 〃 bucket Clearance between dozer NBU3-00020 ø36×t0.1") 50(1.2") and frame NBU3-00021 ø36×t1.14") 〃 〃 cylinder head and dozer 3-4 .0(0.0~3.5(0.5(0.1") 50(1.39") 2.04"~0.96") 1.1”) 〃 〃 Clearance between bucket 10 cylinder head and arm 51(2.16") 2.5(5.0") 50(1.0~2.96") 1.13") 〃 〃 Clearance between boom 4 195(7.96") 1.0~2.0~2.5(5.0") 50(1. Unit: mm(in) Item Criterion Spacer No.0 Clearance between swing 2 〃 〃 cylinder rod and head bracket 51(2.1"~0.5~1.5~2.02”~0.0 Clearance between boom 6 51(2.0(0.04"~0.31") 134.08"~0.1") 〃 〃 and bracket Clearance between arm and 13 135(5.5(0.0") 50(1.04"~0.04"~0.2") 55(2.96") 1.02"~0.0 Clearance between dozer MBU3-00022 ø41×t0.0") 50(1.0") 50(1.96") 1. Standard a b Part Number Dimension clearance Clearance between swing NBU3-00020 ø36×t0.0~3.0~2.0~2.3(0.3") 1.0~2.5(7.31") 134.5(0.5(0.5(0.3")0.5 1 cylinder head and swing post 53(2.5~5.7") 193.0~2.04"~0.08"~0.5 cylinder head and swing post MBU3-00023 ø41×t1.2") 55(2.9") 149.5~4.5(5.0~3.04") 〃 〃 bucket link Clearance between arm and 14 135(5.1") 〃 〃 cylinder rod and boom Clearance between arm 7 51(2.96") 1.5 15 53(2.5~2.1") 〃 〃 Clearance between bucket 11 51(2.5 16 57(2.5(0.1") 50(1.1") 〃 〃 cylinder rod and dump link Clearance between dump link 12 135(5.3") 0.96") 1.04"~0.02”~0.5 and swing post MBU3-00025 ø46×t1.5(0.0~2.04”~0.1") 〃 〃 cylinder rod and arm Clearance between boom 9 and arm 150(5.5~1.96") 2. 3-2 Inspection and adjustment 3-2-1 Measuring the natural fall of the attachment 1. Measuring the location of the attachment Set the temperature of the hydraulic oil to 50±5°C. Adjust the height of arm/bucket joint so that it equals that of the boom joint. Then, retract the dozer cylinder to the minimum length and stop the engine. 2. Measurement Draw a reference line on the cylinder head with a Magic Marker and measure the length from the line to the cylinder tube. Measure the length again 3 minutes later. Then record the difference in the length Unit: mm (or less) Cylinder name Standard value Allowance Boom cylinder 10 20 Arm cylinder 10 20 Bucket cylinder 5 10 Dozer cylinder 5 10 Make 1 and 2 the same height. W: Weight About: 165 kg Arm cylinder Bucket cylinder Boom joint...1, Dozer cylinder Boom cylinder Arm/bucket joint...2, Mark: Direction of cylinder movement 3-5 3-2-2 Measuring the speed of attachment cylinder (at full engine speed and oil temperature 50±5°C) New standard Allowable Condition Machine position Unit value limit Boom Make bucket teeth 2.8±0.5 3.7 Up touch the ground Down 2.6±0.5 3.6 Extend cylinder to the Maximum length Arm Dig Retract cylinder to the 3.4±0.6 4.7 minimum length Dump 3.1±0.5 4.3 Extend cylinder to the maximum length Bucket Retract cylinder to the 3.2±0.5 4.6 Dig minimum length sec Dump 2.2±0.4 3.0 Extend cylinder to the maximum length Dozer Make dozer contact Up 1.0±0.3 1.4 the ground Down 1.0±0.3 1.3 Lift dozer to the maximum height Swing swing Right Retract cylinder to the 5.8±0.5 8.0 minimum length swing Left 5.0±0.6 6.0 Extend cylinder to the maximum ground 3-6 4 ENGINE CONTENTS 4-1 Specification 4-2 Performance curve 4-3 Location of serial number 4-3-1 Engine 4-3-2 Standard engine speed 4-4 Inspection and maintenance procedures for engine parts . 318 cc Ignition order 1–3–2 Dimensions Overall length 556 mm Overall width 440 mm Overall height 615 mm Rated output 19.m / 1.h Dry weight 135 kg Fuel oil Diesel fuel Fuel pump Bosh type Governor Centrifugal type Generator 12V × 50A Starter 12V × 1.800 min-1 Maximum idling speed 2.100 min-1 Performance Maximum torque 85 N.9 kW(27 ps) / 2.200 ± 25 min-1 Fuel consumption 247 g / kW.600 ± 30 min-1 Minimum idling speed 1.4-1 Specification Engine S3L2 Type In-line 3 cylinder 4cycle overhead valve type Number of cylinders–bore × stroke 3–78 mm × 92 mm Displacement 1.7 kW Battery 12V × 60 AH 4-1 . m) 70 (27.7 ps) 20.h) 250 240 0 1000 2000 3000 NL / 2300–30 min-1 Engine speed (min-1) 4-2 .4-2 Performance curve Without fan Output torque 85 80 75 (N.4 kW / 2400 min-1 20 Brake hose power (kW) With fan 10 Fuel consumption 260 (g / kW. (identification plate) 4-3-2 Standard engine speed (at new machine delivery) Conditions Idling speed Maximum idling speed 2.450 ± 70 min-1 4-3 .4-3 Location of serial number 4-3-1 Engine Type of Engine Engine No.600 ± 30 min-1 Speed when 1P relief is used 2.450 ± 70 min-1 Speed when 2P relief is used 2. 1 piston at top dead center on the No. (c) With No.m) TDC (top dead center) mark for No.) Item Standard Valve clearance (both inlet 0. (3) Loosen the lock nut for the adjusting screw.1 IT(Injection timing) mark piston by using the procedure that follows: (a) Turn the crankshaft until TDC mark on the crankshaft pulley is aligned with the mark on the timing gear case.m sequence Tightening torque (88 ± 5 N.4-4 Inspection and maintenance procedure for engine parts Inspecting and Adjusting Valve Clearance Front of engine NOTE 3L 8 4 2 7 Make an adjustment to the valve clearance when 6 1 3 5 the engine is cold.25(0.1 and No.3 pistons compression stroke. With a feeler gauge inserted between the rocker arm and valve cap.4 Mark on timing pistons gear case (2) Find top dead center compression position for No.2 and (b) With No. TDC mark for No.1 piston at top dead center on the compression stroke. 10 9 11 (1) Slightly loosen the cylinder head bolts and retighten them to the specified torque in number sequence.0098) and exhaust valves) 4-4 . adjust the valve clearance by turning the adjusting screw. Unit: mm(in.5 kgf. the rocker arms will not be Timing mark moved when the crankshaft is turned approximately 20° in both directions. the rocker arms will not be moved when the crankshaft is turned approximately 20° in both directions. Cylinder head bolt tightening 9 ± 0. 1 cylinder has been adjusted. Firing order (injection Crankshaft rotation sequence) angle Adjusting valve clearance S3L 1–3–2 240° ! CAUTION After the valve clearance on the valves for all cylinders has been adjusted. 4-5 . turn the crankshaft 180° in the direction of engine rotation and adjust the valve clearance on the valves for the remainder of the cylinders in firing order (injection sequence). turn the vrankshaft two or three times and make sure the valve clearance is correct.(4) Hold the adjusting screw and tighten the lock nut. (5) After the valve clearance of the valves for No. ) to 1. Keep the tip of the nozzle pointed away from the operator and into the fuel collector. disassemble the nozzle and change the thickness of the washer.002 0 in.Inspecting and Adjusting Injection Nozzles 1.066 9 in.1 mm(0.) ! WARNING When the injection nozzles are tested. Slowly operate the tester handle to bleed (remove) air from the tester. (b) Operate the tester handle at a speed of one stroke per second to make a slow increase in pressure until the valve in the injection nozzle starts to open. Read the maximum gauge pressure at the instant Fuel injection nozzle ready for test fluid flows from the tip. 4-6 . Injection pressure (valve 140 +5 0 kgf/cm 2 +71 opening pressure) (19910 psi) Standard [13729 +490 0 kPa] Removing tip from injection nozzle NOTE An increase or decrease of washer thickness by 0. Fuel comes from the orifices in the nozzle tip with high pressure. 10 kinds of washer are available in thickness from 1.70 mm(0.) in increments of 0. The fuel can pierce (go through) the skin and cause serious injury to the operator.25 mm(0.004 in. be sure to wear eye protection.) will vary the injection pressure by 10kgf/cm2 (142 psi)[981 kPa].Inspection (1) Injection pressure (valve opening pressure test) (a) Install the injection nozzle on the tester.049 2 in.05 mm (0. (c) If the injection pressure is incorrect. (b) Operate the tester handle at a speed of one stroke Good Discharge pattern for nozzle per second to make sure the discharge is straight.m) (c) If the injection nozzle is still bad after the tip has been washed. (b) After cleaning the tip.25 kgf. 3.5 N. Any change is an indication of a bad nozzle. NOTE a) Do not touch the sliding surface of the needle valve. b) When installing the new nozzle tip. replace the tip. ! CAUTION Don not hit the tip when removing it from the injection Needle valve Body nozzle. The discharge must be straight.8 ± 2. put the needle valve in the body in clean diesel fuel. Wash the needle valve and body in clean diesel fuel.75 ± 0. (use orifice with a restriction again) (Recondition or replace) Orifice restriction test (3) Nozzle tip washing and replacement (a) loosen the retaining nut and remove the tip from the injection nozzle. Do not use needle valves or bodies with other bodies or needle valves.(2) Orifice restriction test (a) Look at the orifice discharge pattern (shape of discharge) when fluid begins to flow through the injection nozzle. After washing.m Tightening torque (36. remove synthetic resin film from the tip and slide the needle valve in the body in clean diesel fuel to wash off inhibitor completely. install it in the nozzle and tighten the retaining nut to the specified torque. 4-7 . Washing nozzle tip NOTE Keep the needle valves with their respective bodies. 5 kgf.m] 1 orifice.5 N.5±0.25 kgf.75±0.m nozzle or in nozzle [36.8±2. Disassembly sequence and inspection points 1 Retaining nut 5 Spring 2 Nozzle tip asse 6 Washer 3 Piece 7 Body 4 Pin 4-8 .m] 7 Check for wear Check test force 6 and squareness 5 Check for wear or 4 damage 3 Check for too much 2 Tightening torque: carbon on tip of 3.m [54±5 N.Disassembly Tightening torque: 5. (b) The compression pressure varies with change of engine rpm. (2) The enigne is at the normal operating temperature. (b) The compression pressure would be slightly higher than the standard in a new or overhauled engine owing to breaking-in of the piston rings. Measurement (1) Move the control lever to a position for shutting off fuel supply.Measuring Compression Pressure 1. 4-9 . Install the compression gauge and adapter(ST332270) combination to a cylinder on which the compression pressure is to be measured. starter and battery are all in normal condition. rpm 290 — 30 30 Compression SL (427) (427) pressure [2942] [2942] kgf/cm2(psi)[kPa] 32 32 SL2 (455) (455) [3138] [3138] Maximum permissible difference between average compression 3 pressure of all cylinders in the engine. It drops as the engine components wear down. etc. 2. and the air cleaner. (3) Turn the engine with the starter and read the gauge pressure at the instant the gauge pointer comes to stop. ! CAUTION Measuring compression pressure (a) Be sure to measure the compression pressure on all cylinders. Compression gauge and adapter (2) Remove all glow plugs from the engine. (42. (4) If the gauge reading is below the limit. overhaul the engine. Item Standard Limit Engine speed. Inspection Check to make sure– (1) The crankcase oil level is correct. valve seats.7) kgf/cm2(psi)[kPa] [294] ! CAUTION (a) It is important to measure the compression pressure at regular intervals to obtain the data on the gradual change of the compression pressure. This makes it necessary to check engine rpm at the time of measuring the compression pressure. Thread.025(0.1(8±0.3±1.1)[11.7±2)[17.5 — — 3±0.m(lb.5±4)[44±5] Fuel injection nozzle holder M20 1.125±0.5 18 — 2.5(65±4)[88±5] Rocker cover bolt M8 1.5] Delivery valve holder — — 19 — 4.75±0.3±1.1)[11.6±3)[22.5(127±18)[172±25] Main bearing cap bolt M10 1.2±2.7±2)[34.5 27 — 17.5 22 10 4±0. mm Bolt or nut Width Clamp Torque.5(36±4)[49±5] Oil filter M20 1.5 21 — 5.25 14 29.2)[1.75±0.6(26±4)[35±6] Special nut for torque spring M12 1.1±0.25(38±2)[51.7 8 — 0.2(7.15±0.25 14 87 9±0.75±0.25 12 58 1.5 17 31.55±0.3±0.5 — — 1.5±0.5(98±4)[132±5] Oil pan bolt (for tractor M8 1.15(8.5±4)[44±5] Starter B terminal M8 1.3±2.25(12.5] Thermoswitch M16 1.25 12 25 2.3±1.2±0.5±0.5 3. kgf.0 14 — 3.3±1.5] Rear plate bolt (for tractor engine) M12 1.15(8.5±1(47±7)[64±10] Rear plate bolt(stamping) M8 1.7)[12±1] Oil pressure switch PT1/8 — 26 11 1±0.1(8.25(25.5(14±4)[20±5] set Glow plug M10 1.5±2.5 22 33 5±0.25 12 40 1.ft)[N.15(8.5(40±4)[54±5] Retaining nut for delivery M16 0.5±0.6±0.25 12 — 1.5 2.4(16.2)[27.0 17 — 2±0.25 12 60 1.5(32.2±1.8±2.3(20.3±1.5±2.5] valve holder body Sliding sleeve shaft M10 1.5±1(69±7)[93±10] Rear plate bolt(standard) M12 1.25±0.25 19 29 13.5] Flywheel bolt M12 1.7)[10.9±0.5±3] engine) Oil pan drain plug M14 1.3±1.8±1] 4-10 .2] Stop solenoid nut M30 1.5] Glow plug connection plate M4 0.4)[10±2] Fuel injection pipe nut M12 1.75 19 — 3.5] Connecting rod cap nut M9 1.15±0.6±4] Crankshaft pulley nut M18 1.5 36 — 4.7±0.2±0.m] Diameter Pitch across flats length Cylinder head bolt M10 1.25 17 28 6.5] Rocker shaft bracket bolt M8 1.25 12 16 1.8±0.5(22±4)[29±5] Fuel leak0off pipe nut M12 1.25(27±2)[37±2.5(32.25 17 28 9.5±0.25 17 81 5.1)[11.5(29±4)[39±5] Pressure relief valve M22 1.25(20±2)[27±2.5±0. 9 M16x1.6) 294 30 217 4-11 .2 15±1.0±1.9) 49 5 36 100 M20x1.0-18.4-41.5 27(1.85-9.2-9.61) 226±20 23.2 M14x1.5 32.3) 157 16 116 180 M30x1.1 5.5 27(1.87) 34±4 35±0.3}(7.8-54.0}(5. d.80-12.5 41(1.0-4.2{3.5 22(0.0-1.Tightening Torques for Standard Bolts and Nuts Unit:N-m{kgf-m}(lbf-ft) Bolt Sise 4T 7T M6 7.80{0.4 M12x1.7) 39 4 29 80 M16x1.7-30.5 22(0.2}(10.5±3.67) 25±3 25±0.5±10. All bolts and nuts appearing in this manual should be tighrened according to this table unless otherwise indicated.2 M24x1.8-1.5{1.2±3.2) 98 10 72 150 M27x1.4) M12 9.6{1.5 41(1.5 24(0.5{5.8-15.3±2.5}(13.25 17(0.5 19(0.4) 53.18) 98±10 10.5 108.6 M20x1.4) 196 20 145 220 M33x1.5 Tightening Torques for Standard Union Nuts(for Dry Condition) Nominal Internal Nominal Diameter Width Across Flars N-m kgf-m lbf-ft Diamerer x Thread Pichmm mm(in) 63 M14x1.94) 44±5 4.5-7.7-30.9-73.0±10 72.7{1.5-2.1) 29.55) 15±2 15±0.4 25.2) Note: a. The table above applies only to standardized bolts and nuts.25 12(0.0 166.3±7. Tightening Torques for Standard Eye Bolts(for Dry Condition) Torque Nominal Diaerer x Thread Pitch Width Across Flars Strength Class: 4r mm mm(in) N-m kgf-m lbf-ft M8x1.4) 14.2) M8 9.5 36(1.8-2.7 M10x1.8 M27x1.5 42(1.9 M10 17. without lubricaring threads with oils.1) 78 8 58 120 M22x1.47) 8±1 8±0.4) 196 20 145 200 M30x1.0±2.5 30(1.42) 147±15 15.0-4.8-7.7-24.5 36(1.5 54.06) 74±5 75±0.2}(21.5 36(1. Standard bolts and nuts should be tightened in "dry" condition.2}(21.5 30(1.6) 245 25 181 254 M36x1.3 18.5 32(1.3±14.7-21.8±0.0±2.25 14(0.5±0.2{3. All torques shown assume use of spring washer together with bolts and nuts.6 M18x1.4-41.5}(39. 5 MAIN PUMP CONTENTS 5-1 Specification 5-2 Structure 5-3 Removing and installing the pump 5-3-1 Removing the pump 5-3-2 Installing the pump 5-4 Performance test of the hydraulic pump 5-4-1 Measuring instrument 5-4-2 Preparation 5-4-3 Connecting tester 5-4-4 Measuring procedure 5-4-5 P-Q characteristic curve . 3") 45(1.6 20.PB Displacement cc/rev 17.6 17.5(1.5 17.056 0 286.5 4.5") 103(4.5 Rated pressure MPa 20.5(1.P2.4") M O S1 170(6.PB2 PF 1/4 P1.5 10.5(1.P3 PF 1/2 Direction of rotation Clockwise seen from shaft side Weight (kg) 25 5-1 .1") SOL A SOL B (P4) X P3 P2 P1 34.PB1.5-1 Specification 67.0") 27.5(2.1") 0.0") 241(9.8") Pump type PVD-15B-35BP-11G5-4621H P1 P2 P3 PA.7(11.7") 128(5.9 1 S1 PF 1 /4 Port size PA.7") PA PB1 PB2 25.2 2.7") 146(5. Spring guide 31. Body 16. Bearing 38. Spring T1 29. Seal washer 7. O-ring 2. Valve assembly 5-2 . Spring pin 4. Valve plate 19. O-ring 12. Spring holder 30. Piston 20. Gear pump 9. O-ring 13. Conical washer 40. Retainer 34.5-2 Structure 23 25 3 27 1 18 21 16 28 27 21 19 26 12 30 10 15 11 27 8 24 7 5 9 31 4 22 6 42 29 20 14 13 17 2 34 33 32 39 41 38 40 37 36 35 1. Shoe 21. Socket head bolt 5. O-ring 42. Shoe holder 22. Body 15. Barel holder 23. Collar 11. Shaft 17. Plug 3. O-ring 14. Swash plate 24. Washer 33. Oil seal 39. Snap ring 41. Packing 27. Bearing 37. Pin 36. Spring C 28. Needle 25. Cylinder 18. Plug 8. Pin 26. Nut 6. Rod 32. Coupling 10. Stopper pin 35. m * Precautions on installing the pump 1. Bolt Tightening torque M12 × 30 90~115 N. Remove the pump mounting bolts(1).5-3 Removing and installing the pump 5-3-1 Removing the pump 1. 5-3-2 Installing the pump 1. elbow and hoses around the pump. insert a screwdriver and remove the pump little by little with equal force applied on the right and left sides. Remove the pump from the flange 2. 2. Remove the nipple. TEE. Make sure there is no misalignment. When tightening the bolts 1. Replace with a new pump and install it on the pump flange 2. 3. Attach a cap to the removed hoses to keep dust off. Check that the spline of the shaft fits smoothly with the boss of the coupling. tighten the left and right side bolts slowly and evenly. Store the nipples and elbows in treated oil. If removal is difficult. 3 2 1 5-3 . 6 MPa Hose for testing (2. Connect the removed hose to the outlet of the tester. Connect the hose on the discharge of the pump to the inlet of the tester. 4. At the same time. 5-4-3 Connecting tester 1. 2. 4.5-4 Performance test of the hydraulic pump 5-4-1 Measuring instrument pressure tester Measuring range of flow rate ( /min) 7 Hydraulic Measuring range of pressure (MPa) 0 ~ 34. record the engine speed. 5-4-4 Measuring procedure Open the throttle valve of the tester and start the engine. Park machine on flat ground and stop engine. Connect pressure gauge to port measuring port. Remove the hose on the pump port of the control valve.3 Measuring range of temperature (°C) 0 ~ 150 Port size PF1 O ring type Pressure gauge 49 MPa.9 MPa Tachometer Diesel tachometer (digital type) Equivalent to the hose of 20. 3.987 psi) high pressure (Nominal size PF1/ 2-PF1/ 2×1m) 5-4-2 Preparation 1. Read the pressures on the pressure gauge and measure the flow at that time. 5-4 . Hydraulic pressure tester OUT Throttle valve IN CLOSE OPEN 5-5 . 5 15 T = PD = 5.21 200π (kgfm) 10 P3 = 175 kgf-cm2 5 0 100 200 300 400 420 Rated pressure P1 + P2 (kgf-cm2) 5-6 .5-4-5 H36C Pump Performance P-Q Characteristics cc / rev 20 17.21 200π (kgfm) P3 = 10 kgf-cm2 Pump flow Q’ty T = PD = 3. . 6 HYDRAULIC OIL FILTER CONTENTS 6-1 Installation 6-2 Hydraulic oil filter 6-2-1 Line filter (SP10) 6-2-2 Suction filter 6-2-3 Pilot filter 6-2-4 Line filter(SP08) 6-3 Maintenance procedure 6-3-1 Replacing the line filter 6-3-2 Replacing the suction filter 6-3-3 Replacing the pilot filter 6-3-4 How to clean the suction filter . 6-1 Installation Line filter (SP08) Line filter Suction filter Oil cooler Pilot filter 6-1 . 6-2 Hydraulic oil filter 6-2-1 Suction filter Grain size 150 mesh Filtration capacity 330 /min(Max) Oil temperature -20°C~120°C 6-2-2 Line filter Filtration accuracy 10µ Filtration capacity 125 /min (Max.) Proof pressure 0.7 MPa Oil temperature -20°C~120°C ※ Opening pressure of bypass valve (other part) 0.15Mpa 6-2 . (Max.9 MPa Filtration accuracy 31 µ Filtration area 5 cm2 Oil temperature -20°C~120°C 6-3 .6-2-3 Line filter(only P.O return) Filtration accuracy 10µ Filtration capacity 125 /min (Max.) Opening pressure of bypass valve 0.103 MPa Proof pressure 0.m Filtration capacity 2 /min.m 6-2-4 Pilot filter PT 1/4 PT 1/4 Tightening torque: 60~80 N.) Proof pressure 3.7 MPa Oil temperature -20°C~120°C Port size 2×PT1 Tightening torque 20 N.T. 5. Using a brush. 6-3-3 Replacing the pilot filter 1. Stop the engine.06”) width). Add new hydraulic oil through the hydraulic oil intake. 3. Remove the pilot filter 6-2-3 with a spanner (27 mm(1. 6-3-2 Replacing the suction filter 1. remove any sediment inside the tank and rinse out the tank. While cleaning the element. Remove the filter to check whether the net of the element is damaged. fit the O ring in the flange side groove firmly so that hydraulic oil does not leak.5 6-4 . Attach pipes to install the filter to the tank. Immerse the element in it. After cleaning. inspect and maintain line filters after the first 100 service hours. Remove the bolts and spring washers which retain the filter to the hydraulic oil tank. then every 500 service hours. 3. 2. 2.6-3 Maintenance procedure 6-3-1 Replacing the line filter 1. 2. * Replace with a new one if the net is damaged or the mesh is widened. 4. 3. 3. 2. Prepare a can with clean treated oil. blow compressed air inside the strainer to blow off the treated oil. Remove the line filter 6-2-1 with a filter wrench. 6. 6-3-4 How to clean the suction filter 1. wash out foreign matter sticking to the element. If necessary. Stop the engine. check the hydraulic oil tank at the same time. * Replace with a new one if the net is damaged or the mesh is widened. Check whether any foreign matter is sticking inside the element. Remove the suction filter to check whether the net of the element is damaged. replace the cartridge assembly. Use a hard brush if the element is heavily stained. and pull off the filter. * In general. Stop the engine. When installing the filter. Total amount of hydraulic oil : 50. . 7 CONTROL VALVE CONTENTS 7-1 Specification 7-2 Disassembly and assembly 7-2-1 Replacing the O ring on the contact surface and each block assembly 7-2-2 Replacing the O ring on the Spool 7-2-3 Removing the load check valve 7-2-4 Replacing the relief valve assembly and the O ring 7-3 Structure of the relief valve 7-3-1 Main relief valve 7-3-2 Port relief valve 7-4 Precautions for handling 7-4-1 Handling 7-4-2 Installation 7-4-3 Operation . P3.7-1 Specification BUCKET TRAVEL TRAVEL DOZER SWING BOOM SLEW ARM PTO 130. A5.2 130.5 MPa at 5 /min 7-1 . P2. B1~B9 PF 3 / 8 P1 and P2 Main relief pressure 20. B5 Port relief pressure 23. B2. T1 PF 1 / 2 T2 PF 3 / 4 A1~A9.5 10 390 10 Port size P1.2 65±0.6 MPa at 42 /min P3 Main relief pressure 17.2 MPa at 25 /min A2.5 65±0. NUT 15. SPACER SECTION ASS'Y 21. ANTI-VOID VALVE ASS'Y 4. SHUT OFF VALVE ASS'Y 6. RELIEF VALVE ASS'Y 7-2 . BLOCK ASS'Y 19. O-RING 29. BLOCK ASS'Y 23. O-RING 11. BOLT 14. MAT(B) 13. RELIEF VALVE ASS'Y 3. RELIEF VALVE ASS'Y 10. BLOCK ASS'Y 26. BLOCK ASS'Y 25.O. RELIEF VALVE ASS'Y 2. OUTLET SECTION ASS'Y 17. BLOCK ASS'Y 20. BLOCK ASS'Y 24. NUT 9. BLOCK ASS'Y 27. 20 14 26 10 21 14 11 TURNING 14 12 21 DOZER 14 13 26 20 14 25 23 22 21 2 4 19 17 14 3 23 21 22 16 19 14 5 15 14 19 6 BUCKET 19 17 14 19 7 BOOM 17 17 14 DRIVE:R 9 19 14 19 28 15 DRIVE:L 19 26 ARM 17 27 29 1. BLOCK ASS'Y 18. CONTROL VALVE ASS'Y 16. O-RING 5. BLOCK ASS'Y 22. MAT(A) 12.T. 1 18 SWING 19 8 25 P. NUT 7. O-RING 8. INLET SECTION ASS'Y 28. 10.O. 11 12. ORIFICE 10. O-RING 6. SPRING 16. 14 24 7 6 25 5 26 (for Arm) 4 (for Arm) 27 (for Arm) 1 28 (for Arm) 3 29 (for Arm) FOR BOOM/BUCKET/SLEW DRIVE(R)(L)/SWING P. 9. SOCKET HEAD 19. END. SPOOL 31. SEAT. SEAT. (L)) 8. SPOOL 21. SPOOL 7-3 . SPRING 23. PLUG 5. O-RING 13. CAP 18. POPPET 11. POPPET 8. 13. SPRING 22. SPOOL 24. CAP 17. SPOOL 30. O-RING 20. POPPET 4. O-RING 9. 16 3 17 20 (for Bucket) 2 18 21 5 19 22 (for Bucket) 7 4 23 (for Bucket) 28 (for Drive (R)./DOZER/ARM 1. SPOOL 25.T. SPRING 3. BOLT. PLUG 32. SPRING 14. SPRING 7. SPOOL 27. O-RING 2. SPOOL 28. SPOOL 29. PLUG 15. SPOOL 26. SPRING 12. The tightening torque of the tie rod nut is 24 N. When disassembled. After tightening. While tightening them. Be careful not to damage the machine contact surface. When assembling.7-2 Disassembly and assembly 7-2-1 Replacing the O ring on the contact surface and each block assembly 1. it is recommended to replace the O rings on the contact surface. clean the contact surface so that no dust sticks to the surface. 5. 2. place them on their side. check that the Spool of each block operates smoothly. 6. 3. Tighten nut temporarily. Then attach the O ring and reassemble in the reverse order of the above procedure.m. 7-4 . When attaching the O ring. 4. Loosen the nut of tie rod. Remove each block. give grease to it. check the level of the mounting legs and tighten the nut. Pressing the inlet cover and end cover from above. cap nut of adjusting screw and hexagon nut are loosened. During installation. On the cap side 1) Loosen the cap mounting screws (4) and remove the cap (5). 7-2-4 Replacing the relief valve assembly and the O-ring. 1. 4. 7-5 .7-2-2 Replacing the O ring on the Spool 1. give grease to the O-ring. Take out Spool (6) and replace O-ring (7) 2) Rinse the Spool and insert it in the body. 5 72 6 3 2 Load check valve Load check spring 7-2-3 Removing the load check valve (For Drive (R). Remove the load check spring and load check valve from the valve block. check whether the small hole on the center of relief piston is clogged with foreign matter. replace the O-ring or the relief valve assembly. At this time. 3. 2. 2) Replace the backup ring (2) and O-ring (3). 2. 2. always check relief set pressure using the pressure gauge.m. Tightening torque of the cap mounting screw is 9 N. Clean the parts sufficiently before assembling them. 3) When mounting the O-ring presser. Remove the inlet section assembly and the relief valve. the relief set pressure and flow rate shall be conformed to the specification indicated on the page of external drawing. be sure not to damage the O-ring. Keep each load check valve in order so as not to confuse it with other valve block. When the relief valve assembly is removed. When the relief set. 2. 5. (L)) 1. be careful not to damage the O-ring. 4 The Spool is replaced in the units of the block assembly. On the lever side 1) Remove the mounting screws (1) of the O-ring presser from the block. If necessary. 3) When installing the spring cap. Main poppet 10. Adjuster kit 13. Pilot spring 14. O-ring 18. Poppet 9. O-ring 16.Name plate 3. Pilot spring 14. O-ring 3. O-ring (1B-P10) 7-6 . Piston 11. Pilot poppet 12.Backup ring 6.7-3 Structure of the relief valve 7-3-1 Main relief valve 7 2 1 8 6 5 9 4 16 17 3 Part Tightening torque Cap nut 30 N. O-ring 16. Cap 7. Pilot sheet 11.m 15 12 14 11 10 13 1. Backup ring 17.O-ring 2.O-ring (1B-P10) 4. Sleeve 9.O-ring 5. O-ring 4. Spring 13.m Installation of the relief valve 70 N. Cap 7. poppet 10.m Installation of 70 N. Wave washer 5.m the relief valve 4 5 18 17 16 13 12 7 3 1. Plug 8. Spring 15. Backup ring 2. Pilot poppet 12. Adjuster kit 15. Name plate 6. Backup ring 17. O-ring 7-3-2 Port relief valve 9 2 8 6 14 1 15 10 11 Part Tightening torque Cap nut 30 N. Plug 8. plug each port to prevent dust and water from entering it. adjust it in the following manner. If the temperature falls below 0°C.7-4 Precautions for handling (Installation and operation should conform to the following items. c. remove the cap nut and turn adjusting screw of the relief valve installed on the inlet section clockwise with an Allen wrench.7 MPa valve per rotation UP e. Always lock the valve when it is set to the specified pressure. Do not paint the spool. When raising the pressure. Tighten the valve joints with the specified tightening torque. 3. When stocking a valve for a long time. Relief valve pressure adjustment DOWN Main relief Approx. 2.) 7-4-1 Handling When handling and carrying valves. 15. 17. Install the operation link so that the spool moves correct in the direction of shaft. 5. Keep the oil temperature between -20°C and 80°C. check that the hydraulic circuit and the oil are both clean (cleanliness of hydraulic oil must be higher than the NAS12 class). d. be careful neither to drop them nor bang the spool end and cap. b. warm up the machine. 7-4-3 Operation 1. 1) Procedure for adjusting the main relief valve: a. because the high temperature and spatter may damage the O ring of the spool and the dust seal. Never remove the plug on each port to prevent dust from entering until piping work begins. If there is a mounting hole for the pressure gauge. Operate the control lever to read the indication of the pressure gauge when cylinder reaches the stroke end. 4.7 MPa valve per rotation Port relief Approx. If the set pressure differs from the specified value. Be careful when welding near a valve. 2. Be careful so that no unnecessary force acts on the valve through the piping. 3. Never raise the set pressure of the main relief valve and port relief valve beyond the specified set pressure. 7-4-2 Installation 1. Raise the temperature of the hydraulic oil to 50 to 60°C and set the engine speed to the rated value. 7-7 . Install a pressure gauge between the pump and control valve in the measuring position. Before operation. use it. 8 JOYSTICK (PILOT VALVE) CONTENTS 8-1 Specification 8-2 Structure . 52 25.5–1.7 3.6 30 2.2 1.8 20.6 3.7 10.5 110 26.1 2 4 6 6.5 35.15 1.49 Pressure 0 0 0 0 0 1.0 2.1 Secondary 0.8-1 Specification Double-Operating Torque Secondary Pressure(kgf/cm2) 35.7 25° 19° Secondary Pressure(MPa) 3.14 21.91–0.7 5–1 0.0 10.2 –0.2 1.34 13.0 Operating Torque(Nm) 3.5 Single-Operating Torque 2.5 7 Push-rod Stroke(mm) 0 5 10 15 19 Operating Angle 86.0 20.02 30.5 1.0 1.4 19.8 Operating Torque(kgf-cm) 30.4 2.5 P T 1 3 2 4 26° 26° 45° 8-1 .7 2.0 30.5 3.95 9.78 18. PLUG 21. PLATE 19. O-RING 15. SPRING 27. CIRCULAR PLATE 8-2 . SPRING PIN 6. BUSH 18. LOCK NUT 3. WASHER 2 26. BUSH 7. SPOOL 20. JOINT 29. PORT PLATE 13. CONNECTOR 8. HOUSING(4P) 9. SPRING SEAT 25. SEAL 23. SEAL WASHER 14. LEVER 4. JOYSTICK VALVE ASS’Y 11. BELLOWS 10. BOLT 16. HEX. O-RING 24. PUSH ROD 22.8-2 Structure 1 24 23 25 22 29 26 21 13 20 9 19 27 12 14 11 15 18 16 10 17 28 2 8 7 5 4 3 6 1. CASING 12. SPRING 28. KNOB 5. SPRING PIN 17. ADJUSTING NUT 2. 9 PILOT VALVE(1) (TRAVEL) CONTENTS 9-1 Specification 9-2 Structure . 9-1 Specification 9-1 . H. S. STEEL 13 SEAT. PUSH 28 CAM 12 SHIM 29 BALL.9-2 Structure 1 30 31 29 26 27 28 11 7 6 5 19 4 9 14 10 25 2 13 15 21 8 17 23 12 24 22 16 18 20 2 1 PILOT VALVE ASS’Y 18 O-RING 2 CASING 19 SCREW. SPRING 30 SET SCREW 14 PISTON 31 BELLOWS 15 BALL. STEEL 16 RO PLUG 17 PLUG 9-2 .C 3 CASING(DAMPER) 20 SPOOL 4 COVER 21 SEAT. SPRING 5 PLUG 22 WASHER 6 GREASE CAP 23 SPRING 7 PACKING 24 SPRING 8 O-RING 25 SPRING 9 O-RING 26 CAM SHAFT 10 O-RING 27 BUSH 11 ROD.. HEX. . 10 PILOT VALVE(2) (SWING • PTO) CONTENTS 10-1 Specification 10-2 Structure . 96 1.90 50 50 4.92 TP 3.1") 84(3.90 4.47 15 15 1.97") 65(2.3") 130–0.41 A 3.cm) (N.8(1.1") 150(5.94 2.98 0.41 45 45 4.96 20 20 1.) Operating angle 10-1 .9") Secondary pressure Operating torque 2 (MPa) (kgf-cm ) (kgf.56") 10 10 44.49 0 0 2 4 6 8 10 (deg.42 Circuit diagram 2.94 30 30 2.98 10 10 0.47 0.45 25 25 2.m) B 4.92 40 40 3.49 5 5 0.42 35 35 3.2(5.10-1 Structure 24(0.76") 80(3.45 1.94") 50(1. SPRING 10 SHIM 23 STEEL BALL 11 SHIM 24 O-RING 12 SPUR 25 O-RING 13 HOLDER. 4 24 6 17 22 3 9. 11 16 12 2 14 21 1 PILOT VALVE 14 PLATE. COMP 4 PUSHER 17 BOLT 5 SHIM 18 SCREW 6 CAM 19 WASHER 7 PIN 20 WASHER 8 BOOT 21 SCREW 9 SHIM 22 PIN. COMP 3 COVER 16 SPRING. 10 25 15 13 19 5. NAME 2 BODY 15 SPRING.10-2 Structure 1 23 20 8 18 7 26. SPRING 26 PUSHER ASS’Y 10-2 . . 11 PILOT VALVE(3) (DOZER) CONTENTS 11-1 Specification 11-2 Structure . 88 7.98 10 40 3.97") 71(2.0") 50(1.49 5 20 1.96 20 80 7.96 0 2 4 6 8 10 12 (deg. 100(3.9") 150(5.5–1.90 50 200 19.49–0.92 40 160 15.4N 2.8") 12 12 140(5.41 45 180 17.5kgf/cm2) 2.9") Secondary pressure Operating torque 2 (MPa) (kgf-cm ) (kgf.92 6.4N 0.15MPa (29.58 A 153(kgf/cm) 3.8 1.47 15 60 5.m) 4.42 35 140 13.84 77(kgf/cm) 1.2") 83(3.) Operating angle 11-1 . K.76 13.11-1 Specification 76(3.60 B 4.94 30 120 11.45 25 100 9.1MPa (5–1kgf/cm2) 0.6N 65(kgf/cm) 0.89–0.72 15N TP 137(kgf/cm) 2.cm) (N.27") OGYO K.64 3. NAME 26 PUSHER ASS’Y 13 SPRING COMP 27 BODY ASS’Y 14 CAM 11-2 . 20 13 15. K. 18 5 4. 3 25 7 17 12 6 OGYO K. 9 24 10 8 21 2.11-2 Structure 1 16 11 14 19 19 22 23 26. 27 1 DOZER PILOT VALVE 15 SHIM 2 SHIM 16 BOLT 3 SHIM 17 BOLT 4 BODY 18 WASHER 5 SPOOL 19 WASHER 6 SPRING COMP 20 SCREW 7 SLEEVE 21 SPRING PIN 8 COVER 22 PIN 9 PUSHER 23 STEEL BALL 10 PIN 24 O-RING 11 BOOT 25 O-RING 12 PLATE. . 12 SLEW MOTOR CONTENTS 12-1 Specification 12-2 Structure 12-3 Standard of maintenance 12-3-1 Slew bearing & slew case 12-4 Inspection and adjustment 12-4-1 Measuring the natural slew distance 12-4-2 Measuring the over slew distance after stopping 12-4-3 Measuring the required time for slewing . 000Hr 83 (99.455 min-1 Flow rate 24 / min Overload relief set pressure 15. B PORTS) (T PORT) 39 187 168 149.5 222 242 Port Port size 7.0 cm3 Maximum speed 1. PORT) (A.5) G3/8 2—G 3 / 8 7 77 G3/8 (DR.5 150 283 (208) ( 174) 10 5 43 R 96 53 ( 127) ( 139) 150h8 Type PCR-2B-10A-P-8565A Reduction Output torque 731 N. of threads Z 12 Weight 34 kg 12-1 .5 R10 A PF 3/8 B PF 3/8 13H7 50 35 T PF 3/8 25 Dr PF 3/8 G1/4 (PP PORT) Initial oil replace 500Hr Second and later replace 1.5 Hydraulic motor Capacity 16.C (seen from the output shaft) .D .7 MPa at 24 / min Pinion gear Module 5 No.5 25.m Output speed 68 min-1 Reduction ratio 1 / 21.12-1 Specification 2—M16 25 Direction of rotation P.2 50 10 Direction of rotation Oil inlet Oil outlet Clockwise A B 111 Counterclockwise B A 25. S1 gear 32. Pin 12-2 . O-ring 11. Brake piston 63 2. Snap ring 68. Carrier 1 26. Thrsut washer 2 41. Piston 57. Shoe 58. Valve plate 56. Spacer 18. Bearing 67. Bearing 45. Pin 24. Filter 64. Cylinder barrel 55. Plate S 53. Snap ring 43. O-ring 6. S2 gear 33. Bearing 66. Spring pin 70. Thrust washer 1 40. Ring 49. Oil seal 46. Pre-load collar 42. Ring seal 36. Pin 63. Poppet 14. Retainer 62. Pin 48. Swash plate 61. O-ring 37. B1 gear 30. O-ring 22. Disk plate 4. Carrier 2 27. O-ring 21. Spring C 65. Ring 2 51.12-2 Structure 13 9 15 7 11 27 17 3 8 19 14 6 10 26 16 2 23 24 28 5 43 25 32 18 51 21 52 22 53 49 1 50 20 44 12 41 31 38 4 3639 38 55 58 35 46 57 33 56 34 37 30 48 42 40 47 29 45 68 70 66 70 59 60 69 61 54 64 65 62 67 1. Shaft 54. Shoe holder 59. Back up ring 23. Spring 10. O-ring 19. Screw 69. Needle 34. Body 25. Piston 15. A internal gear 29. Spring ass’y 3. Spring 17. Thrust plate 2 39. Retainer 13. Thrust plate 1 38. Pinion shaft 28. Barrel holder 60. O-ring 5. Plug 9. Needle 35. Ring 1 50. Screw 47. Bearing 44. Relief valve 7. O-ring 20. Body H 52. B2 gear 31. Seat 12. Check valve 8. Cap 16. m M12×75 10.9 Tightening torque 120 N.9 Tightening torque 120 N.m Tightening torque 310 N.9 M16×45 10.12-3 Standard of maintenance 12-3-1 Slew bearing and slew case M12×75 10.m 12-3 . 4”) 125 12-4-2 Measuring the over slew distance after stopping Maintain the oil temperature at 50±5°C while the engine is running at full speed. Position of the machine Maintain the hydraulic oil temperature at 50±5°C. Make the boom joint pin (1) and arm bucket pin (2) put on a horizontal line. slew the Machine by one turn and measure the over slew length (at bucket edge) after stopping.12-4 Inspection and adjustment 12-4-1 Measuring the natural slew distance 1. Stretch the arm to the maximum length on a flat place. Unit : deg Standard value Weight W (kg) 45 125 (1) (2) W 12-4-3 Measuring the required time for slewing Extend the bucket cylinder to maximum length. retract the arm cylinder to the minimum length. (Moving distance of slew bearing outer race)Valid gear length Unit mm or less Standard value Allowance Weight (W) kg 30(1.2”) 60(2. Make a slope or use a sleeper to incline the machine by 12°. 12° put a weight (W) in the bucket (filling the bucket with soil). put a weight(W) in the bucket (filling the bucket with soil). Measurement Put a mark on the slew bearing outer race and the truck frame and measure the flow rate (deviation rate) of 3 minutes. make the boom parallel to the slope and stop engine. empty the bucket and measure the required time for slewing 5 turns following the first turn. 2. Unit : sec Standard value Allowance 33±4 47 12-4 . Set the attachment diagonally. . 13 TRAVEL MOTOR CONTENTS 13-1 Specification 13-2 Structure 13-3 Handling the travel motor 13-4 Measuring travel motor idling and travelling time 13-5 Inspection and adjustment . B PF1/2 Pilot PF1/4 Dr PF1/4 Item Item Reduction Output torque N.m 2666 Equivalent capacity cc / rev 958.5(4.2 / 637.C.5(11.1") PCD 192(7.7 Filtering (µM) 10 Hydraulic Working pressure MPa 20.6 / 15. 232(9.6") Direction of rotation (viewing from output axis) DR Direction Oil pouring Oil discharging of rotation port port RED A Clockwise B A B Counterclockwise A B PP Port Port size A.8") 70(2.2/56.553 700cc hydraulic motor (min-1) 2.D.6 SAE-30-CD Lubricating oil motor Output speed of 1.9 Oil ISO-VG46 gear Reduction ratio 1/40.6 Oil temperature(°C) -20~100 Others Capacity cc / rev 23.7") 122.8") A port Pilot port P.4 -1 Output speed (min ) 38.4 13-1 .13-1 Specification Drain port B port 297.311 Weight kg 43 Flow rate /min 37. O-ring 14. Seal ring 89. Screw (M8×40) 19. Thrust collar 2.13-2 Structure 1. Control cylinder 41. O-ring (IB-P25) 65. Spring V3 53. Retainer 45. Spring pin (5×12AW) 74. Oil seal 70. Snap ring 13-2 . S1 gear 85. Spring C 44. Bearing (6201) 60. Bearing 5. B1 pin 87. Spur 46. Piston seal 64. Plug 29. Valve plate 35. Choke 77. Relief valve cartridge 27. Cover 80. Spring pin (4×20AW) 13. Plug 54. B2 gear 84. Pin (h7 A8×15) 75. Backup ring 78. Name plate 22. Piston 36. Floating seat 3. Pin (h7 B4×6) 23. Plug 16. Carrier l 81. Snap ring (S-35) 10. Piston seal 63. Snap ring 9. Body-2 32. Snap ring (H-28) 72. O-ring (IB-G100) 62. O-ring (IA-P12. Carrier ll 82. Stopper ring 42. Swash plate 40. Snap ring (S-30) 18. Shoe 37. Plug 20. Block 25. O-ring (IB-P11) 21. Choke 57. O-ring 4. Ball 71. O-ring (IB-P7) 69. O-ring (IB-P12) 30. Snap ring (S-13) 12. O-ring (IB-G125) 61. Check valve 47. B1 gear 83. Snap ring (S-25) 11. O-ring (IB-P8) 68. Sloop 49. Thrust washer 17. Barrel holder 39. S2 gear 86. Shoe holder 38. O-ring (IB-P14) 66.5) 67. Spling V1 51. Screw (M10×25) 73. Body 79. Plug 76. Spring V2 52. Shuttle spool 50. Needle 6. Thrust washer 24. Plug 55. Spring guide 48. O-ring (IB-P15) 28. Thrust washer 8. O-ring 15. Needle 7. Pin 43. Ring 58. Bearing (6204) 59. Body-1 31. Shaft 33. Cylinder barrel 34. O-ring (IB-P28) 26. Plug 56. B2 pin 88. Use them as the oil intake port.13-3 Handling the travel motor Add lubricating oil according to the following procedure.000 service hours or 1 year Standard maintenance Tightening torque Sprocket tightening torque 110 N. 4. starting from the top in that order. then wind seal tape around the plug before tightening. The cover has three plugs.m 13-3 . Add lubricating oil through the oil intake until the oil comes out of the intake port. Turn the motor so the plugs are at right angle to the floor.m Motor tightening torque 110 N. Oil intake port(G 3/8) Oil quantity check port (G 1/8) Oil drain port(G 3/8) 2. Amount of lubricating oil 700cc Schedule for replacing lubricating oil: First: After the first 200 service hours or 2 months Second and later times : Every 1. oil quantity check and oil drain ports. remove the plugs from the oil intake and oil quantity check port with an Allen wrench. 1. Plug the oil intake and oil quantity check port. First. 3. 2±2 (Engine running at full speed and oil temperature of 50±5°C) 13-5 Inspection and adjustment 1. After travelling 3m on ground level. Unit : sec Standard value Low 14.7”) 450(17. Measuring meander distance in travelling Measure the meandering distance by travelling on hard ground.8 High 9.13-4 Measuring travel motor idling and travelling time 1.0 m (29.5 ft) 13-4 . Unit : mm or less Standard Max. value 170(6. Standard value Low 22.7”) (Engine running at full speed and oil temperature of 50 ± 5˚C) 9. Idle crawler for ten turns and measure the required time.8 (Engine running at full speed and oil temperature of 50±5°C) 2.6±2 High 15.5±0. measure the required time to travel 20m.2±0. . 14 HYDRAULIC CYLINDER CONTENTS 14-1 Structure 14-2 Disassembly and assembly 14-2-1 Disassembly procedure 14-2-2 Procedure for disassembling inner parts 14-3 Assembly 14-3-1 Assembly procedure 14-3-2 Inspection procedure 14-3-3 Precautions for assembly . m 10 10 10 10 17 J Tightening torque N.6”) ø40 (1.0”) 50 (2.0”) 50 (2.8”) ø50 (2.1”) ø90 (3.6 20.6”) B Pin diameter (head) mm ø40 (1.7”) 125 (4.2”) 920 (36.4”) ø40 (1.2”) 795 (31.2 10.0”) Clevis width mm G2 50 (2.7”) 470 (18.3 force* Pulling ton 7.4”) ø40 (1.5 9.0”) 50 (2.2 7.0”) 600 (24.6 17.8”) ø45 (1.0”) 50 (2.5 13.5 M33 × 1.7”) 652 (25.9”) G1 50 (2.0”) 50 (2.6”) ø35 (1.14-1 Structure H J I D C A B F K E G1 G2 Cylinder Boom Arm Bucket Swing Dozer Item Weight kg 32 32 27 31 23 Trust Pushing ton 10.0”) 50 (2.8”) ø45 (1.8”) ø45 (1.5”) F Stroke mm 609 (24.5 M30 × 1.0”) 50 (2.9”) ø80 (3.0”) 1609 (63.2 5.5 *Main relief pressure MPa 20.2 14-1 .6”) ø40 (1.0”) D Cylinder bore mm ø80 (3.0”) 500 (19.5 M30 × 1.4”) E Maximum contracted length mm 920 (36.6”) ø35 (1.6 20.6 20.3”) 957 (37.1”) ø80 (3.6”) ø40 (1.5 M30 × 1.m 460 460 430 460 540 I Tightening torque N.3”) 595 (23.8”) 1295 (51.0”) H Tightening torque N.0”) 50 (2.9 7.1”) ø75 (2.2 9.6”) C Rod diameter mm ø45 (1.2 A Pin diameter (rod) mm ø40 (1.6”) ø40 (1.m 900 900 780 900 1250 Size of piston screw K (size × pitch) M30 × 1.5 10.5”) Maximum extended length mm 1529 (60.2”) 1520 (59. Cushion bearing 2. Cylinder head assembly 5. 1. Retainer 17. Pin bush 3. Rod 13. Wiper ring 18. Cushion ring 23. Rod packing assembly 7. Packing assembly 9. Steel ball 10. Rod bush 15. Cylinder assembly 11. O-ring 21. Set screw 14-2 . Tube 12. O-ring 19. Rod cover 14. Dust seal 4. Piston 26. Piston assembly 6. Backup ring 20. U-ring 16. Stopper 25. O-ring 22. Spacer 24. Piston packing assembly 8. Slide ring 27.14-2 Disassembly and assembly 1 3 23 22 25 23 17 18 20 19 16 17 21 15 14 13 7 11 27 24 10 5 6 9 10 12 4 28 8 23 22 26 2 23 The illustration shows a boom cylinder. Seal ring assembly 28. B 2. Place the removed piston rod assembly on a wooden bench or a waste to prevent damage. pull the piston rod about a third of the length. do not deform the Hard wood cylinder. Pull out 14-3 . Blow air alternately from ports A Vice and B and operate the piston rod to drain oil from the cylinder inside. A Tighten the vice carefully. Disassembling the piston rod assembly Slowly turn the piston rod assembly to remove it from the cylinder tube assembly. Loosen and remove the rod cover from the cylinder tube assembly with a hook wrench. To remove the piston.14-2-1 Disassembly procedure 1. Counterclockwise Rubber or waist 3. Hold the cylinder with the vice. press them out with a pressing machine to remove them. If they are to be reused. 14-4 . Be careful not to damage the groove on the cover and piston. Be careful because the piston rod assembly may come out of the vice and be damaged if it is set diagonally. Remove the piston assembly from the piston rod assembly (after removing the set bolts).4. the snap ring must be removed first. Press (example of a cylinder rod) 4. 14-2-2 Procedure for disassembling inner parts 1. Disassembling the piston rod and cylinder tube assembly As the bushes are pressed fit to the rod head. 3. Because it is difficult to remove the dust seal and rod packing without damaging them. 2. remove them by inserting a eyeleteer or a similar tool and prying them out. Disassembling the piston assembly Hold the piston rod assembly with a vice. Make a working face for the rod cover Packing case assembly on the workbench and move the rod cover to and fro to remove it. Disassembling the packing assembly Remove the packing by prying it with an eyeleteer or a screwdriver. Be careful not to damage the groove of the cover and piston. Backward Remove the backup ring then the O ring with Forward a screwdriver. • Set the piston rod assembly on a level block so that it becomes parallel to the level block. Hard wood • Put the waste between hard wood and the piston to prevent the surface sliding from being damaged. For a spherical bearing. Then remove the cushion bearing in the direction of the arrow. Disassembling rod cover Put piston rod assembly on a holding jig on Holding jig the work bench. be careful not to damage them. or any defect which may affect its operation. The assembly procedure is the reverse of disassembly. 5. If you must reuse them. cuts or foreign matter sticking to the packing. discoloring. • Cylinder tube assembly • Rod cover assembly • Piston rod • Piston assembly 14-3-2 Inspection procedure Clean each disassembled part with light oil or treated oil except for the packings. bucket and swing) and seal rings (arm and swing). etc. Thoroughly clean the sliding surface. 3. Check the sliding surface of piston rod for damage. 4. after tightening the set bolts. cracks. Other types of oil will remarkably shorten the life of the packing. packing groove. Check all parts for flaws. Tighten the rod cover. (Coating hydraulic oil is effective for rust prevention to a certain degree. O ring. If the part is not used for a long time after being cleaned. Execute assembly work paying attention to the direction of cushion bearings (boom.) 1. Before assembly. Check each part for metallic powder or other foreign matter sticking to it. uneven abrasion. 3. or burrs which may affect the operation. 3. (Inside of the tube. check that there are no tears. 2. check whether metallic powder or other foreign matter is not sticking to any of the parts and whether the parts can be reused. 14-3-3 Precautions for assembly Assemble the cylinder while paying attention to the following matters. Replace the set bolts with new ones. arm. 4. Coat hydraulic oil on each part before assembling them. oil hole. further tighten and firmly fix them by hitting with punch at two points on the periphery. 1.) 2. 2. rod. etc. Packings and seals are usually replaced with new one. 14-5 . deformation. Packings are cleaned with petroleum hydraulic oil. piston and nuts with a specified tightening torque shown in the attached table (page 14-1). In assembling. Check fully before starting assembly work. 4. Replace the packings with new ones before assembly.14-3 Assembly 14-3-1 Assembly procedure 1. execute a rust proof treatment. Assemble beforehand the parts into the following assemblies. rust. disassembly and assembly .15 SWIVEL JOINT CONTENTS 15-1 Specification and Structure 15-2 Structure. 6 MPa Port size E~H PF 1/4 A~D PF 1/2 Working speed 10 min-1 *A to H and D rain denote the position of the port. Travelling A.98 MPa A~D.1") 73 (2. Drain 15-1 .15 MPa Working pressure E 0.3") 78(3.9") 124(4. Dozer E. Travelling B.15-1 Specification and Structure H 0. G 20. F. Travelling C. Dozer F.9") G. Travelling H.9") 110(4. Overdrive D. A C E H G D F B 100(3. Coat a little hydraulic oil or grease on the O rings before assembly. Bolt 9. 2. check the O ring and sliding part for flaws and other defects. Socket head bolt 7. Assembly is usually executed in the opposite order of disassembly. Thrust washer 6. 3. Plug 10 5.disassembly and assembly 15 1. Remove the shaft (3) from the hub (2) upward. 2. Spring washer 10. Assembly: 1. Cylinder 3. Slipper seal 16 4 14. tap a hammer on the shaft by rotating it and pull it up. Packing assembly 12. Dust seal 14 5 13 6 7 9 12 8 Disassembly: 1. O-ring 11 2 13. Before assembly. Cap 3 8. Remove the bolts (6) and thrust washer (5). Roter 4.15-2 Structure. * Be careful so that O ring does not become trapped. Knock pin 11. Remove bolt (8) and cap(7). O-ring 17 15. Because the shaft is tightened by the tension of the O ring. Swivel joint assembly 2. 15-2 . . 16 CRAWLER CONTENTS 16-1 Structure and operation 16-1-1 Crawler (Steel) 16-1-2 Track frame 16-2 Standard of maintenance 16-2-1 Crawler (Steel) 16-3 Disassembly and assembly 16-3-1 Installing the crawler 16-3-2 Removing the crawler 16-3-3 Track frame spring 16-3-4 Life of the rubber crawler 16-3-5 Handling the rubber crawler . Spring 16-1 .8") 2 101. Idler 2.6 mm(4. Pin 16-1-2 Track frame 2 1 3 4 5 1.0") 1. Track frame 3. Shoe 2. Track roller 5.16-1 Structure and operation 16-1-1 Crawler (steel) 1 300 mm(11. Guard (for steel crawler) 4. 08") Replace Bush outer 5 32.3") Pad or replace mm 3 Grouser height 16. Item Unit Standard Allowance Remarks value Measure by stretching 5 1 Link pitch 101.1") links except for the master link 2 Link height 61(2.6”±0.5(2.2(1.06”) 7(0.26") 29(1.3") Pad or replace 4 Pin clearance 0.6(4.4") 58.5±1.5(0.16-2 Standard of maintenance 16-2-1 Crawler (steel) 1 5 2 4 3 No.0”) 104(4.33(0.012”) 2(0.14") Replace diameter 16-2 . For a rubber crawler.16-3 Disassembly and assembly 16-3-1 Installing the crawler 1. the crawler by using the idler as it 2 is. 1 2. Steel: 25 to 35 mm(1. drive motor to bring it above the idler and for steel 3 crawler.6") 16-3 . Tension the crawler Tighten the cartridge valve (1) of the adjust cylinder. fix the master pin (3) into the hole. Crawler After the sprocket put on the crawler (2).4") Rubber: 10 to 15 mm(0. Install steel bar and heavy duty hammer into the undercarriage. grease and adjust the tension.0"~1.4"~0. 16-3-2 Removing the crawler 1. Weight (rubber crawler): 314 kg (157×2) 16-4 . drain grease and loosen the crawler (2). Loosen the crawler. Weight (steel crawler): 364 kg (182×2) 3) As rubber crawler is endless and of solid material. 1 By loosen the cartridge valve (1) of the adjust cylinder. 3 2) Turning in the direction of the idler side. Crawler 1) Lift the main frame with attachment and put blocks under to lift the machine. push the idler to the end and remove the rubber crawler by using steel bar from the idler. 2. remove 2 crawler master pin (3) and then the crawler (2) from track frame. 7”) 3 left and right faces Replace of idler guide 3-2 Idler support 162±1. Item Standard Remedy Allowable limit Deformation of Bend 5 (0.0 (6.0(6.5 (4.4”±0.5” -0.0 +0.02 ) 119 (4.0”) 16-5 .04”) 157 (6.7”) Distance between +1.5 (8.0” -0 ) 131 (5.04 3-1 Track frame 166 -2.2”) Spring Standard value Allowable limit 4 (free length) Replace Set length 203.0 +0.16-3-3 Track frame spring 3 1 4 2 Unit: mm No.9” -0.4") (Twist between left and Twist right crawler frames) Opening of idler 5 (0.2") (Overall length of track frame) 1 frame Correct 10 (0.2”) Pad or replace faces of idler guide +0 +0 2-2 Idler frame 124 -0.2") Distance between Standard value Allowable limit 2 upper and lower 2-1 Track frame 126+1.08 ) 171 (6.04 -0 (5. 5") 25. Note that the life slightly differs depending on the conditions of site and the operation of the machine.) (4) If the machine is going to be stored for a long time.98") 25(0.510±12(178"±0. (This may affect the adhesion of the core metal.1") Center of rubber crawler steel core 300(11. of cords 40±4 Range of working temperature -25°C~55°C Width × pitch 300×52.0") 28(1.8") (pitch) 52.1") Description Value Total length of rubber crawler 4. PRECAUTIONS: (1) Wipe immediately if fuel or hydraulic oil sticks to rubber crawler.98") 37.5(1.5 16-6 . (2) Check that there are no sharp edges protruding on the ground.5(1. 25(0.5(2. never store it where it will be directly exposed to sunlight. (3) Avoid using on beach. 16-3-4 Life of the rubber crawler Abrasion loss (mm) Standard life 20 e 15 ac al urf ner (so il) es Ge ng api ret 10 dsc Lan nc Co 5 0 500 1000 1500 2000 2500 3000 Service hours (H) Check the remaining life of the rubber crawler by the abrasion loss in the rubber crawler height as shown in the figure below.5") Steel cord Tension 800 kg / piece Steel cord No. 3. 16-3-5 Handling the rubber crawler 1. Protect from salt Do not operate on beach (Core metal will rust due to salt corrosion). keep it indoors to prevent exposure to direct sunlight and rain. 5. Prevent foreign matter from entering the rubber crawler Foreign matter will strain the crawler and cut it. 4. 2. No sharp turns Do not turn sharply on a road with a high-friction factor (such as a concrete road). 16-7 . clean it promptly. 6. Do not run over or turn on a sharp edge If you run over or turn on a projecting sharp edge or a stepped grade. Keep oil products away from the rubber crawler If you spill fuel or hydraulic fluid on the rubber crawler. the machine will partially load on the rubber crawler and split it or cut the threads of the rubber crawler and the inner steel cord. Store indoors If the machine is not used for a long time. 17 SPRING CASE AND GREASE CYLINDER CONTENTS 17-1 Structure 17-2 Specification of spring 17-3 Disassembly and assembly 17-3-1 How to disassemble and assemble the ad just cylinder 17-3-2 How to disassemble and assemble the spring case . 5(11.3") L set length (mm) 233.D. shrinkage (kg ) 4. Set length L L0 Name Value Name Value No.C.C. Plate 8. (outer diameter)(mm) 107(4.D.1(7. Grease nipple (PT1/8-A) 5. Dust seal (DKR-40) 17-2 Specification of spring d ø O. Spacer 2.D.3") Set force (kg) 2. O-ring (IB-P40) 12.698 øI. ø I.650 Wire diameter d (mm) 22(0. (Inner diameter) (mm) 63(2.9 (2.0”) P. Backup ring (T2-P40) 13.9") Lo Free length (mm) 286. Split pin 7. Cartridge valve 4. shrinkage (mm) 195.17-1 Structure 1 13 12 2 3 5 6 7 8 9 4 10 11 1. Cylinder 9. (Center diameter) (mm) 85(3.5 Length at max. of active coils 7. Snap ring (H-52) 3. Spring 10.5(9.2") Spring constant (kgf/mm) 50.D. P.7") Total number of coils 9 ø O. Rod 11.2") 17-1 . Castle nut 6.D.5") Force at max.D. Attach the cartridge valve to the adjust cylinder rod so that the screw on the second step reaches the tapped hole. dust seal. Cylinder 9. Attach the O-ring. 2. Note: • Adjust and assemble carefully so that air does not remain in the adjust cylinder tube. Backup ring (T2-P40) 10. Attach the adjust cylinder rod to adjust the cylinder tube carefully so that the seals are not damaged. Rod 11.9") 17-3-1 How to disassemble and assemble the adjust cylinder 1. O-ring (IB-P30) 8. backup ring and O-ring. Split pin 3.17-3 Disassembly and assembly 1. *Coat grease on the O-ring and dust seal before assembly. Remove the snap ring. b. Spring 5. Apply grease before hand in the adjust cylinder tube. Remove the cartridge valve from the adjust cylinder rod. Split pin 7. b.m 17-2 . backup ring and spacer to adjust cylinder tube. spacer. Cartridge valve 4. Castle nut 14. When attaching the adjust cylinder rod. c. • Coat grease on the piston of the cylinder tube rod before assembly. tighten the cartridge valve after checking that grease comes out of the grease drain hole. Disassembly a. a. Remove the cylinder rod from the adjust cylinder tube. Castle nut 6. Idler yoke Cylinder effective stroke: 150 mm(5. Assembly The assembly procedure is the reverse of the disassembly procedure. Scraper (DSI) 12. Backup ring (T2-P40) 13. Tightening torque of the cartridge valve: 187 to 210 N. Spacer 2. Assembly The assembly procedure is the reverse of disassembly. Attach the spring to adjust cylinder tube using the special tool and set the spring to the specified position with the castle nut. Remove the spring from adjust cylinder tube. b. be careful during assembly. Remove the castle nut for the mounting spring.5mm(9. Note: • Be careful when using the tool when removing the spring. 2.2") 17-3 . After adjustment. completely bend the split pin. a. Disassembly Lower the spring force between the front idler and adjust cylinder tube using a pressing machine and the special purpose tool. Also. 17-3-2 How to disassemble and assemble the spring case 1. Spring set length: 233. 18 IDLER CONTENTS 18-1 Standard of maintenance 18-1-1 Idler . 8”) 24 (0.4”) Pad or replace 5 Width of tread mm 20 (0.6”) ø265 (10.9”) Pad or replace 6 Quality of lubricating oil cc 80 Gear oil or engine oil 18-1 .2”) ø307(12.1”) 2 Outer diameter of tread mm ø269 (10.4”) Pad or replace 3 Width of projected part mm 25 (1.0”) 21 (0.18-1 Standard of maintenance 18-1-1 Idler 2 1 5 3 4 No. Item Unit Standard Allowance Remark value Outer diameter of mm Pad or replace 1 projected part ø311(12.8”) Pad or replace 4 Overall width mm 65 (2.6”) 60 (2. 19 SPROCKET CONTENTS 19-1 Disassembly and assembly 19-1-1 Removing the sprocket 19-1-2 Installing the sprocket 19-2 Standard of maintenance 19-2-1 Sprocket . m (72. Crawler Refer to the explanation of crawler installation.m~110 N. 19-1-2 Installing the sprocket 2 1. 2. Sprocket 1 Attach the sprocket to travelling motor assembly and tighten the mounting bolts (1).19-1 Disassembly and assembly 19-1-1 Removing the sprocket 1 2 1. Crawler Refer to the explanation on crawler removal.3~80 lb- ft) 2. Sprocket Remove sprocket mounting bolts (1) and then sprocket (2) from the travelling motor assembly. Tightening torque:100 N. 19-1 . 8(12.4")ø305.0") 19(0. 4 N.8(12.07") Pad or replace 2 Minor diameter of sprocket mm ø313.m 100~110 — motor mounting bolt (M10 P1.m 100~110 — sprocket mounting bolt (M10 P1.19-2 Standard of maintenance 19-2-1 Sprocket 1 2 4 3 No.5) 19-2 . Item Unit Standard Allowance Remarks value 1 Width of sprocket teeth mm 25(1.0") Pad or replace Tightening torque of Tighten some more.5) Tightening torque of Tighten some more. 3 N. . 20 TRACK ROLLER CONTENTS 20-1 Standard of maintenance 20-1-1 Track roller . 1 1.m 325 Tighten some more.5(0.7") — Pad or replace 6 Roller side clearance mm 0.9") 21(0. Item Unit value Allowance Remarks Outer diameter of 1 mm ø115(4.06”) Replace bush 7 Tightening torque for mounting roller N.8") Pad or replace 4 Overall width mm 108(4.6”) Pad or replace 3 Width of projected part mm 24(0.20-1 Standard of maintenance 20-1-1 Track roller 4 3 5 7 6 8 2 1 Standard No.5”) — Pad or replace projected part 2 Outer diameter of tread mm ø95(3.2±0.3") — Pad or replace 5 Width of tread mm 42(1.7”) ø92(3.(M24 P3) 8 Quantity of lubricating oil cc 100 Gear oil or engine oil 20-1 . 21 CARRIER ROLLER CONTENTS 21-1 Standard of maintenance 21-1-1 Carrier roller . 9”) Pad or replace 2 Overall width mm 100 (3.0”) ø73 (2.m 22 mounting roller (M8 P1. Item Unit Standard value Allowance Remarks Outer diameter of 1 projected part mm ø76 (3.21-1 Standard of maintenance 21-1-1 Carrier roller 2 4 5 3 1 No. 4 N.008”±0.5 (0.004”) 1.9”) — Pad or replace 3 Roller side clearance mm 0.25) 5 Quantity of lubricating oil cc 70 Gear oil engine oil 21-1 .1 (0.06”) Replace bush Tightening torque for Tighten some more.2±0. 22 ELECTRICAL EQUIPMENT CONTENTS 22-1 Structure and function 19-1-1 Electric circuit diagram 22-2 Failure and remedy 22-2-1 Starter system 22-2-2 Alter nator system . 22-1 Structure and function 22-1-1 Electric circuit diagram 22-1 . Malfunction of the plunger of Correct or replace magnetic switch.Contractor drops and is always Replace off. Reconnect cable. Starter does not stop even . Starter rotates at its full speed . loosening (bad earth) earth).Malfunction of armature or field Correct or replace coil . . of the connecting wire between magnetic switch and motor termi- nals . tighten tween the battery and the mag.Spline which engaged with the Free the spline when the starter switch is pinion of armature shaft is caught pressed.Wrong installation Reinstall the ring gear. connected. .Wrong adjustment of plunger gap Adjust before the pinion engages with (distance l) the ring gear. Pinion does not come out even . .Loose connection of contractor Tighten connections. disconnection or the short-circuit of coil . Clean commutator.Permanent set of pinion sleeve Replace spring.Disconnection of the wire harness.Brush is worn out or brush spring Replace or adjust.22-2 Failure and remedy 22-2-1 Starter system Failure Cause Remedy .Commutator is dirty.Short-circuit inside switch Replace switch when starter switch is turned .Malfunction of overrun clutch Replace when the pinion engages with the ring gear and the starter rotates. is touching. connections (make good netic switch. . . .Disconnection of the cable be. Engine does not start even .Improper engagement of pinion Correct the engagement.Contact surface of contractor is Correct or replace rough. switch terminal. Starter does not rotate even and ring gear when the pinion engages with . and the pinion cannot move. 22-2 . Reconnect and tighten loose connection of the battery or connections. .Loosening of field coil and brush Tighten coil and brush. Improper earth conection Make good earth conections.Cords between terminals are Reconnect cord-tighten disconnected or connectors are in connections.22-2-2 Alternator system Failure Cause Remedy .Coil is disconnected or burnt. tween each terminal . movement of brush and slip ring . Adjust.Wrong installation Connect.Diode is damaged. .Capacitor broke down.Brush and slip ring do not contact.Alternator internal short-circuited 22-3 .Loose connection of cords be.Defective alternator Replace .Defective bearing Replace. down. . .Defective fan belt Replace.Short-circuit of coil Replace .Diodes on (+) and (-) sides broke Replace. .Fan belt slips. Fuse melts. . Replace . . Tighten connections. loose connection. Noise . Cannot be charged.Improper contact or insufficient Clean slip ring and brush holder. Connect or replace . Insufficient charge .Defective diode Replace Overcharge . Replace . 23 TROUBLESHOOT- ING CONTENTS 23-1 Troubleshooting . check Replace pump Ass'y or faulty. OK Pressure Check the pressure on incorrect Relief valve faulty Adjust to correct main relief valve. 23-1-2 Operation power is weak Check the level of If not enough Fill up with HYD. disassemble. Flow Faulty Check the level of HYD. occur from pump. HYD. adjustment. Large internal leak on Replace Ass'y. Intake system faulty. 23-1 . Pumps or couplings Disassemble. oil Replace HYD. oil. oil. oil low Large internal leak pump Replace pump Ass'y. Deterioration of the HYD. Repair faulty piping part. oil has Check cause of bubbles No bubbles in it. or replace Ass'y. flow from pump.23-1 Troubleshooting 23-1-1 All functions not operational Check the level of If not enough Fill up with HYD. and remove it. HYD. on pump. oil. OK Clean. control valve. oil. couplings. oil. HYD. adjust Faulty relief valve. OK Abnormal noise Yes Clean up suction filter. pressure. 23-2 . If the OK pilot system. OK Check the action Faulty of joystick. OK Fuse has blown. on pump No. Faulty Blocked up with Check the pilot filter. OK Check the wiring. then replace. Check the action of limit switch or solenoid valve. then flush and inner parts of out or replace. Replace fuse. control valve. spring is weak.3 and seals. Refit wiring. OK If it is faulty spool Check control valve sticking. LIMIT SWITCH- SOLENOID VALVE. OK Check the set Faulty Check the pressure Incorrect Replace HYD. 23-1-3 No operation on boom. pilot filter. arm. bucket & slewing Check set condition Reset or adjust of safety lock lever. short Faulty circuit of FUSE BOX. OK Check parts of each Clean or replace port on control valve. limit switch. pump pressure on pilot port. contamination of Clean or replace. Clean or replace. Replace seals or block Ass'y. Only one Problem changed to direction opposite direction Check the travelling for both(forward. Change over valve section Internal leak on backward)directions. Replace motor Ass'y. Action faulty (does not relieve Check the action of pressure) Pump was faulty. OK Drive motor broken. pressure or replace other pump's port and relief valve. port A⇔port B swivel joint. Contamination Disassemble. 23-3 . repair Faulty drive motor. OK Faulty action on spool. Faulty OK Faulty linkage. or replace Ass'y. the relief valves. Replace pump Ass'y.23-2 Travelling system 23-2-1 Right (or left) hand side of crawler does not work correctly Faulty Check the spool stroke. Action OK (relieves pressure) Check the counter Faulty Check plunger. then test. No travelling in either direction Check plunger. Check the link system. repair or replace Ass'y. Low Replace or change over pressure Adjust to correct the relief valve with the OK Faulty relief valve. or Ass'y. Faulty Counter balance Replace seals valve is faulty. Faulty clean or replace. Adjustment or replace. balance valve. OK OK Replace seals or Faulty action on spool. Problem changed to opposite direction Change over the outlet hoses No. then test travelling. 1. Check the link system. to correct tension. opposite direction Change over the hoses from swivel joint to drive Internal leak on Replace seals or motor L/H to R/H. balance valve. block Ass'y. 23-2-2 Travelling meander by slow speed on only right (left) hand side. OK Internal wear or breakage. then swivel joint. or replace Ass'y. OK Faulty Check the spool stroke. Faulty pump. Nothing changed Contamination Disassemble.2 pumps. Replace pump Ass'y. 23-4 . Repair or replace. Faulty Faulty linkage. pressure or replace test travelling. Is the meander distance Yes OK within tolerance? No Check the tension of Faulty Remove any foreign crawler and check for the matter and re-adjust foreign matter present. Problem changed to clean or replace. relief valve. Ass'y. Adjustment or replace. Nothing changed Problem changed to opposite direction Low Change over the relief pressure Adjust to correct valves right to left and Faulty relief valve. test travelling. repair Faulty drive motor. Nothing changed Check the counter Faulty Check plunger. Problem Replace counter balance solved Faulty counter Replace counter valve (brake valve). 23-2-3 Machine fails to hold on incline If you can see any movement (outside tolerance). 23-5 . balance valve. Nothing changed Problem solved Replace drive Replace drive motor. motor Ass'y. balance valve. Faulty drive motor. 23-6 . Replace valve or Ass'y. etc. Adjust to correct pressure or replace. Faulty Faulty control valve. or slew bearing. Check the function of Faulty Change over relief slewing operation valves to the other system (dozer. Check the pinion gear on slew motor and Gear is damaged Replace pinion gear (also) bearing gear. or replace. Replace seals or pump Ass'y. OK Faulty pump.23-3 Slewing system 23-3-1 No operation both (right/left) slewing. repair Faulty slew motor. Replace seals or relieving or not? valve block. swing).1's or No. Replace slew bearing. Faulty slew relief valve. Not relieving Is slew motor Spool is sticking. push bucket by hand. It has resistance Take the slew motor off. OK Low pressure Faulty relief valve. OK Not turning Check slew when Seized slew bearing. then test. Relief valve is sticking Disassemble. or replace slew motor Ass'y.2's. clean bucket by hand. It can be turned Disassemble. clean or replace. pump port. Faulty OK Change over outlet hoses to pump No. It is relieving No resistance Test slew when push Disassemble. then test. 23-7 . Clean or replace. 23-3-3 Turning acceleration slow. the overturn is higher than tolerance Is the distance Yes under tolerance? OK Above tolerance Low pressure Check the turning Faulty relief valve. 23-3-2 It is possible to turn right (left) but not left (right) Not relieving Change over control Lever moved valve pilot port to left (right). OK Problem Faulty control valve block. motor Ass'y. Faulty relief valve. Clean or replace. then test. circuit pressure. OK Internal leak on Replace turning turning motor. A⇔B. relieving or not. Check the relief It is relieving valve on turning. opposite direction Repair or replace Faulty joystick. Replace inner parts changed to or valve block. joystick Ass'y. Relief valve is sticking Faulty Disassemble. swing). Clean or replace. 23-3-5 Turning movement when the machine is parked on a slope Is the distance lower Yes OK than tolerance? No Low Check the slew pressure pressure. OK Internal leak on slew motor. OK Internal leak on slew motor. Change over outlet hoses to pump Faulty Replace valve No. Faulty control valve. pressure or replace. system (dozer. then test. clean or replace. Change over relief Low valves to the other OK pressure Adjust to correct pump port or replace. Faulty relief valve. Clean or replace. 23-8 . Replace motor Ass'y. 23-3-4 Extreme slow slew speed Does the turning Yes speed meet the OK specified speed? Slow Check the action of OK Check the slew the turning operation circuit pressure. Faulty Low pressure Faulty relief valve.1's or No. or Ass'y. then test.2's. Faulty relief valve. Relief valve is sticking Disassmble. then test. Replace valve block Ass'y. Ass'y. Disassemble. Adjust to correct pressure or replace relief valve. then replace. right to the other pump's port hand travelling). If spring is weak. OK Faulty port relief valve. clean or replace. Low OK pressure Faulty relief valve. Faulty Faulty control valve.23-4 Boom system(for arm and bucket cylinders the same method as follows) 23-4-1 No movement on boom cylinder Does Check the movement move Change over boom section of boom for both port A⇔port B directions. OK Breakage on inside of cylinder. replace Does not move seals or replace. then Faulty of control valve. clean or replace. Check the inner parts If it is a sticking spool. replace Faulty pump. OK Replace inner parts or cylinder Ass'y. 23-9 . Faulty OK Change over outlet hoses from the other pump. or replace relief valve. seals. OK Disassemble. or replace. then test. Check the function of boom operation Faulty Change over relief valve system (bucket. Faulty Replace inner parts or Faulty joystick. Faulty Change over outlet Disassemble. If spring of control valve. pressure or replace relief valve. Faulty Replace valve Faulty control valve. is weak. Faulty Replace inner parts Faulty joystick. then test. replace OK hoses from the other seals. to the other pump port or right hand travelling). block Ass'y. or replace pump pump. Faulty If it is sticking spool. Faulty Check the action on boom Change over relief valve operation system (bucket. OK Breakage on inside of cylinder. OK Slow No Are the directions Change over relief valve slow (lack of power)? port A⇔port B OK Adjust to correct OK Faulty relief valve. replace. Ass'y. Relief valve is sticking Disassemble. Low OK pressure Adjust to correct Faulty relief valve. or Ass'y. pressure or replace relief valve. clean or replace. OK Faulty pump. then replace. then Check the inner parts clean or replace. 23-10 . OK Replace inner parts or cylinder Ass'y. 23-4-2 Slow action or lack of power on boom cylinder Check the cylinder Correct working speed. then test. OK Check the internal leak on control valve. clean valve. boom section B. OK Faulty port relief Disassemble. 23-11 . OK No Change over relief Faulty Internal leak on valve Replace inner parts boom cyl. 23-4-3 Natural fall of boom Check the fall is Yes within tolerance. or cylinder Ass'y. boom cylinder. Change over hoses Faulty Internal leak on Replace valve boom section A⇔ control valve (spool). block Ass'y.⇔bucket. then check. or replace. or cylinder Ass'y. then test. Ass'y or control valve Ass'y. Faulty suction valve.23-5 Swing system 23-5-1 No movement on swing system Operation on just Yes one direction. Contamination Disassemble. Change over the outlet hoses No. 23-5-2 Drifting swing cylinder Air leaking out of swing cylinder. If OK Internal leak on or Ass'y. Clean or replace. Faulty Replace valve block OK Faulty control valve. 3 pumps and then test. clean Faulty or replace. Faulty Adjustment or Faulty linkage. Check the link system. or Ass'y. Otherwise then test. slewing). Broken parts inside Replace inner parts the swing cylinder. or seals. pressure or replace relief valve. or disassemble and replace seals. clean or replace the suction valve. Low pressure Adjust to correct Faulty relief valve. 23-12 . control valve. Replace block Ass'y Change over hoses. No Faulty Replace or change over Check the function of the relief valve with the swing operation system other pump's port and (dozer. Check internal leak on control valve. OK Replace block Ass'y Faulty action on spool.2. Not working properly Internal leak on Replace inner parts swing cylinder. replace. OK Replace pump Ass'y Faulty pump. Check the spool stroke.