Hitachi Zaxis ZX160W PDF [PDF]

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Technical Manual (Operational Principle)



Vol No.: TOCBBE-00



INTRODUCTION TO THE READER • This manual is written for an experienced technician



to provide technical information needed to maintain and repair this machine. • Be sure to thoroughly read this manual for correct product information and service procedures.



• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.): Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-298-32-7173 FAX: 81-298-31-1162



ADDITIONAL REFERENCES • Please refer to the materials listed below in addition to this manual.



• The Operator’s Manual • The Parts Catalog



• Operation Manual of the Engine • Parts Catalog of the Engine • Hitachi Training Material



MANUAL COMPOSITION • This manual consists of three portions: the Techni-



• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.



• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.



• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/disassemble procedures.



cal Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.



IN-01



INTRODUCTION PAGE NUMBER • Each page has a number, located on the center



lower part of the page, and each number contains the following information: Example : T 1-3-5 Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual



W: Workshop Manual



SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.



•



CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.



• IMPORTANT:



Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.



•



IN-02



NOTE: Indicates supplementary technical information or know-how.



INTRODUCTION UNITS USED Example : 24.5 MPa (250 kgf/cm2, 3560 psi)



• SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units.



Quantity Length Volume



Weight Force Torque



To Convert From mm mm L L m3 kg N N N⋅m N⋅m



Into in ft US gal US qt yd3 lb kgf lbf kgf⋅m lbf⋅ft



A table for conversion from SI units to other system units is shown below for reference purposees.



Quantity



Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 1.0197 0.7375



Pressure Power Temperature Velocity Flow rate



IN-03



To Convert From MPa MPa kW kW °C km/h min-1 L/min mL/rev



Into kgf/cm2 psi PS HP °F mph rpm US gpm cc/rev



Multiply By 10.197 145.0 1.360 1.341 °C×1.8+32 0.6214 1.0 0.2642 1.0



INTRODUCTION (Blank)



IN-04



SECTION AND GROUP CONTENTS



SECTION 1 GENERAL Group 1 Specification Group 2 Component Layout Group 3 Component Specifications



SECTION 2 SYSTEM TECHNICAL MANUAL (Operational Principle)



Group 1 Control System Group 2 Hydraulic System Group 3 Electrical System



SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Swing Device Group 3 Control Valve Group 4 Pilot Valve Group 5 Travel Device Group 6 Signal Control Valve Group 7 Steering Valve Group 8 Brake Valve Group 9 Transmission Control Valve Group 10 Others (Upperstructure) Group 11 Others (Undercarriage) TECHNICAL MANUAL (Troubleshooting)



All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.



SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Excavator Test Group 5 Component Test Group 6 Adjustment



SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Component Layout Group 3 Troubleshooting A Group 4 Troubleshooting B Group 5 Troubleshooting C Group 6 Electrical System Inspection Group 7 ICX



COPYRIGHT(C)2003 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved



←これ以下 記載しない



WORKSHOP MANUAL SECTION 1 GENERAL INFORMATION SECTION 3 UNDERCARRIAGE Group 1 Precautions for DisassemGroup 1 Swing Bearing bling and Assembling Group 2 Travel Motor Group 2 Tightening Torque Group 3 Center Joint Group 3 Painting Group 4 Transmission Group 4 Bleeding Air from HydrauGroup 5 Axle lic Oil Tank Group 6 Axle Lock Cylinder Group 7 Check Valve SECTION 2 UPPERSTRUCTURE (Axle Lock Cylinder) Group 1 Cab Group 8 Propeller Shaft Group 2 Counterweight Group 3 Main Frame SECTION 4 FRONT ATTACHMENT Group 4 Pump Device Group 1 Front Attachment Group 5 Control Valve Group 2 Cylinder Group 6 Swing Device Group 3 Hose-Rupture Safety Valve Group 7 Pilot Valve Group 4 Check Valve Group 8 Pilot Shut-Off Valve (Blade/Stabilizer) Group 9 Signal Control Valve SECTION 5 ENGINE Group 10 Travel Shockless Valve Group 11 Solenoid Valve Group 12 Pilot Relief Valve Group 13 Steering Valve Group 14 Brake Valve Group 15 Accumulator Charging Valve Group 16 Transmission Control Valve



SECTION 1



GENERAL ―CONTENTS― Group 1 Specifications



Group 3 Component Specifications



Specifications............................................ T1-1-1



Engine.......................................................T1-3-1



Working Ranges ....................................... T1-1-6



Engine Accessories ...................................T1-3-4 Hydraulic Component................................T1-3-5



Group 2 Component Layout Main Component Layout ........................... T1-2-1



Electrical Component ..............................T1-3-10



Electrical Component Layout .................... T1-2-4 (Overview) Electrical System (Relays) ....................... T-1-2-5 Electrical System ................................... T-1-2-7 (Monitors and Switches) Electrical System (Column Box)............... T-1-2-8 Pump Device ............................................ T1-2-9 Swing Device ............................................ T1-2-9 Signal Control Valve.................................. T1-2-9 Control Valve .......................................... T1-2-10 Auxiliary control Valve............................. T1-2-10 4-Unit Solenoid Valve Unit ...................... T1-2-10 3-Unit Solenoid Valve Unit ...................... T1-2-10 Travel Shockless Valve / Accumulator Chrging Valve ...................................... T1-2-11 Transmission Control Valve .................... T1-2-11 Travel Device .......................................... T1-2-11 Filter ....................................................... T1-2-11



CBBT-1-1



(Blank)



CBBT-1-2



GENERAL / SPECIFICATIONS SPECIFICATIONS Standard GAUGE, REAR BLADE C H



D



B G P



F



N



E K



J Q



I



O R



L A MCBB-12-001



Type of Front-End Attachment Type of Arm Bucket Capacity (Heaped) Operating Weight Basic Machine Weight Engine Type Engine DIN 6271 net SAE J1349 net ISO 9249 net ECE-R24 A: Overall Width (Excluding Rearview Mirrors) B: Cab Height C: Rear End Swing Radius D: Rear End Length E: Minimum Ground Clearance F: Counterweight Clearance G: Engine Cover Height H: Overall Width of Upperstructure I: Wheelbase J: Swing-center to Rear Axle K: Front Wheel Tread L: Rear Wheel Tread M: Stabilizer Spread N: Max.Raising Height O: Max.Digging Depth P: Blade Height Q: Front Axle to Front of Chassis R: Rear Axle to Rear of Chassis Tire Size Swing Speed Travel Speed (fast/low/creeper) Gradeability



－ m3 (yd3) kg (lb) kg (lb) － -1 kW/min (PS/rpm) kW/min-1(PS/rpm) kW/min-1(PS/rpm) kW/min-1(PS/rpm) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) － min-1(rpm) km/h(mph) degree(%)



NOTE: ※ Working mode



T1-1-1



Monoblock boom 2-piece boom 2.58m (8 ft 6 in) 2.50m (8 ft 2 in) PCSA 0.60m3 (0.78yd3), CECE 0.55m3 15800 (34800) 16400 (36200) 12400 (27300) 12400 (27300) ISUZU AA-4BG1TC 90.2(123)/2300 ※84.8(115)/1850 90.2(123)/2300 ※84.8(115)/1850 90.2(123)/2300 ※84.8(115)/1850 90.2(123)/2300 2530 (8’ 4”) 3045 (10' 0") 2190 (7' 2") 2190 (7' 2") 360 (1’ 2”) 1215 (4' 0") 2345 (7' 8") 2465 (8' 1") 2550 (8' 4") 1000 (3' 3") 1915 (6' 3") 1915 (6' 3") 440 (1’ 5”) 150 (6") 590 (1' 6") 1015 (3' 4") 1025 (3’ 4”) 10.00-20 14PR 13.3 32.0／9.0／2.3 (19.9／5.6／1.4) 35(70)



GENERAL / SPECIFICATIONS Standard GAUGE, REAR STABILIZER C H



D



B G F E K A



J I



Q



L R



M MCBB-12-002



Type of Front-End Attachment Type of Arm Bucket Capacity (Heaped) Operating Weight Basic Machine Weight Engine Type Engine DIN 6271 net SAE J1349 net ISO 9249 net ECE-R24 A: Overall Width (Excluding Rearview Mirrors) B: Cab Height C: Rear End Swing Radius D: Rear End Length E: Minimum Ground Clearance F: Counterweight Clearance G: Engine Cover Height H: Overall Width of Upperstructure I: Wheelbase J: Swing-center to Rear Axle K: Front Wheel Tread L: Rear Wheel Tread M: Stabilizer Spread N: Max.Raising Height O: Max.Digging Depth P: Blade Height Q: Front Axle to Front of Chassis R: Rear Axle to Rear of Chassis Tire Size Swing Speed Travel Speed (fast/low/creeper) Gradeability



－ m (yd3) kg (lb) kg (lb) － kW/min-1(PS/rpm) kW/min-1(PS/rpm) kW/min-1(PS/rpm) kW/min-1(PS/rpm) 3



mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) － min-1(rpm) km/h(mph) degree(%)



NOTE: ※ Working mode



T1-1-2



Monoblock boom 2-piece boom 2.58m(8 ft 6 in) 2.50m (8 ft 2 in) PCSA 0.60m3 (0.80yd3), CECE 0.55m3 16300 (35900) 16800 (37000) 12800 (28200) 12800 (28200) ISUZU AA-4BG1TC 90.2(123)/2300 ※84.8(115)/1850 90.2(123)/2300 ※84.8(115)/1850 90.2(123)/2300 ※84.8(115)/1850 90.2(123)/2300 2530 (8’ 4”) 3045 (10' 0") 2190 (7’ 2”) 2190 (7’ 2”) 360 (1’ 2”) 1215 (4’ 0”) 2345 (7’ 8”) 2465 (8’ 1”) 2550 (8’ 4”) 1000 (3’ 3”) 1915 (6’ 3”) 1915 (6’ 3”) 3570 (11’ 9”) － － － 1015 (3’ 4”) 1030 (3’ 5”) 10.00-20 14PR 13.3 32.0／9.0／2.3 (19.9／5.6／1.4) 35 (70)



GENERAL / SPECIFICATIONS Standard GAUGE, FRONT BLADE REAR STABILIZER C H



D



B G P



F



N K



E J



O



A



Q



I



L R



M



MCBB-12-003



Type of Front-End Attachment Type of Arm Bucket Capacity (Heaped) Operating Weight Basic Machine Weight Engine Type Engine DIN 6271 net SAE J1349 net ISO 9249 net ECE-R24 A: Overall Width (Excluding Rearview Mirrors) B: Cab Height C: Rear End Swing Radius D: Rear End Length E: Minimum Ground Clearance F: Counterweight Clearance G: Engine Cover Height H: Overall Width of Upperstructure I: Wheelbase J: Swing-center to Rear Axle K: Front Wheel Tread L: Rear Wheel Tread M: Stabilizer Spread N: Max.Raising Height O: Max.Digging Depth P: Blade Height Q: Front Axle to Front of Chassis R: Rear Axle to Rear of Chassis Tire Size Swing Speed Travel Speed (fast/low/creeper) Gradeability



－ m3 (yd3) kg (lb) kg (lb) － -1 kW/min (PS/rpm) kW/min-1(PS/rpm) kW/min-1(PS/rpm) kW/min-1(PS/rpm) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) － min-1(rpm) km/h(mph) degree(%)



NOTE: ※ Working mode



T1-1-3



Monoblock boom 2-piece boom 2.58m(8 ft 6 in) 2.50m (8 ft 2 in) PCSA 0.60m3 (0.80yd3), CECE 0.55m3 16900 (37300) 17400 (38400) 13500 (29800) 13500 (29800) ISUZU AA-4BG1TC 90.2(123)/2300 ※84.8(115)/1850 90.2(123)/2300 ※84.8(115)/1850 90.2(123)/2300 ※84.8(115)/1850 90.2(123)/2300 2530 (8’ 4”) 3045 (10’ 0”) 2190 (7' 2") 2190 (7’ 2”) 360 (1’ 2”) 1215 (4’ 0”) 2345 (7’ 8”) 2465 (8’ 1”) 2550 (8’ 4”) 1000 (3’ 3”) 1915 (6’ 3”) 1915 (6’ 3”) 3570 (11’ 9”) 440 (1’ 5”) 150 (6") 590 (1' 6") 1315 (4’ 4”) 1030 (3’ 5”) 10.00-20 14PR 13.3 32.0／9.0／2.3 (19.9／5.6／1.4) 35 (70)



GENERAL / SPECIFICATIONS Standard GAUGE, FRONT STABILIZER REAR BLADE C H



D



B G P E



F



N



K M



J Q



I



O R



L A MCBB-12-004



Type of Front-End Attachment Type of Arm Bucket Capacity (Heaped) Operating Weight Basic Machine Weight Engine Type Engine DIN 6271 net SAE J1349 net ISO 9249 net ECE-R24 A: Overall Width (Excluding Rearview Mirrors) B: Cab Height C: Rear End Swing Radius D: Rear End Length E: Minimum Ground Clearance F: Counterweight Clearance G: Engine Cover Height H: Overall Width of Upperstructure I: Wheelbase J: Swing-center to Rear Axle K: Front Wheel Tread L: Rear Wheel Tread M: Stabilizer Spread N: Max.Raising Height O: Max.Digging Depth P: Blade Height Q: Front Axle to Front of Chassis R: Rear Axle to Rear of Chassis Tire Size Swing Speed Travel Speed (fast/low/creeper) Gradeability



－ m3 (yd3) kg (lb) kg (lb) － -1 kW/min (PS/rpm) kW/min-1(PS/rpm) kW/min-1(PS/rpm) kW/min-1(PS/rpm) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) － min-1(rpm) km/h(mph) degree(%)



NOTE: ※ Working mode



T1-1-4



Monoblock boom 2-piece boom 2.58m (8 ft 6 in) 2.50m (8 ft 2 in) PCSA 0.60m3 (0.80yd3), CECE 0.55m3 16900 (37300) 17400 (38400) 13500 (29800) 13500 (29800) ISUZU AA-4BG1TC 90.2(123)/2300 ※84.8(115)/1850 90.2(123)/2300 ※84.8(115)/1850 90.2(123)/2300 ※84.8(115)/1850 90.2(123)/2300 2530 (8’ 4”) 3045 (10’ 0”) 2190 (7' 2") 2190 (7’ 2”) 360 (1’ 2”) 1215 (4’ 0”) 2345 (7’ 8”) 2465 (8’ 1”) 2550 (8’ 4”) 1000 (3’ 3”) 1915 (6’ 3”) 1915 (6’ 3”) 3570 (11’ 9”) 440 (1’ 5”) 150 (6”) 590 (1' 6") 1320 (4’ 4”) 1025 (3’ 4”) 10.00-20 14PR 13.3 32.0／9.0／2.3 (19.9／5.6／1.4) 35 (70)



GENERAL / SPECIFICATIONS Standard GAUGE, FRONT REAR STABILIZER C H



D



B G F E J



K A



Q



I



L R



M



MCBB-12-005



Type of Front-End Attachment Type of Arm Bucket Capacity (Heaped) Operating Weight Basic Machine Weight Engine Type Engine DIN 6271 net SAE J1349 net ISO 9249 net ECE-R24 A: Overall Width (Excluding Rearview Mirrors) B: Cab Height C: Rear End Swing Radius D: Rear End Length E: Minimum Ground Clearance F: Counterweight Clearance G: Engine Cover Height H: Overall Width of Upperstructure I: Wheelbase J: Swing-center to Rear Axle K: Front Wheel Tread L: Rear Wheel Tread M: Stabilizer Spread N: Max.Raising Height O: Max.Digging Depth P: Blade Height Q: Front Axle to Front of Chassis R: Rear Axle to Rear of Chassis Tire Size Swing Speed Travel Speed (fast/low/creeper) Gradeability



－ m3 (yd3) kg (lb) kg (lb) － -1 kW/min (PS/rpm) kW/min-1(PS/rpm) kW/min-1(PS/rpm) kW/min-1(PS/rpm) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) － min-1(rpm) km/h(mph) degree(%)



NOTE: ※ Working mode



T1-1-5



Monoblock boom 2-piece boom 2.58m(8 ft 6 in) 2.50m (8 ft 2 in) PCSA 0.60m3 (0.80yd3), CECE 0.55m3 17300 (38100) 17900 (39500) 13900 (30600) 13900 (30600) ISUZU AA-4BG1TC 90.2(123)/2300 ※84.8(115)/1850 90.2(123)/2300 ※84.8(115)/1850 90.2(123)/2300 ※84.8(115)/1850 90.2(123)/2300 2530 (8’ 4”) 3045 (10' 0") 2190 (7’ 2”) 2190 (7’ 2”) 360 (1’ 2”) 1215 (4’ 0”) 2345 (7’ 8”) 2465 (8’ 1”) 2550 (8' 4") 1000 (3' 3") 1915 (6’ 3”) 1915 (6’ 3”) 3570 (11’ 9”) － － － 1320 (4’ 4”) 1030 (3’ 5”) 10.00-20 14PR 13.3 32.0／9.0／2.3 (19.9／5.6／1.4) 35 (70)



GENERAL / SPECIFICATIONS WORKING RANGES MONOBLOCK BOOM



G



C



D



E



F A B



MCBB-12-006



Type of Front-End Attachment Category



2.22 m (7 ft 3 in) Arm



2.58 m (8 ft 6 in) Arm



3.10 m (10 ft 2 in) Arm



Backhoe



Backhoe



Backhoe



mm



8650



9000



9460



(ft in)



(28′ 5″)



(29′ 6″)



(31′ 0″)



Item A: Maximum Digging Reach B: Maximum Digging Depth C: Maximum Cutting Height D: Maximum Dumping Height E: Transport Height



Monoblock Boom



mm



4970



5340



5840



(ft in)



(16′ 4″)



(17′ 6″)



(19′ 2″)



mm



8810



9090



9340



(ft in)



(28′ 11″)



(29′ 10″)



(30′ 8″)



mm



6110



6350



6600



(ft in)



(20′ 0″)



(20′ 10″)



(21′ 8″)



mm



3210



3045



3120



(ft in)



(10′ 6″)



(10′ 0″)



(10′ 3″)



Standard Gauge, Rear Blade/Stabilizer F: Overall Transport



mm



8510



Length (Max)



(ft in)



(27′ 11″)



Standard Gauge,



Radius



Standard Gauge, Rear Blade/Stabilizer



8820 (28′ 11″)



Standard Gauge,



Front Blade, Rear Stabilizer



9090



Front Blade, Rear Stabilizer



9120



Front Stabilizer, Rear Blade



(29′ 10″)



Front Stabilizer, Rear Blade



(29′ 11″)



Front Rear Stabilizer G: Minimum Swing



8790 (28′ 10″)



Front Rear Stabilizer



mm



3340



2900



2920



(ft in)



(10′ 11″)



(9′ 6″)



(9′ 7″)



T1-1-6



GENERAL / SPECIFICATIONS 2-PIECE BOOM



G



C D E



F A B



MCBB-12-007



Type of Front-End Attachment Category



2.21 m (7 ft 3 in) Arm



2.50 m (8 ft 2 in) Arm



3.10 m (10 ft 2 in) Arm



Backhoe



Backhoe



Backhoe



mm



9020



9280



9800



(ft in)



(29′ 7″)



(30′ 5″)



(32′ 2″)



Item A: Maximum Digging Reach B: Maximum Digging Depth C: Maximum Cutting Height D: Maximum Dumping Height E: Transport Height



2-piece Boom



mm



5440



5730



6300



(ft in)



(17′ 10″)



(18′ 10″)



(20′ 8″)



mm



9650



9800



10090



(ft in)



(31′ 8″)



(32′ 2″)



(33′ 1″)



mm



6810



6970



7260



(ft in)



(22′ 4″)



(22′ 10″)



(23′ 10″)



mm



3300



3340



3610



(ft in)



(10′ 10″)



(10′ 11″)



(11′ 10″)



Standard Gauge, Rear Blade/Stabilizer F: Overall Transport



mm



8550



Length (Max)



(ft in)



(28′ 1″)



Standard Gauge,



Radius



Standard Gauge, Rear Blade/Stabilizer



8880 (29′ 2″)



Standard Gauge,



Front Blade, Rear Stabilizer



9220



Front Blade, Rear Stabilizer



9180



Front Stabilizer, Rear Blade



(30′ 3″)



Front Stabilizer, Rear Blade



(30′ 1″)



Front Rear Stabilizer G: Minimum Swing



8920 (29′ 3″)



Front Rear Stabilizer



mm



3070



3030



3430



(ft in)



(10′ 1″)



(9′ 11″)



(11′ 3″)



T1-1-7



GENERAL / SPECIFICATIONS (Blank)



T1-1-8



GENERAL / Component Layout MAIN COMPONENT LAYOUT Upperstructure 2



3



4



5



6



7



8



9



10



12



11



1



13 14 15 16 17 29 18 19



28 27



20 26 25



24 23



22



1 - Pilot Valve (Left)



9 - Center Joint



16 - Accumulator (Pilot Circuit)



2 - Positioning/Auxiliary Pilot Valve 3 - Steering Valve 4 - Brake Valve



10 - Signal Control Valve



17 - 4-Unit Solenoid Valve Unit



11 - Swing Device 12 - Control Valve



18 - 3-Unit Solenoid Valve Unit 19 - Pilot Filter



13 - Accumulator (Transmission Circuit) 14 - Transmission Control Valve



20 - Steering Filter 21 - Pump Device



15 - Pilot Relief Valve



22 - Engine



5 - Travel Pilot Valve 6 - Pilot Valve (Right) 7 - Blade/Stabilizer Pilot Valve 8 - Auxiliary Control Valve



T1-2-1



21



T1F3-01-02-001



23 - Shuttle Valve (Swing Parking Brake Release Circuit) 24 - Accumulator Charging Valve 25 - Travel Shockless Valve 26 - Shuttle Valve (Blade/Stabilizer Circuit) 27 - Blade/Stabilizer Signal Shift Valve 28 - Accumulator (Brake Circuit) 29 - Pilot Shut-Off Valve



GENERAL / Component Layout Undercarriage



2



1



3



4



5



8 7



6 T1F3-01-02-002



1 - Blade Cylinder 2 - Rear Axle



3-



2-Unit Solenoid Valve (Blade/Stabilizer) 4 - Axle Lock Cylinder



5-



Front Axle



7-



Transmission



6-



Stabilizer Cylinder



8-



Travel Motor



T1-2-2



GENERAL / Component Layout Front Attachment 2-Piece Boom



Monoblock Boom 1



2



2



3 4 7



7 4



1 5



6



6



T1F3-01-02-004



T1F3-01-02-003



1 - Bucket Cylinder



3-



Positioning Cylinder



2 - Arm Cylinder



4-



Boom Cylinder



5-



Hose-Rupture Safety Valve (Positioning) 6 - Hose-Rupture Safety Valve (Boom)



NOTE: Hose-rupture safety valves (5), (6), (7) are optional.



T1-2-3



7-



Hose-Rupture Safety Valve (Arm)



GENERAL / Component Layout ELECTRICAL COMPONENT LAYOUT (Overview)



1



2



Refer to the Transmission Control Valve. (T1-2-11)



Refer to the Signal Control Valve. (T1-2-9)



Refer to the Swing Device. (T1-2-9)



3



Refer to the Control Valve. (T1-2-10)



4



15



5



14



Refer to the Pump Device. (T1-2-9)



13



6 Refer to the Travel Shockless Valve and Accumulator Charging Valve. (T1-2-11)



Refer to the Filter. (T1-2-11)



12



7 T1F3-01-02-011



11



10



9



8



1 - Service Brake Pressure Switch 2 - Fuel Sensor



5 - EC Motor/EC Sensor 6 - 3-Unit Solenoid Valve Unit



9 - Coolant Temperature Sensor 10 - Battery Relay



3 - 4-Unit Solenoid Valve Unit 4 - Hydraulic Oil Temperature Sensor



7 - Engine Oil Pressure Switch 8 - Overheat Switch



11 - Glow Plug Relay 12 - Battery



T1-2-4



13 - Air Cleaner Restriction Switch 14 - Brake Remaining Pressure Switch 15 - Slip Ring



GENERAL / Component Layout ELECTRICAL SYSTEM (RELAYS)



1



2



5



4



3



6



7



8 9



Relay Position (T1-2-6)



10



T1F3-01-02-012



1 - QOS Controller 2 - Transistor Unit 2



45-



Transistor Unit 1 Fuse Box



78-



3 - Flasher Relay



6-



Dr. ZX Connector to MC



T1-2-5



Learning Switch ICX (Information Controller)



9 - MC (Main Controller) 10 - Dr. ZX Connector to ICX



GENERAL / Component Layout Relay Position



A



1 2



T1F3-01-02-012



3



View A



4 5 6 7 8 9



30 29 28 27 26



10 11 12



25 24 23



13 14 15



22 21



16



20 T1F3-01-02-013



19 18



17



1 - Head Lamp Relay (Left-Lower) (R29) 2 - Parking Brake Relay 3 (R30) 3 - Parking Brake Relay 2 (R11) 4 - Work Light Relay (R4)



9-



Head Lamp Relay (Right-Lower) (R13) 10 - Wiper Relay A (R6)



5 - High Beam Relay (R14) 6 - Wiper Relay B-1 (R7)



13 - Right Clearance Light Relay (R12) 14 - Horn Relay (R5)



7 - Starter Relay (R10)



15 - Wiper Relay B-2 (R8)



8 - Work Light Relay (R3)



16 - Load Damp Relay (R1)



11 - Wiper Relay B-3 (R9) 12 - Washer Relay (R2)



17 - Left Turn Signal Relay (R15) 18 - Work Brake Indicator Relay (R18) 19 - Neutral Signal Relay (R21) 20 - Right Turn Signal Relay (R16) 21 - Travel Forward Pi Cut Relay (R24) 22 - Axle Lock Relay (R19) 23 - Travel Motor Alarm Relay (R22)



T1-2-6



24 - Stop Lamp Relay (R17) 25 - Travel Reverse Pi Cut Relay (R25) 26 - Parking Brake Alarm Relay (R23) 27 - Transmission Changeover Relay (R20) 28 - Auto-Acceleration Cancel Relay (R26) 29 - Parking Brake Relay 1 (R27) 30 - Left Clearance Light Relay (R28)



GENERAL / Component Layout ELECTRICAL SYSTEM (Monitors and Switches)



1 2 19



18 3



17 16



4



15



MCBB-01-022



5



14 6 7 13



20



8



12 11



21



10 MCBB-01-012



22



9



23



24



25



26 M216-01-021



MCBB-01-014



1 - Coolant Temperature Gauge 2 - Fuel Gauge



8-



3 - Display Selection Switch



10 -



4 - Set Switch



11 -



5 - Work Mode Switch



12 -



6 - Fuel Level Indicator



13 - Air Filter Restriction Indicator 14 - Overheat Indicator



7 - Alternator Indicator



9-



Blade/Stabilizer Operation Indicator Overload Alarm Indicator (Optional) Hydraulic Oil Filter Restriction Indicator Engine Oil Pressure Indicator Preheat Indicator



15 - Digging Mode Indicator



22 - Work Light Switch



16 - Attachment Mode Indicator 17 - Liquid Crystal Display (LCD) 18 - Auto-Idle Indicator



23 - Power Mode Switch



19 - Auto-Acceleration Indicator 20 - Engine Control Dial 21 - Engine Speed Control Mode Selection Switch



T1-2-7



24 - Auto-Idle/Acceleration Selector 25 - Brake Switch 26 - Shift Lever



GENERAL / Component Layout ELECTRICAL SYSTEM (Column Box) 8 1, 2, 3, 4



5



9



10



12



11



6



13



12 MCBB-01-004



14



15



16



17



18



19



20



MCBB-01-005



7



22



21 MCBB-01-006



1 - Turn Signal Switch 2 - Light Switch 3 - Dimmer Switch



789-



4 - Passing Switch 5 - Hazard Light Switch



Horn Switch Turn Signal Indicator Abnormal Travel Motor Indicator 10 - Work Light Indicator 11 - Travel Mode Indicator



6 - Wiper Switch



12 - Auxiliary 2



13 - Auxiliary 1 14 - Brake Oil Pressure Gauge 15 - Speed Meter



18 - Clearance Light Indicator 19 - Parking Brake Indicator 20 - Work Brake Indicator



16 - Hazard Light Indicator 17 - High-Beam Indicator



21 - Axle Lock Indicator 22 - Brake Oil Pressure Indicator



T1-2-8



8



GENERAL / Component Layout PUMP DEVICE 2



1



6



5



4



3



T1F3-01-02-008



SWING DEVICE



10



9



8



7



T1F3-01-02-007



SIGNAL CONTROL VALVE 12



13



11



T1F3-03-06-003



T178-03-02-001



1 - Steering Pump



5-



2 - Pilot Pump



6-



3 - Pump 1



N sensor (Engine)



8-



Torque Control Solenoid Valve 7 - Pump 2 Control Pressure Sensor



Pump 2 Delivery Pressure Sensor 9 - Pump 1 Control Pressure Sensor 10 - Pump 1 Delivery Pressure Sensor



4 - Pump 2



T1-2-9



11 - Pressure Sensor (Front Attachment) 12 - Pressure Sensor (Auxiliary) 13 - Pressure Sensor (Swing)



GENERAL / Component Layout CONTROL VALVE



AUXILIARY CONTROL VALVE 1



4



2



T1F3-03-03-018 T176-01-02-003



3



3-UNIT SOLENOID VALVE UNIT



4-UNIT SOLENOID VALVE UNIT



9



5



6



7



8



10



11



T178-01-02-003



T1F3-01-02-010



1 - Pressure Sensor (Arm Roll-In) 2 - Main Relief Valve



4-



Overload Relief Valve (Auxiliary Control Valve) 5 - Solenoid Valve Unit (SC)



7-



Solenoid Valve Unit (SI)



8-



Solenoid Valve Unit (SG)



3 - Pressure Sensor (Boom Raise)



6-



9-



Max. Pump 1 Flow Rate Limit Solenoid Valve



Solenoid Valve Unit (SE)



T1-2-10



10 - Max. Pump 2 Flow Rate Limit Solenoid Valve 11 - Max. Pump 1 Flow Rate Shift Solenoid Valve



GENERAL / Component Layout TRAVEL SHOCKLESS VALVE/ ACCUMULATOR CHARGING VALVE



TRANSMISSION CONTROL VALVE 9 10



1



2



3



4



8



5



11



12 T1F3-01-02-006



7



6 T1F3-01-02-005



FILTER



TRAVEL DEVICE



17



13 14



18 15



19



16



MCBB-07-026



T1F3-01-02-009



1 - Travel Shockless Valve 2 - Pressure Sensor (Travel Forward) 3 - Travel Forward Pi Cut Solenoid Valve 4 - Pressure Sensor (Brake Oil Pressure Gauge) 5 - Accumulator Charging Valve



6-



Travel Reverse Pi Cut Solenoid Valve 7 - Pressure Sensor (Travel Reverse) 8 - Transmission Control Valve



11 - Accumulator (Transmission Circuit) 12 - Parking Brake Pressure Switch 13 - N sensor (Travel)



9-



14 - Transmission



Transmission Changeover Solenoid Valve 10 - Parking Brake Solenoid Valve



15 - Travel Motor



T1-2-11



16 - Travel Motor Drain Pressure Switch 17 - Pilot Filter 18 - Steering Pump Delivery Pressure Sensor 19 - Steering Filter



GENERAL / Component Layout (Blank)



T1-2-12



GENERAL / Component Specifications ENGINE Manufacturer ..................................................ISUZU Model..............................................................AA-6BG1TC Type................................................................Diesel, 4-Cycle, Water-cooled, Inline, Direct Injection Cyl. No.- Bore × Stroke ..................................4-105 mm×125 mm (4.13 in×4.92 in) Piston Displacement ......................................4329 cm3 (264 in3) Rated Output ..................................................84.8 kW/1850 min-1 (115 PS/1850 rpm) HP Mode: 90.2 kW/2300 min-1 (123 PS/2300 rpm) Compression Ratio.........................................18:1 Dry Weight......................................................362 kg (800 lb) Firing Order ....................................................1-3-4-2 Rotation Direction...........................................Clockwise (Viewed from fan side) COOLING SYSTEM Cooling Fan....................................................Dia. 600 mm (23.6 in), 7 Blades (N-Type Blade, Unequal Pitch), Draw-in Type Fan Pulley Ratio .............................................Engine rpm × 0.84 Thermostat .....................................................Cracking Temperature at Atmospheric Pressure: 82 °C (180 °F) Full Open (Stroke: 10 mm or more) Temperature: 95 °C (203 °F) Water Pump....................................................Centrifugal Belt Driven Type LUBRICATION SYSTEM Lubrication Pump Type...................................Gear Pump Oil Filter ..........................................................Full-Flow Paper Element Type with Bypass Oil Cooler .......................................................Water Cooled Integral Type STARTING SYSTEM Motor ............................................................. Magnetic Pinion Shift Reduction Type Voltage / Output............................................. 24 V / 4.5 kW PREHEAT SYSTEM Preheating Method ........................................ Glow Plug (QOS Type) ENGINE STOP SYSTEM Stop Method ...................................................Fuel Shut-Off



T1-3-1



GENERAL / Component Specifications ALTERNATOR Type................................................................Regulator Integrated AC Type Voltage / Output..............................................24 V / 50 A (Brushless) SUPERCHARGING SYSTEM Type................................................................Exhaust-Turbocharger Type TD04HL FUEL SYSTEM Type............................................................... BOSCH Type (ADS Type) Governor ....................................................... Centrifugal All Speed Control RSV Type Injection Nozzle ............................................. Multi-Hole Type PERFORMANCE IMPORTANT: This list shows design specifications, which are not servicing standards. Fuel Consumption Ratio (Digging) .................Less than 211±14 g/kW/h (155±10 g/PS⋅h) at 84.8 kW/1850 min-1 (at Working Load (P Mode)) (Traveling) ...............Less than 238±14 g/kW/h (175±10 g/PS⋅h) at 90.2 kW/2300 min-1 (at Full Load (Pedal Mode)) Injection Timing ..............................................9 ° before T.D.C. Maximum Output Torque ................................More than 449±39 N⋅m (45.8±4 kgf⋅m) at approx. 1800 min-1 Injection Pressure...........................................18.14 MPa (185 kgf/cm2) Compression Pressure...................................3.04 MPa (31 kgf/cm2) Valve Clearance (Inlet / Exhaust)...................0.4 / 0.4 mm (when cool) No Load Speed (Digging)...............................Slow: (at Full Load: 950+500 min-1) Fast: (at Full Load: 2530±25 min-1) (at Working Load: 2150±50 min-1) (Traveling) ............................Fast: (at Full Load: 2530±25 min-1)



T1-3-2



GENERAL / Component Specifications Engine Performance Curve (AA-6BG1TC) Test Condition: 1. In conformity with JIS D1005 (Performance Test Method for Diesel Engine Used for Construction Machinery) under standard atmospheric pressure. 2. Equipped with the fan and alternator. Traveling at HP Mode



Torque N⋅m



Digging at P Mode



Output kW Traveling at HP Mode



Digging at P Mode



Fuel Consumption Ratio g/kW⋅h



-1



Engine Speed min (rpm) ×100



T1-3-3



T1F3-01-03-002



GENERAL / Component Specifications ENGINE ACCESSORIES RADIATOR ASSEMBLY Type............................................................. Radiator/Oil Cooler Tandem Type Assembly Weight ......................................................... 73 kg (160 lb) Radiator Oil Cooler Capacity....................................................... 7.8 L (2.1 US gal) 18.0 L (1.7 US gal) Air-Tight Test Pressure................................ 100 kPa (1.0 kgf/cm2, 14.5 psi) 1500 kPa (15 kgf/cm2, 217 psi) Cap Opening Pressure................................ 49 kPa (0.5 kgf/cm2, 7 psi) − Intercooler Capacity....................................................... 7.2 L (1.7 US gal) Air-Tight Test Pressure................................ 250 kPa (2.5 kgf/cm2, 36 psi) Cap Opening Pressure................................ − BATTERY Capacity....................................................... 55 Ah (5-Hour Rate) Voltage......................................................... 12 V Weight ......................................................... 17.7 kg (39 lb) × 2



T1-3-4



GENERAL / Component Specifications HYDRAULIC COMPONENT • Upperstructure



PUMP DEVICE Drive Gear Ratio.............................................Main Pump: 1, Pilot Pump: 1, Steering Pump: 1 MAIN PUMP Type................................................................Swash-Plate Type, Variable Displacement Tandem Plunger Pump Maximum Flow (Theoretical Value)................Pump 1: 184 L/min (48.5 US gpm) Pump 2: 172 L/min (45.4 US gpm) REGULATOR Type................................................................Hydraulic Pressure Operated Type PILOT PUMP, STEERING PUMP Type................................................................Fixed Displacement Type Gear Pump Maximum Flow (Theoretical Value)................27.8 L/min (7.34 US gpm) CONTROL VALVE Model..............................................................HCV06EH-101 Type................................................................Pilot Pressure Operated Type (4-Spools + 5-Spools) Main Relief Set-Pressure Normal: 34.3 MPa (350 kgf/cm2, 4980 psi) Overload Relief Set-Pressure ........................37.3 MPa (380 kgf/cm2, 5420 psi) at 50 L/min (13.2 US gpm) (Boom, Arm Roll-In, Bucket Roll-In) 39.2 MPa (400 kgf/cm2, 5690 psi) at 50 L/min (13.2 US gpm) (Arm Roll-Out, Bucket Roll-Out) AUXILIARY CONTROL VALVE Type .................................. Pilot Pressure Operated Type Overload Relief Set-Pressure ............ 28.0+0.980 MPa (285+100 kgf/cm2, 4070+1420) at 80 L/min SWING DEVICE Type................................................................Two-Stage Reduction Planetary Gear Reduction Gear Ratio.....................................14.9 SWING MOTOR Model..............................................................M5X130C Type................................................................Swash-Plate Type, Fixed Displacement Axial Plunger Motor VALVE UNIT Type................................................................Non Counterbalance Valve Type Relief Set-Pressure ........................................30.4+1.40 MPa (310+140 kgf/cm2, 4420+2040 psi) at 90 L/min SWING PARKING BRAKE Type................................................................Multi-Disc-Wet Negative Type Release Pressure...........................................1.9 to 2.8 MPa (19 to 28 kgf/cm2, 284 to 384 psi)



T1-3-5



GENERAL / Component Specifications SOLENOID VALVE UNIT Function..........................................................⋅ ⋅ ⋅ ⋅



SC SE SG SI



: Arm Regenerative Control : Check Valve (Axle Lock) Control : Brake Valve Control : Travel Motor Swash Angle Control



3-UNIT SOLENOID VALVE Function..........................................................⋅ Maximum Pump 1 Flow Rate Control ⋅ Pump 1 Flow Rate Limit Control ⋅ Pump 2 Flow Rate Limit Control 2-UNIT SOLENOID VALVE (AUXILIARY FLOW RATE CONTROL) (OPTIONAL) Function..........................................................⋅ Auxiliary Flow Rate Control 2-UNIT SOLENOID VALVE (BLADE/STABILIZER) (OPTIONAL) Function..........................................................⋅ Check Valve (Blade/Stabilizer) Control SIGNAL CONTROL VALVE Function..........................................................⋅ ⋅ ⋅ ⋅



Shock Reducing (Boom Raise) Pump Flow Rate Control Bucket Flow Rate Control Swing Parking Brake Release



PILOT SHUT-OFF VALVE Type................................................................Rotary Type PILOT RELIEF VALVE Relief Set-Pressure ..................... 3.7+0.2−0.1 MPa (37.7+2−1 kgf/cm2, 538+29−15 psi) at 13 L/min STEERING VALVE Relief Set-Pressure ..................... 17.2 MPa (175 kgf/cm2, 2500 psi) at 23 L/min Overload Relief Set-Pressure ............ 22.6 MPa (230 kgf/cm2, 3286 psi) at 1 L/min BRAKE VALVE Brake Pressure......................... 7.0 MPa (71 kgf/cm2, 1018 psi) ACCUMULATOR CHARGING VALVE Charging (Cut-in) Pressure............... 12.3 MPa (125 kgf/cm2, 1788 psi) Stopping to Charge (Cut-out) Pressure .... 15.0 MPa (153 kgf/cm2, 2181 psi)



T1-3-6



GENERAL / Component Specifications TRAVEL SHOCKLESS VALVE Type .................................. Slow Return Valve (With the 2-Unit Solenoid Valve) TRANSMISSION CONTROL VALVE Type .................................. With the 2-Unit Solenoid Valve Reducing Valve Set-Pressure ............ 3.4 MPa (35 kgf/cm2, 494 psi) Relief Set-Pressure ..................... 1.3 MPa (13 kgf/cm2, 189 psi) at 4 L/min OVERLOAD RELIEF VALVE (OUTSIDE) Overload Relief Set-Pressure ............ 39.2+0.940 MPa (400+9.60 kgf/cm2, 5700+1370 psi) at 50 L/min OIL COOLER BYPASS CHECK VALVE Cracking Pressure ...................... 600 kPa (6 kgf/cm2, 87 psi) at 5 L/min



T1-3-7



GENERAL / Component Specifications • Undercarriage TRAVEL MOTOR Type........................................................ Bent-Axis Type Variable Displacement Axial Plunger Motor TRAVEL BRAKE VALVE Type........................................................ Counter Balance Valve Type Relief Set Pressure ................................ 40±0.2 MPa (408 kgf/cm2, 5820±30 psi) TRANSMISSION (DIRECT CONNECTION TO REAR AXLE) Type........................................................ Two-Speed Powershift Transmission Relief Gear Ratio.................................... High Speed Side : 1.39 Low Speed Side : 5.35 AXLE (FRONT, REAR) Type........................................................ Front : Steering Drive Axle with Hub Reduction Rear : Rigid Axle with Hub Reduction Final Reduction Gear Ratio.................... 13.848 AXLE LOCK CYLINDER Rod Diameter ......................................... 90 mm (3.54”) Stroke ..................................................... 96 mm (3.78”) Fully Retracted Length ........................... 83 mm (3.27”) Plating Thickness ................................... 30 µm (1.18 µin)



T1-3-8



GENERAL / Component Specifications • Front Attachment CYLINDER • Monoblock Boom: Boom Rod Diameter ......................................... 80 mm (3.15”) Cylinder Bore.......................................... 110 mm (4.33”) Stroke ..................................................... 1005 mm (3’3”) Fully Retracted Length ........................... 1655 mm (5’5”) Plating Thickness ................................... 30 µm (1.18 µin)



Arm 90 mm (3.54”) 120 mm (4.72”) 1365 mm (4’5”) 1905 mm (6’3”) 30 µm (1.18 µin)



Bucket Rod Diameter ......................................... 75 mm (2.95”) Cylinder Bore.......................................... 105 mm (4.13”) Stroke ..................................................... 935 mm (3’0”) Fully Retracted Length ........................... 1460 mm (4’9”) Plating Thickness ................................... 30 µm (1.18 µin)



• 2-Piece Boom: Boom Rod Diameter ......................................... 80 mm (3.15”) Cylinder Bore.......................................... 110 mm (4.33”) Stroke ..................................................... 940 mm (3’1”) Fully Retracted Length ........................... 1680 mm (5’6”) Plating Thickness ................................... 30 µm (1.18 µin)



Arm 90 mm (3.54”) 120 mm (4.72”) 1365 mm (4’5”) 1905 mm (6’3”) 30 µm (1.18 µin)



Bucket Rod Diameter ......................................... 75 mm (2.95”) Cylinder Bore.......................................... 105 mm (4.13”) Stroke ..................................................... 935 mm (3’0”) Fully Retracted Length ........................... 1460 mm (4’9”) Plating Thickness ................................... 30 µm (1.18 µin)



Positioning 120 mm (4.72”) 170 mm (6.69”) 648 mm (2’2”) 1290 mm (4’3”) 30 µm (1.18 µin)



• Optional: Blade Rod Diameter ......................................... 60 mm (2.36”) Cylinder Bore.......................................... 105 mm (4.13”) Stroke ..................................................... 195 mm (7.68”) Fully Retracted Length ........................... 615 mm (2’0”) Plating Thickness ................................... 30 µm (1.18 µin)



T1-3-9



Stabilizer 70 mm (2.76”) 120 mm (4.73”) 381 mm (1’3”) 854 mm (3’0”) 30 µm (1.18 µin)



GENERAL / Component Specifications ELECTRICAL COMPONENT BATTERY RELAY Voltage / Current ....................... 24 V / 100 A GLOW RELAY Voltage ................................ 24 V HORN Voltage / Current ....................... 24 V⋅1.5±0.5 A Sound Pressure ........................ 113±5 dB (A) ILLUMINATION Specifications .......................... Work Light : Halogen 24 V, 70 W Cab Light : 24 V, 10 W Head Light: Halogen 24 V, 75 / 70 W Turn Signal Light : 24 V, 21 W Clearance Light : 24 V, 4 W License Plate : 24 V, 10 W Tail Light : 24 V, 10 W Stop Light : 24 V, 21 W AIR CONDITIONER Refrigerant......................................................134 a Cooling Ability.................................................19.3 MJ/h (4600 kcal/h) Cool Air Volume..............................................550 m3/h or More Heating Ability.................................................21.0 MJ/h (5000 kcal/h) or More Warm Air Volume............................................400 m3/h or More Temperature Adjusting System ......................Electronic Type Refrigerant Quantity .......................................1000±50 g Compressor Oil Quantity................................180 cm3



T1-3-10



MEMO ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... 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MEMO ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... 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SECTION 2



SYSTEM —CONTENTS— Group 1 Control System



Group 3 Electrical System



Outline ...................................................... T2-1-1



Outline ......................................................T2-3-1



Engine Control .......................................... T2-1-2



Main Circuit ...............................................T2-3-2



Pump Control .......................................... T2-1-27



Electric Power Circuit ................................T2-3-3



Valve Control .......................................... T2-1-40



Indicator Light Check Circuit .....................T2-3-4



Other Controls ........................................ T2-1-53



Accessory Circuit ......................................T2-3-5



Electric and Hydraulic



Preheat Circuit ..........................................T2-3-6



Composite Circuit Control ..................... T2-1-71



Starting Circuit...........................................T2-3-8 Charging Circuit ......................................T2-3-12



Group 2 Hydraulic System Outline ...................................................... T2-2-1 Pilot Circuit ............................................... T2-2-2 Service Brake Circuit .............................. T2-2-12



Parking Brake Circuit ..............................T2-3-16 Serge Voltage Prevention Circuit.............T2-3-18 Engine Stop Circuit..................................T2-3-19



Steering Circuit ....................................... T2-2-13 Main Circuit............................................. T2-2-14



CBBT-2-1



(Blank)



CBBT-2-2



SYSTEM / Control System OUTLINE The main controller (MC) is employed to control machine operations. Electronic signals from the engine control dial, and various sensors and switches are sent to the MC.



• • • • • • • • • • • • • • • • • • • • • • • •



Input Signals EC Sensor → Engine Control Dial → Pump 1 Control Pressure Sensor → Pump 2 Control Pressure Sensor → Pump 1 Delivery Pressure Sensor → Pump 2 Delivery Pressure Sensor → Steering Pump Delivery Pressure → N sensor (Engine) → N sensor (Travel) → Pressure Sensor (Travel Forward) → Pressure Sensor (Travel Reverse) → Pressure Sensor (Front Attachment) → Pressure Sensor (Swing) → Pressure Sensor (Boom Raise) → Pressure Sensor (Arm Roll-In) → Pressure Sensor (Auxiliary) (OP) → Pressure Sensor (Arm Roll-Out) (OP)→ Hydraulic Oil Temperature Sensor → Parking Brake Pressure Switch → Travel Motor Drain Pressure Switch → Auto-Idle/Auto-Accelerator Selector → Power Mode Switch (HP/E/P) → Shift Lever (N/D/L) → Work Mode Switch (Digging/Attachment) →



MC



Brake Switch Learning Swing Key Switch Auxiliary Mode Switch (OP)



Output Signals Engine Control (EC Motor) Engine Control Dial Control Forward/Reverse Travel Pedal Control Engine Slowdown Control HP Mode Control E Mode Control Auto-Idle Control Auto-Acceleration Control Auto-Warming Up Control Slow Idle Speed-Up Control *Attachment Operation Speed Increase Control *Attachment Operation Speed Limit Control Engine Learning Control Pump Control (Torque Control Solenoid Valve) Speed Sensing Control Travel Speed Sensing Control Travel Pump 1 Flow Rate Shift Control Flow Rate Limit Control (When Combined Operation of the Travel and Front Attachment) *Pump 1 Flow Rate Limit Control *Pump 2 Flow Rate Limit Control Steering Pump Torque Reduction Control Valve Control Arm Regenerative Valve Superfine Travel Speed Control Travel Motor Excessive Rotation Control



• Engine Speed Control Mode Selection Switch (Pedal/Dial/Creeper) → • • • •



After processing the received signals in the logic circuits, the MC sends out control signals to the EC motor, solenoid valve unit, and torque control solenoid valve to control the engine, pumps and valves.



Work Brake Control *Auxiliary Flow Rate Control Other Controls Parking Brake Alarm Control Brake Dragging Prevention Control Travel Motor Alarm Control Forward/Reverse Shifting Restriction Control Work Mode Control *Overload Alarm Control *Travel Alarm Control *Swing Alarm Control



→ → →



NOTE: OP: Optional *Control system available only on the machine equipped with the optional parts.



T2-1-1



SYSTEM / Control System ENGINE CONTROL The engine control has the following functions:



• • • • • • • • • • • •



Engine Control Dial Control Forward/Reverse Travel Pedal Control Engine Slowdown Control HP Mode Control E Mode Control Auto-Idle Control Auto-Acceleration Control Auto-Warming Up Control Slow Idle Speed-Up Control *Attachment Operation Speed Increase Control *Attachment Operation Speed Limit Control Engine Learning Control



T2-1-2



SYSTEM / Control System



Engine Control System Layout



Parking Brake Pressure Switch N Sensor (Travel)



Column Box Learning Switch Pressure Sensor Travel Forward Travel Reverse Front Attachment Swing Boom Raise Arm Roll-In Auxiliary (Optional)



Key Switch



Engine Control Dial



Travel Motor Drain Pressure Sensor



Pump 1 Delivery Pressure Sensor



Pump 2 Delivery Pressure Sensor



EC Sensor Auto-Idle/Acceleration Selector Auto-Idle EC Motor



Auto-Acc eleration



Pump 1 Control Pressure Sensor Pump 2 Control Pressure Sensor



Power Mode Switch HP Mode E Mode P Mode



Hydraulic Oil TemAuxiliary Mode Switch (Optional) perature Sensor



Work Mode Switch Digging Mode Attachment Mode



Engine Speed Control Mode Selection Switch



Shift Lever



Brake Switch



Pedal



Neutral



Dial



D Mode



Creeper



L Mode



Work Brake Parking Brake Axle Lock OFF T1GL-02-01-001



NOTE: OP: Optional *Control system available only on the machine equipped with the optional parts.



T2-1-3



SYSTEM / Control System Engine Control Dial Control Function: Controls the engine speed in response to the rotation angle of the engine control dial and reduces the engine speed by 100 min-1 to reduce fuel consumption and noise level when all control levers are in neutral.



Engine Speed



Engine speed is reduced by 100 -1 min when the control levers are in neutral.



Control Range



Operation: The MC drives the governor lever in response to the rotation angle of the engine control dial to regulate the engine speed. NOTE: Even if the control dial is rotated to the full speed position, the governor lever doesn’t come in contact with the full speed stopper. (Refer to the HP mode control.) When all control levers are turned to neutral (the travel and front attachment sensors are OFF), the MC drives the EC motor so that the engine speed is reduced from the maximum speed by 100 min-1. Engine speed reduction (100 min-1) requirements: • Engine Speed Control Mode Selection Switch: Dial or Creeper Position • Auto-Idle / Auto-Acceleration Selector: Auto-Idle or OFF Position • Power Mode Switch: HP or P Position NOTE: When the engine speed control mode selection switch is not in the pedal or creeper position, the MC recognizes that the engine speed control mode selection switch is in the dial position. When the power mode switch is not in the HP or E mode position, the MC recognizes that the power mode switch is in the P mode position. NOTE: The signals from N sensor (travel) are sent to the MC via the column box. When the shift lever is not in either the N or L position, the MC recognizes that the shift lever is in the D position. NOTE: The engine governor stopper position is adjusted so as to match the travel pedal control. Accordingly, the governor lever doesn’t come in contact with the stopper in the normal mode.



T2-1-4



Slow Idle



Fast Idle



Engine Control Dial Position



NOTE: The engine speed is reduced from the maximum speed by 100 min-1. Therefore, when the engine speed set by the engine control dial is already slower than the maximum speed by 100 min-1, the engine speed remains unchanged. This engine speed reduction control is activated regardless of whether the auto-idle and/or auto-acceleration control is activated or not.



SYSTEM / Control System



Parking Brake Pressure Switch Pressure Sensor Travel Forward Travel Reverse Front Attachment



Engine Control Dial EC Sensor Auto-Idle/Acceleration Selector Auto-Idle EC Motor



Auto-Acc eleration Power Mode Switch HP Mode E Mode P Mode



Engine Speed Control Mode Selection Switch



Brake Switch



Shift Lever



Pedal



Neutral



Dial



D Mode



Creeper



L Mode



Work Brake Parking Brake Axle Lock OFF T1GL-02-01-002



NOTE: The illustration indicates system operation when each switch is placed in the following position. Engine Speed Control Mode Selection Switch: Dial Position Shift Lever: L Position Brake Switch: Work Position Auto-Idle/Auto-Acceleration Selector: Auto-Idle Position Power Mode Switch: P Position



T2-1-5



SYSTEM / Control System Forward/Reverse Travel Pedal Control



• When driving the machine Function: When driving the machine, the MC controls the engine speed corresponding to the accelerator pedal stroke and/or pump loads so that travel operation at an economical engine speed can be achieved. Operation: Detection signals from the travel forward or reverse pilot pressure sensor and from the pump 1 delivery pressure sensor, and set-signal (D or L) of the shift lever are sent to the MC. After processing these information, the MC drives the EC motor so that the most proper engine speed is selected. Requirements: • Brake Switch: OFF or Axle Lock Position • Engine Speed Control Mode Selection Switch: Pedal Position • Shift Lever: D or L Position NOTE: When the brake switch is not in the work brake position and the parking brake pressure switch is OFF, the MC recognizes that the brake switch is in either the acceleration lock or OFF position.



T2-1-6



SYSTEM / Control System



Parking Brake Pressure Switch Pressure Sensor Travel Forward Travel Reverse



Pump 1 Delivery Pressure Sensor EC Sensor



EC Motor



Engine Speed Control Mode Selection Switch



Shift Lever



Brake Switch



Pedal



Neutral



Work Brake



Dial



D Mode



Parking Brake



Creeper



L Mode



Axle Lock OFF T1F3-02-01-008



NOTE: The illustration indicates system operation when each switch is placed in the following position. Engine Speed Control Mode Selection Switch: Pedal Position Shift Lever: L Position Brake Switch: Axle Lock or OFF Position



T2-1-7



SYSTEM / Control System • When excavating operation Function: The engine speed is allowed to control with the forward/reverse travel pedal in addition to the engine control dial during excavation operation. Operation: When the following conditions are satisfied, the MC drives the EC motor in proportion to the forward/reverse travel pedal stroke (due to the sensing pressure signals from the travel forward pilot pressure sensor) so that the engine speed is controlled. NOTE: The engine speed range to be controlled with the forward/reverse travel pedal is up to the P mode maximum engine speed in the engine control dial control mode plus 200 min-1. Conditions: • Brake Switch: Work Brake Position • Shift Lever: N Position • Engine Speed Control Mode Selection Switch: Pedal Position



T2-1-8



SYSTEM / Control System



Parking Brake Pressure Switch Pressure Sensor Travel Forward Travel Reverse



EC Sensor



EC Motor



Engine Speed Control Mode Selection Switch



Shift Lever



Brake Switch



Pedal



Neutral



Dial



D Mode



Creeper



L Mode



Parking Brake Parking Brake Axle Lock OFF T1GL-02-01-005



NOTE: The illustration indicates system operation when each switch is placed in the following position. Engine Speed Control Mode Selection Switch: Pedal Position Shift Lever: N Position Brake Switch: Work Brake Position



T2-1-9



SYSTEM / Control System Engine Slowdown Control Function: When reducing travel speed (when the travel pilot valve is returned to neutral), the engine speed is gradually reduced, preventing cavitation from occurring in the travel motor. Operation: 1. When the following conditions are satisfied and the travel speed is slower than approximately 20 km/h, the MC drives the EC motor, causing the engine speed to gradually reduce to the travel idle speed. 2. When the travel speed is faster than approximately 20 km/h, the engine speed is gradually reduced to 1700 min-1 and is once held to run at that speed. 3. After the travel speed is reduced to slower than approximately 20 km/h, the engine speed is again reduced gradually to the minimum speed.



The travel pilot valve is in neutral (the engine slowdown starts). Engine Speed Maximum Speed 1700 min



Conditions: • Engine Speed Control Mode Selection Switch: Pedal Position • Forward/Reverse Travel Pedal: After the pedal is fully pressed for longer than 4 seconds during travel operation (forward or reverse), when the accelerator pedal is returned to neutral. NOTE: When the brake switch is not in the work brake position and the parking brake pressure switch is OFF, the MC recognizes that the brake switch is in either the acceleration lock or OFF position. NOTE: When the Shift Lever is not in either the N or L position, the MC recognizes that the shift lever is in the D position.



T2-1-10



Travel Speed: Approximately 20 km/h



-1



Minimum Speed Travel Speed (Fast)



Travel Speed (Slow)



Travel Speed



SYSTEM / Control System



Parking Brake Pressure Switch Pressure Sensor Travel Forward Travel Reverse



EC Sensor



EC Motor



Engine Speed Control Mode Selection Switch



Shift Lever



Brake Switch



Pedal



Neutral



Work Brake



Dial



D Mode



Parking Brake



Creeper



L Mode



Axle Lock OFF T1GL-02-01-004



NOTE: The illustration indicates system operation when each switch is placed in the following position. Engine Speed Control Mode Selection Switch: Pedal Position Shift Lever: D Position Brake Switch: Axle Lock or OFF Position



T2-1-11



SYSTEM / Control System HP Mode Control Function: Slightly increases digging power such as arm roll-in operation while excavating deeply.



Engine Speed



Operation: The MC drives the EC motor to slightly increase the engine speed set by the engine control dial when all the following conditions exist with the power mode switch is in the HP position. • Engine Control Dial: Set at 1400 min-1 or faster. • Boom Raise and/or Arm Roll-In Control: In Operation • Average Delivery Pressure of Pumps 1 and 2: High NOTE: The engine governor stopper position is adjusted in the HP mode. Accordingly, the governor lever doesn’t come in contact with the stopper in the normal mode.



T2-1-12



1550 min 1400 min



Slow Idle



Maximum speed increases by 200 -1 min



-1



-1



Fast Idle



Engine Control Dial Position



SYSTEM / Control System



Boom Raise Arm Roll-In



Pump 1 Delivery Pressure Sensor



Pump 2 Delivery Pressure Sensor



Engine Control Dial EC Sensor



EC Motor



Power Mode Switch HP Mode E Mode P Mode T1GL-02-01-006



T2-1-13



SYSTEM / Control System E Mode Control Function: Reduce the engine speed by the constant specified ratio.



Engine Speed



Engine speed is reduced at the constant specified ratio.



Operation: The MC drives the EC motor to reduce the engine speed set by the engine control dial when the power mode switch is in the E mode position. The engine speed is reduced in proportion to the rotation angle of the engine control dial.



Slow Idle



Fast Idle



Engine Control Dial Position



Engine Control Dial



EC Motor



Power Mode Switch



E Mode



T1GL-02-01-036



T2-1-14



SYSTEM / Control System (Blank)



T2-1-15



SYSTEM / Control System Auto-Idle Control Function: Reduces the engine speed when all control levers are in neutral to reduce fuel consumption and noise level. Operation: Approx. 4 seconds after all control levers are return to neutral, the MC drives the EC motor so that the engine speed is reduced to the auto-idle speed. As soon as a control lever is operated (the travel and/or front attachment pressure sensor is turned ON), the MC drives the EC motor so that the engine speed is increased to the original engine speed (set by the engine control dial).



Engine speed is reduced to the auto-idle speed 4 seconds later.



Engine Speed Fast Speed Auto-Idle Speed



Auto-Idle System Deactivation Requirements: • Control Levers: Being operated (either travel or front attachment control levers with pilot sensor ON) • Power Mode Switch: When the E mode is changed to P mode or the P mode is changed to the E mode. • Engine Control Dial: When engine speed is changed.



T2-1-16



Slow Idle



Fast Idle



Engine Control Dial Position



SYSTEM / Control System



Pressure Sensor Travel Forward Travel Reverse Front Attachment Engine Control Dial EC Sensor Auto-Idle/Acceleration Selector Auto-Idle EC Motor



Auto-Acceleration Power Mode Switch HP Mode E Mode P Mode



T1GL-02-01-008



T2-1-17



SYSTEM / Control System Auto Acceleration Control Function: Automatically regulates the engine speed to meet the machine operating conditions. When all the control levers are in neutral, the engine speed is reduced to reduce fuel consumption and noise level. Operation: When a control lever is operated with the auto-idle/acceleration selector in auto acceleration position, the MC calculates the most proper engine operating speed corresponding to the signals from pressure sensors (travel, swing, boom raise, and arm roll-in), the pump control pressure sensors, and the pump delivery pressure sensors. Then, the MC drives the EC motor so that the engine speed is set to the rotation speed calculated by the MC. When all control levers are returned to neutral, the engine speed is reduced by 400 min-1 from the maximum speed first. Then, 4 seconds later, the engine speed is further reduced to the auto-idle speed. Conditions: • Engine Speed Control Mode Selection Switch: Dial or Creeper Position • Auto-Idle/Auto-Acceleration Selector: Auto-Acceleration Position • Power Mode Switch: HP or P Position



Engine Speed VS. Control Lever Operations: Engine Speed Engine speed is reduced from the maximum speed -1 by 400 min .



Fast Speed AutoAcceleration Speed



Engine speed is reduced to the auto-idle speed 4 seconds later.



Auto-Idle Speed Slow Speed



Slow Idle



Fast Idle



Engine Control Dial Position



Operating Time Progress VS. Engine Speed Change Control Lever Stroke Full Stroke



Neutral Position Time



NOTE: When the engine speed control mode selection switch is not in either the pedal or creeper position, the MC recognizes that the engine speed control mode selection switch is in the dial position. When the power mode switch is not in either the HP or E mode position, the MC recognizes that the power mode switch is in the P mode position. NOTE: When all control levers are returned to neutral, the engine speed is reduced by 400 min-1 from the maximum speed. In case the engine speed is set by the engine control dial and is running at a speed slower than the maximum speed by 100 min-1, the engine speed will be reduced by 300 min-1.



Engine Speed Fast Idle Speed (P Mode)



In response to the control lever stroke and the pump delivery pressure, the optimum engine speed is selected.



Auto Acceleration Control



Auto-Idle Engine Speed



T2-1-18



Time



SYSTEM / Control System



Pressure Sensor Travel Forward Travel Reverse Swing Boom Raise Engine Control Dial



Pump 1 Delivery Pressure Sensor



Pump 2 Delivery Pressure Sensor



Arm Roll-In EC Sensor



Auto-Idle/Acceleration Selector AutoIdle Auto-Acc eleration



EC Motor



Pump 1 Control Pressure Sensor



Power Mode Switch HP Mode E Mode P Mode



Engine Speed Control Mode Selection Switch



Pump 2 Control Pressure Sensor



Pedal Dial Creeper T1GL-02-01-009



NOTE: The illustration indicates system operation when each switch is placed in the following position. Auto-Idle/Auto-Acceleration Selector: Auto-Acceleration Position Power Mode Switch: P Position Engine Speed Control Mode Selection Switch: Dial Position



T2-1-19



SYSTEM / Control System Auto Warming Up Control Function: Automatically warms up the hydraulic system (similar to the auto choke on automobiles). Operation: When the hydraulic oil temperature is below 0 °C (32 °F), the MC drives the EC motor in response to signals from the key switch and the hydraulic oil temperature sensor to run the engine at the auto warming up speed for 15 minutes after starting the engine.



Engine Speed Fast Speed



Auto Warming Up Speed



Increasing Speed



Slow Speed



IMPORTANT: When adjusting the auto-idle speed deactivate the auto warming up control function using Dr. ZX, or wait to adjust until 15 minutes after starting the engine.



Slow Idle



Fast Idle



Engine Control Dial Position



Key Switch



EC Motor



Hydraulic Oil Temperature Sensor



T2-1-20



T1GL-02-01-010



SYSTEM / Control System Slow Idle Speed-Up Control Engine Speed



Function: Prevents the engine from hunting when running the engine at slow speed. Operation: When the travel or front attachment function is operated while the engine is running at a speed between the minimum speed and the Slow Idle Speed-Up Speed, the MC drives the EC motor so that the engine speed is increased to the Slow Idle Speed-Up Speed.



Idle Speed-Up Speed



Increasing Speed



Fast Idle



Slow Idle



Engine Control Dial Position



Pressure Sensor Travel Forward Travel Reverse Front Attachment



Engine Control Dial



EC Motor T1GL-02-01-046



T2-1-21



SYSTEM / Control System Attachment Operation Speed Increase Control (Only on the machines equipped with the auxiliary mode switch (Optional).) Function: Increases the maximum engine speed to the attachment (hydraulic breaker, secondary crusher, primary crusher or vibrating hammer) operating engine speed set by Dr. ZX when the attachment is operated.



When all conditions exist, the maximum engine speed is increased to the speed set by Dr. ZX.



Engine Speed



Operation: When the following conditions exist, the MC drives the EC motor so that the engine maximum speed is increased to the attachment operating speed set by Dr. ZX when the attachment is operated. Operating Conditions: Dr. ZX: Resets the maximum engine speed to a faster (+) attachment (hydraulic breaker, secondary crusher, primary crusher, or vibrating hammer) operating speed in the service mode. Engine Control Dial: Maximum Speed Position Power Mode Switch: HP Mode Auxiliary: In Operation Work Mode Switch: Attachment Mode Auxiliary Mode Switch (Optional): Attachment position (hydraulic breaker, secondary crusher, primary crusher, or vibrating hammer) reset by Dr. ZX.



T2-1-22



Slow Idle



Fast Idle



Engine Control Dial Position



NOTE: When the P mode engine speed is preset to a slower speed in the Dr. ZX service mode, the maximum engine speed won’t be increased when operating the attachment.



SYSTEM / Control System



Engine Control Dial Auxiliary (Optional) EC Sensor



EC Motor Power Mode Switch HP Mode E Mode P Mode Auxiliary Mode Switch (Optional) Work Mode Switch Digging Mode Attachment Mode T1GL-02-01-011



T2-1-23



SYSTEM / Control System Attachment Operation Speed Limit Control (Only on the machines equipped with the auxiliary mode switch (Optional).) Function: Decreases the maximum engine speed to the attachment (hydraulic breaker, secondary crusher, primary crusher or vibrating hammer) operating engine speed set by Dr. ZX when the attachment mode is selected.



Engine Speed



When all conditions exist, the maximum engine speed is reduced to the speed set by Dr. ZX.



Operation: When the following conditions exists, the MC drives the EC motor so that the engine maximum speed is reduced to the attachment operating speed set by Dr. ZX when the attachment mode is selected. Operating Conditions: Dr. ZX: Resets the maximum engine speed to a slower (−) attachment (hydraulic breaker, secondary crusher, primary crusher, or vibrator) operating speed in the service mode. Work Mode Switch: Attachment Mode Auxiliary Mode Switch (Optional): Attachment position (hydraulic breaker, secondary crusher, primary crusher, or vibrating hammer) set by Dr. ZX.



Slow Idle



Fast Idle



Engine Control Dial EC Sensor



EC Motor



Work Mode Switch Digging Mode Attachment Mode Auxiliary Mode Switch (Optional)



NOTE: OP: Optional



T2-1-24



T1GL-02-01-012



SYSTEM / Control System Engine Learning Control Function: Inputs the governor lever stopper positions on both the STOP and FULL sides as the standard data to control the engine. Operation:When the learning switch in the rear console is turned to the engine learning position, the EC motor is driven by the signals from the MC. The EC motor moves the governor lever from the IDLE to FULL and to STOP positions in this order. The EC sensor detects the stopper positions of the governor lever on both the FULL and STOP sides and sends each stopper position signal to the MC. The MC stores these signals in its memory.



IMPORTANT: Be sure to perform the engine learning if the following repair work is done. (Refer to the Troubleshooting Section in T/M.) After performing the engine learning, check that the engine learning has been performed correctly using Dr. ZX. • After the engine, engine control cable, or EC motor has been removed or replaced. • After the MC has been replaced. NOTE: The engine learning is not required when the batteries are replaced.



Learning Switch



Key Switch EC Sensor



EC Motor T1GL-02-01-014



T2-1-25



SYSTEM / Control System (Blank)



T2-1-26



SYSTEM / Control System Pump Control This system performs the following controls. • Speed Sensing Control (Normal) • Travel Speed Sensing Control • Travel Pump1 Flow Rate Shift Control • Flow Rate Limit Control (When Combined Operation of the Travel and Front Attachment) • *Pump1 Flow Rate Limit Control • *Pump2 Flow Rate Limit Control • Steering Pump Torque Reduction Control



NOTE: OP: Optional *Control system available only on the machine equipped with the optional parts.



Pump Control System Layout Column Box



Parking Brake Pressure Switch N Sensor (Travel)



Pressure Sensor Travel Forward



Travel Reverse N Sensor (Engine) Pump2 Delivery Pressure Sensor Front Attachment Pump1 Delivery Steering Pump Pressure Sensor Delivery Pressure Auxiliary (OP) Sensor



Engine Control Dial



Engine Speed Control Mode Selection Switch Pedal Dial Creeper Shift Lever Neutral D Mode L Mode Brake Switch Work Brake Parking Brake Axle Lock



Torque Control Solenoid Valve



Maximum Pump 1 Flow Rate Limit Solenoid Valve



Maximum Pump 1 Flow Rate Shift Solenoid Valve



Maximum Pump 2 Flow Rate Limit Solenoid Valve



OFF T1F3-02-01-001



T2-1-27



SYSTEM / Control System Speed Sensing Control Function: Controls the pump flow rate in response to engine speed changes due to variations in load so that the engine output can be utilized more efficiently. (Engine stall is prevented when the machine operates under adverse conditions such as operating at high altitude.)



Q Flow Rate



Operation: 1. The target engine operating speed is set by controlling the engine control dial. 2. The MC calculates the difference in speed between the target operating speed and the actual operating speed monitored by the N sensor. Then, the MC sends signals to the torque control solenoid valve. 3. The torque control solenoid valve delivers pilot pressure oil in response to the signals received from the MC to the pump regulator, controlling the pump flow rate. 4. If the engine load increases and the actual engine operating speed becomes slower than the target operating speed, the pump swash angle is reduced so that pump flow rate will be reduced. Therefore, the engine load is reduced, preventing engine stall. 5. If the actual engine operating speed becomes faster than the target operating speed, the pump swash angle is increased so that the pump flow rate will increase, by which the engine output can be utilized more efficiently.



T2-1-28



Normal Pump P-Q Curve



Pressure



P



SYSTEM / Control System



N Sensor (Engine) Engine Control Dial



Torque Control Solenoid Valve T1F3-02-01-002



T2-1-29



SYSTEM / Control System Travel Speed Sensing Control Function: The pump flow rate is controlled in response to variations in engine speed due to travel load changes, allowing to use the engine power effectively. Conditions: • Travel Forward or Reverse Operation • Shift Lever: D or L Position • Brake Switch: Axle Lock or OFF Position



Q



NOTE: When the brake switch is not in the brake position and the parking brake pressure switch is OFF position, the MC recognizes that the brake switch is in either the axle lock or OFF position.



Flow Rate



Operation: 1. The MC determines the engine target running speed corresponding to sensing signals detected by the EC dial or the pilot pressure sensor (travel forward or reverse). 2. The MC computes the difference between the engine target running speed and actual engine operating speed detected by the N sensor (engine) and outputs signals to the torque control solenoid valve. 3. In response to the signals from the MC, the torque control solenoid valve sends the pilot pressure to the pump regulators to control the pump flow rate. 4. When the actual engine operating speed becomes slower than the engine target running speed as the load to the engine increases, the pump displacement angle is reduced to reduce the delivery flow rate. Therefore, the load to the engine is reduced, preventing the engine from stalling. 5. If the actual engine operating speed becomes faster than the engine target running speed, the pump displacement angle is increased to effectively utilize the engine power.



T2-1-30



Pump P-Q Curve



Pressure



P



SYSTEM / Control System



Parking Brake Pressure Switch Pressure Sensor Travel Forward Travel Reverse



N Sensor (Engine) Pump1 Delivery Pump2 Delivery Pressure Sensor Pressure Sensor



Engine Control Dial



Engine Speed Control Mode Selection Switch Pedal Dial Torque Control Solenoid Valve



Creeper Shift Lever Neutral D Mode L Mode



Brake Switch Work Brake Parking Brake Axle Lock OFF T1F3-02-01-003



NOTE: The illustration indicates system operation when each switch is placed in the following position. Engine Speed Control Mode Selection Switch: Pedal Position Shift Lever: L Position Brake Switch: Axle Lock or OFF Position



T2-1-31



SYSTEM / Control System Travel Pump 1 Flow Rate Shift Control Function: The maximum flow rate of pump 1 is increased to increase travel speed during travel operation. Operation: 1. The MC recognizes that travel operation is being performed when the following conditions are arranged. 2. The MC activates the pump 1 maximum flow rate shift solenoid valve to increase the displacement angle so that the pump 1 delivers the maximum oil flow.



Q Flow Rate



NOTE: While traveling at slow speed, when the front attachment is operated, too much oil may be supplied to the front attachment actuators. To prevent this operation, when input signals (travel motor speed) from the N sensor (travel) match speed (A) described below, this control system is deactivated. Speed A: During travel acceleration → 800 rpm or slower During travel deceleration → 500 rpm or slower



Maximum flow rate is increased.



Normal Pump P-Q curve



Pressure



Conditions: • Engine Speed Control Mode Selection Switch: Pedal or Dial Position • Travel Pilot Pressure (Forward or Reverse): Output is present. • N sensor (Travel): Output is present. • Front Attachment Pilot Pressure Sensor: No output is present. NOTE: When the brake switch is not in the work brake position and the parking brake pressure switch is OFF position, the MC recognizes that the brake switch is in either the axle lock or OFF position. NOTE: The signals from N sensor (travel) are sent to the MC via the column box. When the shift lever is not in either the N or L position, the MC recognizes that the shift lever is in the D position. NOTE: The signals from the N sensor (travel) is sent to the MC via the column box.



T2-1-32



P



SYSTEM / Control System



Column Box Parking Brake Pressure Switch Pressure Sensor



N Sensor (Travel)



Travel Forward Travel Reverse Front Attachment



Engine Speed Control Mode Selection Switch Pedal Dial Creeper Maximum Pump 1 Flow Rate Shift Solenoid Valve



Shift Lever Neutral D Mode L Mode



Brake Switch Work Brake Parking Brake Axle Lock OFF T1F3-02-01-004



NOTE: The illustration indicates system operation when the front attachment is operated while traveling the machine forward with each switch in the following position. Engine Speed Control Mode Selection Switch: Pedal Position Shift Lever: D Position Brake Switch: Axle Lock or OFF Position



T2-1-33



SYSTEM / Control System Flow Rate Limit Control (When combined operation of the travel and front attachment) Function: The maximum engine speed for travel operation is set faster than that for excavation operation. Therefore, when the front attachment and/or swing system is operated together with the travel system when the engine is running at the travel maximum speed, the increased oil flow is supplied to the front attachment and/or swing actuators so that each actuator may be overloaded. To prevent this overloading, when combined operation of the travel and front attachment and/or swing functions is made, the maximum pump 2 flow rate is reduced.



Q Flow Rate



Operation: 1. The MC recognizes that combined operation of the travel and front attachment functions is being made when the following condition is established. 2. When the MC recognizes that the current engine target running speed is 2050 min-1 (engine target running speed in the HP mode) during travel operation, the MC activates the maximum pump 2 flow rate limit control solenoid valve to reduce the pump 2 maximum flow rate. Conditions: • Shift Lever: Pedal or Dial Position • Travel Pilot Pressure (Forward or Reverse): Output is present. • N Sensor (Travel): Output is present. • Front Attachment Pilot Pressure Sensor: Output is present. NOTE: When the brake switch is not in the work brake position and the parking brake pressure switch is OFF position, the MC recognizes that the brake switch is in either the axle lock or OFF position. NOTE: The signals from N sensor (travel) are sent to the MC via the column box. When the shift lever is not in either the N or L position, the MC recognizes that the shift lever is in the D position.



T2-1-34



Maximum flow rate is reduced.



Normal Pump P-Q Curve



Pressure P



SYSTEM / Control System



Parking Brake Pressure Switch Pressure Sensor



N Sensor (Engine)



Travel Forward Travel Reverse Front Attachment



Engine Speed Control Mode Selection Switch Pedal Dial Creeper



Shift Lever Neutral Maximum Pump 2 Flow Rate Limit Solenoid Valve



D Mode L Mode



Brake Switch Work Brake Parking Brake Axle Lock OFF T1F3-02-01-005



NOTE: The illustration indicates system operation when the front attachment is operated while traveling the machine forward with each switch in the following position. Engine Speed Control Mode Selection Switch: Pedal Position Shift Lever: D Position Brake Switch: Axle Lock or OFF Position



T2-1-35



SYSTEM / Control System Pump 1 Flow Rate Limit Control (Only on the machines with the auxiliary sensor (Optional))



Pump 2 Flow Rate Limit Control (Only on the machines with the auxiliary sensor (Optional))



Function: Limits the maximum pump 1 flow rate when operating a front attachment such as a vibration hammer requiring a large flow rate of hydraulic oil.



Function: Limits the maximum pump 2 flow rate when operating a front attachment such as a hydraulic breaker that doesn’t require a large flow rate of hydraulic oil.



NOTE: When a front attachment, such as a vibration hammer requiring a large flow rate of hydraulic oil is operated, the pressure oil from pumps 1 and 2 is jointly supplied to the auxiliary spool in the control valve. Since pump 2 delivers the maximum flow rate at this time, the vibration hammer doesn’t need the maximum flow rate from pump 1 so that the maximum pump 1 flow rate is limited. (Optional flow combining system: ON)



NOTE: When operating a front attachment such as a hydraulic breaker that doesn’t require a large flow rate of hydraulic oil, the auxiliary flow combiner valve is not shifted. Then, only the pressure from pump 2 flows to the auxiliary spool in the control valve. Since a hydraulic breaker doesn’t need a large flow rate of hydraulic oil, the maximum pump 2 flow rate is limited. (Optional flow combining system: OFF)



Operation: 1. When a front attachment is used, the MC receives signals from the pressure sensor (auxiliary). 2. In response to the signals arriving from the pressure sensor, the MC drives the maximum pump 1 flow rate limit solenoid valve (optional) to reduce the maximum pump flow rate.



Operation: 1. When a front attachment is used, the MC receives signals from the pressure sensor (auxiliary). 2. In response to the signals arriving from the pressure sensor, the MC drives the maximum pump 2 flow rate limit solenoid valve to reduce the maximum pump flow rate.



NOTE: In proportion to the attachment control pedal stroke, the maximum pump flow rated is reduced. The minimum pump swash set-angle for a front attachment (hydraulic breaker, secondary crusher, primary crusher or vibrating hammer) can be set in the service mode of Dr. ZX. Flow Rate Q



Maximum flow rate is reduced.



NOTE: In proportion to the attachment control pedal stroke, the maximum pump flow rated is reduced. The minimum pump swash set-angle for a front attachment (hydraulic breaker, secondary crusher, primary crusher or vibrating hammer) can be set in the service mode of Dr. ZX.



Flow Rate Q



Maximum flow rate is reduced.



Normal Pump P-Q Curve



Pressure



0



P



T2-1-36



Pump Control Pressure



Pi



SYSTEM / Control System



Auxiliary (OP)



Maximum Pump 1 Flow Rate Limit Solenoid Valve



Maximum Pump 2 Flow Rate Limit Solenoid Valve



T1F3-02-01-006



T2-1-37



SYSTEM / Control System Steering Pump Torque Reduction Control Function: When load to the steering pump increases, loads to pump-1 and 2 are reduced so that engine stall is prevented, allowing the engine power to be used efficiently.



Q Flow Rate



Operation: When the MC receives signals from the steering pump delivery pressure sensor, the MC activates the torque control solenoid valve so that the pumps-1 and 2 delivery flow rate is reduced. Accordingly, the total driving power of pumps-1 and 2, and the steering pump is controlled so that it doesn’t exceed the engine output power, allowing the engine power to be used efficiently.



Pump P-Q Curve is reduced in proportion to the steering pump delivery pressure.



Normal Pump P-Q Curve



Pressure P



Steering Pump Delivery Pressure Sensor



Torque Control Solenoid Valve



T1F3-02-01-007



T2-1-38



SYSTEM / Control System (Blank)



T2-1-39



SYSTEM / Control System Valve Control The valve control has the following functions.



• • • • •



Arm Regenerative Control Superfine Travel Speed Control Travel Motor Excessive Rotation Control Work Brake Control Auxiliary Flow Rate Control



NOTE: OP: Optional *Control system available only on the machine equipped with the optional parts.



T2-1-40



SYSTEM / Control System Valve Control System Layout



Parking Brake Pressure Switch



Column Box



N Sensor (Travel)



Learning Switch Pressure Switch Travel Forward Travel Reverse Front Attachment Swing Boom Raise



Key Switch



Arm Roll-In Arm Roll-Out (OP) Auxiliary (OP)



Engine Control Dial



Engine Speed Control Mode Selection Switch



Travel Motor



Displacement Angle Control Valve



Pump 1 De- Pump 2 Delivery Pres- livery Pressure Sensor sure Sensor



Hydraulic Oil Temperature Sensor



Pedal Dial



Pump 2 Control Pressure Sensor



Creeper



Pump 1 Control Pressure Sensor



Solenoid Valve Unit SG SC SE SI



Shift Lever Neutral D Mode L Mode



Brake Switch



Auxiliary Flow Rate Control Solenoid Valve (OP)



Work Brake Parking Brake Axle Lock



Brake Valve



Auxiliary Flow Rate Control Valve



OFF



Brake (Front)



Brake (Rear) Arm Regenerative Valve T1F3-02-01-022



T2-1-41



SYSTEM / Control System Arm Regenerative Control Function: Accelerates the arm roll-in speed to prevent arm hesitation during arm roll-in operation. Operation: The MC activates the solenoid valve unit (SC) so that solenoid valve delivers the pilot pressure oil to shift the arm regenerative valve when signals from the pump 2 delivery pressure sensor, swing pressure sensor, arm roll-in pressure sensor, and boom raise pressure sensor meet the following conditions. When the arm regenerative valve is shifted, the return circuit from the arm cylinder rod side to the hydraulic oil tank is closed. Then, the return oil from the cylinder rod side is combined with the pressure oil from the pump and is routed to the cylinder bottom, accelerating the arm roll-in speed and preventing arm hesitation. (Refer to the COMPONENT OPERATION / Control Valve group.) Operating Conditions: Pump 2 Delivery Pressure Sensor: Low pressure. (The arm doesn’t need much power.) Arm Roll-In Pressure Sensor: High output. (The arm control lever stroke is large.) Swing or Boom raise Sensor: Outputting signal. NOTE: To improve arm leveling performance, the MC gradually activates solenoid valve unit (SC) when the hydraulic oil temperature is at 0 to 10 °C (32 to 50 °F).



T2-1-42



SYSTEM / Control System



Swing Boom Raise Arm Roll-In



Pump 1 Delivery Pump 2 Delivery Pressure Sensor Pressure Sensor



Hydraulic Oil Temperature Sensor



Solenoid Valve Unit SG SC SE SI



Auxiliary Flow Rate Control Valve



Arm Regenerative Valve T1F3-02-01-025



T2-1-43



SYSTEM / Control System Superfine Travel Speed Control Function: The machine is driven in the superfine travel speed mode. Operation: 1. When the following conditions are established, the MC activates solenoid valve unit (SI). 2. When solenoid valve unit (SI) is activated, the pilot oil pressure is routed to the travel motor displacement angle control valve, causing the motor to rotate at a large displacement angle so that the machine travels at the superfine speed. Conditions: • Engine Speed Control Mode Selection Switch: Creeper Position • Shift Lever: D or L Position • N sensor (Travel): Output signal (travel motor speed) is under 1500 min-1. NOTE: When the output signal from N sensor (travel) is 1500 min-1 and up, the MC doesn’t operate this system to prevent cavitation from occurring in the travel motor. NOTE: The signals from N sensor (travel) are sent to the MC via the column box. When the shift lever is not in either the N or L position, the MC recognizes that the shift lever is in the D position.



T2-1-44



SYSTEM / Control System



N Sensor (Travel)



Column Box



Engine Speed Control Mode Selection Switch



Displacement Angle Control Valve Travel Motor



Pedal Dial Creeper Shift Lever Neutral D Mode L Mode



Solenoid Valve Unit SG SC SE SI T1F3-02-01-026



T2-1-45



SYSTEM / Control System Travel Motor Excessive Rotation Control Function: The machine is prevented from running away while descending slopes, protecting the travel motor from damage. Operation: 1. The output signal from N sensor (travel) is sent to the MC. NOTE: The output signals from N sensor (travel) are sent to the MC via the column box. 2. When the signal value from N sensor (travel) exceeds the specified value, The MC activates solenoid valve unit (SI). 3. When solenoid valve unit (SI) is activated, the pilot oil pressure is routed to the travel motor displacement angle control valve so that the travel motor displacement angle increases. NOTE: When the travel motor displacement angle is suddenly increased, cavitation may occur in the travel motor. Therefore, the MC activates solenoid valve unit (SI) slowly so that the travel motor displacement angle changes slowly, preventing the occurrence of cavitation. 4. As the travel motor displacement angle increases, the motor displacement increases, creating braking force to the travel motor. 5. Thereby, the excessive rotation of the travel motor is prevented, reducing travel speed.



T2-1-46



SYSTEM / Control System



N Sensor (Travel)



Column Box Displacement Angle Control Valve Travel Motor



Solenoid Valve Unit SG SC SE SI T1F3-02-01-027



T2-1-47



SYSTEM / Control System Work Brake Control Function: The front and rear brakes are applied during excavation work to stabilize the machine vehicle. Operation: 1. When the MC receives the signal from the brake switch, the MC recognizes that the brake switch is in the work brake position. 2. Then, the MC activates solenoid valve unit (SG). 3. When solenoid valve unit (SG) is activated, the pilot oil pressure is routed to the brake valve so that the brake valve is shifted. 4. When the brake valve is shifted, the pilot pressure from the brake valves routed to the front and rear brakes, causing the brakes to be applied. NOTE: A slight time-lag will occur due to difference in operation start time of solenoid valves when the brake switch is shifted from the work brake to the parking brake. Therefore, the MC activates solenoid valve unit (SG) one second after the brake switch has been shifted to the parking brake position from the work brake position to allow the work brake to be released.



T2-1-48



SYSTEM / Control System



Brake Switch Work Brake Parking Brake Axle Lock Solenoid Valve Unit



OFF



SG SC SE SI Brake Valve



Brake (Front)



Brake (Rear)



T1F3-02-01-028



T2-1-49



SYSTEM / Control System Auxiliary Flow Rate Control (Only on the machines equipped with the auxiliary pressure sensor and auxiliary flow rate control solenoid valve) Function: Restricts the oil flow to the auxiliary spool when the combined operation of the swing, boom raise, and arm roll-in is made while operating a front attachment using the auxiliary spool to maintain controllability of the combined operation. Operation: The MC activates the auxiliary flow rate control solenoid valve (optional) so that the oil flow to the auxiliary spool is restricted under the following conditions. Operating Conditions: Auxiliary Pressure Sensor: ON Swing, Boom Raise, Arm Roll-In Pressure Sensors: ON NOTE: OP: Optional



T2-1-50



SYSTEM / Control System



Swing Boom Raise Arm Roll-In Arm Roll-Out (OP) Auxiliary (OP)



Auxiliary Flow Rate Control Solenoid Valve (OP)



Auxiliary Flow Rate Control Valve



Arm Regenerative Valve



T1F3-02-01-029



T2-1-51



SYSTEM / Control System (Blank)



T2-1-52



SYSTEM / Control System Other Controls Other control systems consist of the following systems.



• • • • • • • •



Parking Brake Alarm Control Brake Dragging Prevention Control Travel Motor Alarm Control Forward/Reverse Shifting Restriction Control Work Mode Control Overload Alarm Control Swing Alarm Control Travel Alarm Control



T2-1-53



SYSTEM / Control System Parking Brake Alarm Control Function: The buzzer sounds when the front attachment is operated with the parking brake applied to protect the transmission. Operation: 1. The MC recognizes that the parking brake is applied when signals from the parking brake pressure switch arrive at the MC. 2. When signals from pilot pressure sensors (front attachment, boom raise, arm roll-in, and swing) are sent to the MC while the parking brake is applied, the MC connects the circuit from terminal #7 on transistor unit 1 to the ground in the MC. NOTE: Even if the same operation is made, the sensing pressure may differ depending on oil temperature. The MC Judges that the front attachment is being operated when the oil temperature and the pilot pressure match the values shown in the following table. Oil Temperature 10 °C or more



Pilot Pressure 0.7 MPa



0 °C up to 10 °C



1 MPa



Below 0 °C



1.5 MPa



Input Sensor Front Attachment Boom Raise Arm Roll-In Swing ↑



3. As terminal #7 is connected to the ground, transistors (a and b) in transistor unit 1 operate so that terminal #4 is connected to the ground. [The emitter on transistor (a) is connected to terminal #3 on transistor unit 1.] 4. Since terminal #4 is connected to the ground, the parking brake alarm relay, which is connected to terminal #4, is magnetized. 5. Then, the buzzer in the column box is grounded through the parking brake alarm relay. 6. As the buzzer is connected to the ground, the buzzer sounds.



T2-1-54



NOTE: When the brake switch is not in the brake position and the parking brake pressure switch is OFF position, the MC recognizes that the brake switch is in either the axle lock or OFF position.



SYSTEM / Control System



Parking Brake Pressure Switch Pressure Sensor Front Attachment Swing Boom Raise Arm Roll-In



Brake Switch Work Brake Parking Brake Axle Lock OFF



Column Box Transistor unit 1 a b



a’



From Fuse #27



Hydraulic Oil Temperature Sensor b’



Parking Brake Alarm Relay



Travel Motor Alarm Relay



From Fuse #20



T1GL-02-01-031



NOTE: This illustration indicates the system operation when the front attachment is operated with the brake switch in the parking brake position.



T2-1-55



SYSTEM / Control System Brake Dragging Prevention Control Function: When the parking brake and the work brake are applied, travel system is deactivated. Operation: 1. The MC recognizes that both the parking brake and the work brake are applied when the MC receives signals from the brake switch and the parking brake pressure switch. 2. Then，the MC grounds the circuits connecting to terminals #6 and #7 on transistor unit 2 in the MC. 3. As terminals #6 and #7 are grounded, transistors (a and a’, and b and b’) in transistor unit 2 operate. Then, terminals #1 and #4 on transistor unit 2 are connected to the ground circuit (terminal 5). [The emitters on transistors (a and a’) are connected to terminal #3 on transistor unit 2.] 4. Since terminals #1 and #4 are grounded, the travel reverse Pi cut relay, which is connected to terminal #1, and the travel forward Pi cut relay, which is connected to terminal #4, become magnetized. 5. Accordingly, the current from fuse #20 flows through each relay and energizes the travel forward Pi cut solenoid valve and the travel reverse Pi cut solenoid valve. 6. Therefore, the pilot oil pressure from the travel pilot valve is interrupted with the solenoid valves, deactivating the travel operation system.



T2-1-56



SYSTEM / Control System



Parking Brake Pressure Switch



Brake Switch Work Brake Parking Brake Axle Lock OFF



From Fuse #20



Transistor Unit 2 a



b



a’



b’



Travel Forward Pi Cut Solenoid Valve



Travel Reverse Pi Cut Relay



Travel Pilot Valve



Travel Reverse Pi Cut Solenoid Valve



Travel Forward Pi Cut Solenoid Valve T1GL-02-01-032



NOTE: The illustration indicates the system operation when the brake switch is placed in the work brake position.



T2-1-57



SYSTEM / Control System Travel Motor Alarm Control Function: In case any abnormality occurs in the travel motor, the engine running speed is reduced and held at the minimum, causing the buzzer to sound and the alarm indicator to light. Operation: 1. The signals from the travel motor drain pressure sensor are sent to the MC. 2. If any abnormality occurs in the travel motor during travel operation, the drain pressure from the travel motor will increase. 3. Then, when the MC judges that the travel motor is abnormal, the MC activates the EC motor so that the engine running speed is reduced and held at the minimum.



7. At the same time, the travel motor alarm relay, which is connected to terminal #1, is also magnetized. 8. Therefore, the current from fuse #20 flows through the travel motor alarm relay, turning the warning indicator in the column box ON.



NOTE: When the travel motor drain pressure is kept at more than 15Mpa (15 kgf/cm2) for 50 ms, the MC judges that the travel motor is abnormal. NOTE: The MC judges that the travel motor is not abnormal when the machine is under the following conditions: • When hydraulic oil temperature is –5 °C or below: • When the shift lever is in neutral: • When the front attachment is operated, or during the period of 3.5 seconds after the front attachment operation is stopped: 4. At the same time, the MC grounds the circuit from terminal #6 on transistor unit 1 in the MC. 5. Thereby, transistors (a’ and b’) operate, connecting terminal #1 to the ground. [The emitter on transistor (a’) is connected to terminal #3 on transistor unit 1.] 6. As terminal #1 is grounded, the buzzer is grounded via terminal #1 so that the buzzer sounds.



T2-1-58



NOTE: This operation continues to be performed until the key switch is turned OFF then ON, or until the fault codes are cleared with Dr. ZX. However, when the system operation is deactivated with the key switch (OFF→ON), only engine control system can be recovered. (The buzzer and the warning indicator are not deactivated ON.)



SYSTEM / Control System



Shift Lever Neutral



Pressure Sensor Front Attachment Swing Boom Raise Arm Roll-In



D Mode L Mode



Travel Motor Drain Pressure Sensor



Brake Switch Work Brake Parking Brake



EC Motor



Axle Lock OFF



Column Box



Buzzer Indicator



Transistor unit 1 a b



a’



From Fuse #27



Hydraulic Oil Temperature Sensor b’



Parking Brake Alarm Relay



Travel Motor Alarm Relay



From Fuse #20



T1GL-02-01-033



T2-1-59



SYSTEM / Control System Forward/Reverse Shifting Restriction Control Function:



If the travel direction is changed to the opposite direction while traveling, adverse effects may occur in the travel circuit and components. To protect the circuit and components from being damaged, the opposite travel direction side pilot pressure is temporarily interrupted so that the opposite direction system is deactivated during travel operation.



Conditions: Shift Lever: D or L Position N Sensor (Travel): Output is present (during travel operation). Either Travel Forward or Reverse Pilot pressure: 0.7 MPa or more



NOTE: When the Shift Lever is not in either the N or L position, the MC recognizes that the shift lever is in the D position. Operation: The MC judges that the machine is traveling forward or reverse when the above conditions are established.



• When traveling forward (travel reverse pilot pressure



is temporarily interrupted): 1. When signals from the travel forward pilot pressure sensor arrives at the MC, the MC judges that the machine is traveling forward, and grounds the circuit connecting to terminal #6 on transistor unit 2 in the MC. 2. Thereby, transistors (a’ and b’) operate, connecting terminal #1 to the ground. [The emitter on transistor (a’) is connected to terminal #3 on transistor unit 2.] 3. As terminal #1 is grounded, the travel reverse Pi cut relay, which is connected to terminal #1, is magnetized. 4. When the travel reverse Pi cut relay is magnetized, the current from fuse #20 flows to the travel reverse Pi cut solenoid valve via the travel reverse Pi cut relay. 5. Then the travel reverse Pi cut solenoid valve operates, deactivating the travel reverse operation circuit.



• When traveling reverse (travel forward pilot pressure



is interrupted): 6. When signals from the travel reverse pilot pressure sensor arrive at the MC, the MC judges that the machine is traveling in reverse, and grounds the circuit connecting to terminal #7 on transistor unit 2 in the MC. 7. Thereby, transistors (a and b) operate, connecting terminal #4 to the ground. [The emitter on transistor (a) is connected to terminal #3 on transistor unit 2.] 8. As terminal #4 is grounded, the travel forward Pi cut relay, which is connected to terminal #4, is magnetized. 9. When the travel forward Pi cut relay is magnetized, the current from fuse #20 flows to the travel forward Pi cut solenoid valve via the travel forward Pi cut relay. 10. Then the travel forward Pi cut solenoid valve operates, deactivating the travel forward operation circuit.



T2-1-60



SYSTEM / Control System



N Sensor (Travel) Shift Lever Travel Motor Drain Pressure Sensor



Pressure Sensor



Neutral



Travel Forward D Mode



Travel Reverse



L Mode



Brake Switch Work Brake Parking Brake Axle Lock OFF



From Fuse #20



Transistor Unit 2 a



b



a’



b’



Travel Forward Pi Cut Solenoid Valve



Travel Reverse Pi Cut Relay



Travel Pilot Valve



Travel Reverse Pi Cut Solenoid Valve



NOTE: The illustration indicates the system operation when travel forward operation is made with the travel mode switch in the D position.



T2-1-61



Travel Forward Pi Cut Solenoid Valve



T1GL-02-01-034



SYSTEM / Control System Work Mode Control Two work modes, digging and front attachment, are available by operating the work mode switch.



• Digging Mode: Normal control is performed.



• Front Attachment Mode: Functions only when a front attachment in the optional kit is operated. The engine speed (see T2-1-22 and 24) and pump flow rate (see T2-1-34) are controlled so as to match the installed front attachment operation in response to the movement of the auxiliary valve spool. The engine speed and pump flow rate control settings are made by using Dr. ZX.



T2-1-62



SYSTEM / Control System (Blank)



T2-1-63



SYSTEM / Control System Overload Alarm Control (Available only on machines equipped with optional parts) Function:



When more than set-load is lifted, the buzzer sounds and the warning indicator lights.



Operation: 1. The MC receives sensing signals from the boom bottom pressure sensor (OP). When the MC judges that the front attachment is overloaded, the MC grounds the circuit from terminal #7 on the transistor unit (OP) in the MC. 2. Thereby, transistors (a and b) operate so that terminal #4 is grounded. 3. Then, the load alarm relay (OP), which is connected to terminal #4, is magnetized. [The emitter on transistor (a) is connected to terminal #3 on the transistor unit (OP).] 4. When the load alarm relay is magnetized, the circuit from the buzzer and the load alarm indicator are grounded via the load alarm relay and the deactivation switch. 5. Then, the buzzer and the alarm indicator operate. NOTE: The buzzer and the alarm indicator can be deactivated with the deactivation switch (OP). OP: Optional



T2-1-64



SYSTEM / Control System



Boom Bottom Pressure Sensor (OP)



Monitor Panel From Fuse #1or #5



Transistor Unit (OP) a b



Load Alarm Relay (OP) From Fuse #18



From Fuse #18



Deactivation Switch (OP) T1GL-02-01-035



T2-1-65



SYSTEM / Control System Swing Alarm Control (Available only on machines equipped with optional parts) Function: When swing operation is made, the buzzer (OP) sounds and the rotating light turns. Operation: 1. When the MC receives sensing signals from the pilot pressure sensor (swing), the MC judges that swing operation is being made. Then, the MC grounds the circuit from terminal #7 on the transistor unit (OP) in the MC. 2. Thereby, transistors (a and b) operate so that terminal #4 is grounded. 3. Then, the swing alarm relay (OP), which is connected to terminal #4, is magnetized. [The emitter on transistor (a) is connected to terminal #3 on the transistor unit (OP).] 4. When the swing alarm relay is magnetized, the circuit from the fuse (OP) flows to the buzzer and the rotating light via the swing alarm relay. NOTE: The buzzer can be deactivated with the deactivation switch (OP). OP: Optional



T2-1-66



SYSTEM / Control System



Pressure Sensor Swing



Transistor Unit (OP)



Swing Alarm Relay (OP) From Fuse (OP)



Buzzer



From Fuse (OP) Deactivation Switch (OP)



Rotating (OP)



T2-1-67



T1GL-02-01-037



SYSTEM / Control System Travel Alarm Control (Only on the machines equipped with the travel alarm device (Optional)) Function: Sounds the buzzer while traveling. Operation: As long as the MC receives signals from the travel pressure sensor when travel operation is made, the MC sends out signals to the travel alarm device to sound the buzzer (optional). NOTE: After traveling continuously for more than 13 seconds, the buzzer can be stopped with the buzzer deactivation switch (Optional). NOTE: To prevent the buzzer from sounding when operation other than traveling (such as work pedal operation) is made, the MC doesn’t activate the buzzer when one of the following condition is established: Shift Lever: N Position Brake Switch: S (work brake) or P (parking brake) Position



T2-1-68



SYSTEM / Control System



Shift Lever



Pressure Sensor Travel Forward



Neutral



Parking Brake Pressure Switch



Travel Reverse



D Mode L Mode



Brake Switch Work Brake Parking Brake Travel Alarm Device (OP)



Axle Lock



Buzzer Deactivation Swing (OP)



OFF



Buzzer (OP)



NOTE: OP: Optional



T2-1-69



T1GL-02-01-038



SYSTEM / Control System (Blank)



T2-1-70



SYSTEM / Control System ELECTRIC AND HYDRAULIC COMPOSITE CIRCUIT CONTROL The electric and hydraulic composite circuit performs the following controls.



• • • • •



Axle Lock Release Control Travel Pilot Pressure Cut Control Blade/Stabilizer Control Parking Brake Control Travel Mode Control



T2-1-71



SYSTEM / Control System Axle Lock Release Control Function: When the operate check valves for axle lock cylinders are shifted with the brake switch, the axle lock cylinder circuits are opened to the hydraulic oil tank, allowing the oil in the axle lock cylinders to freely flow in and out of the hydraulic oil tank so that machine vibration is reduced during traveling. Operation: 1. When the brake switch is turned OFF, the current from fuse #28 is grounded via the brake switch. 2. Then, the axle lock relay is magnetized. 3. When the axle lock relay is turned ON, the current from fuse #28 flows to the axle lock solenoid valve [solenoid valve unit (SE)] via the axle lock relay, energizing the axle lock solenoid valve [solenoid valve unit (SE)].



4. Thereby, the axle lock solenoid valve [solenoid valve unit (SE)] is shifted, causing the pressure oil from the pilot pump to act on check valves (axle lock) through the axle lock solenoid valve [solenoid valve unit (SE)]. 5. Therefore, the check valves (axle lock) are released so that the axle lock cylinders are opened to the hydraulic oil tank.



Axle Lock Relay



Brake Switch (OFF position)



From fuse #28



Check Valve (Axle Lock)



Axle Lock Solenoid Valve [Solenoid Valve Unit (SE)]



Axle Lock Cylinder Pilot Pump



T1GL-02-01-039



T2-1-72



SYSTEM / Control System Travel Pilot Pressure Cut Control Function: When the shift lever is in neutral, the travel forward and reverse pilot pressure is cut so that the travel function becomes inoperable even if the travel pilot valve is operated. Operation: 1. When the shift lever is in neutral, the current from fuse #20 flow to the ground via the shift lever. 2. Thereby, both the travel forward and reverse Pi cut relays are magnetized, turning the relays ON. 3. As the relays are turned ON, the current from fuse #20 magnetizes both the travel forward and reverse Pi cut solenoid valves via each relay, shifting the solenoid valves. 4. When the solenoid valves are shifted, the pilot pressure circuit from the pilot valve is blocked.



Shift Lever From Fuse #20



Travel Forward Pi Cut Relay



Travel Reverse Pi Cut Relay



Travel Pilot Valve



Travel Reverse Pi Cut Solenoid Valve



Travel Forward Pi Cut Solenoid Valve



To Control Valve Travel Spool



T2-1-73



T1GL-02-01-040



SYSTEM / Control System Blade/Stabilizer Control Function: When solenoid valves are activated, the operate check valves are operated, making each blade/stabilizer cylinder operable. Operation: Independent circuits operate each cylinder and are similar. Therefore, the front-right stabilizer cylinder operation is explained here as an example. 1. Each switch is operated to connect each terminal as shown in the table below. Switch Connected Switch Position Terminals Blade/Stabilizer ON #1 to #2 Selection Switch Right and Left Right #4 to #5 Selection Switch Front and Rear #1 to #2 and Front Selection Switch #4 to#5



5. When 2-unit solenoid valve (front-right stabilizer) is shifted, pressure oil from the pilot pump routed to the check valves via the solenoid valve, opening the check valves. 6. Then, the stabilizer cylinder (front-right) becomes operable. 7. When the blade/stabilizer pilot valve is operated under this condition, the stabilizer cylinder (front-right) is operated with pressure oil from the auxiliary control valve. NOTE: When the optional blade is used, right and left circuit operation is always interlocked. Operation circuit to match the operation specification and the type of optional attachment can be arranged by changing connections of optional connectors (A, B, C, D, and E).



2. Terminal #2 on the blade/stabilizer relay (front-right) is grounded via terminals #1 to #2 on the front and rear selection switch, terminals #4 and #5 on the right and left selection switch, and terminals #1 to #2 on the blade/stabilizer selection switch. 3. Then, the current from fuse #29 magnetizes the blade/stabilizer relay (front-right).



Cylinder Connector



NOTE: The monitor panel circuit is also grounded at the same time so that the indicator in the monitor panel comes ON. 4. When the blade/stabilizer relay (front-right) is magnetized, the current from fuse #29 flows to the 2-unit solenoid valve (front-rear stabilizer) via the blade/stabilizer relay (front-right), shifting the 2-unit solenoid valve (front-rear stabilizer).



A B C D E



Front-



Front-



Left



Right



Inde-



Inter-



Inde-



Inter-



pendent



Rear-Left



RearRight



locked



pendent



locked



Inter-



Inde-



Inter-



Inde-



locked



pendent



locked



pendent



Inter-



Inter-



Inde-



Inde-



locked



locked



pendent



pendent



Inde-



Inter-



Inter-



Inde-



pendent



locked



locked



Inter-



pendent



Inter-



Inter-



Inter-



locked*



locked*



locked**



locked**



NOTE: Both cylinders marked with * and ** are interlocked to operate simultaneously.



T2-1-74



SYSTEM / Control System Front and Rear Selection Switch



Right and Left Selection Switch



Optional Connector E Optional Connector A Optional Connector C



Optional Connector B Optional Connector D



Blade/Stabilizer Relay (Front-Right)



Blade/Stabilizer Relay (Front-Left)



Monitor Panel



Blade/Stabilizer Pilot Valve Blade/Stabilizer Relay (Rear-Right)



2-Unit Solenoid Valve [Stabilizer (Front-Right)] Blade Signal Shift Control Valve



Blade/Stabilizer Relay (Rear-Left) From fuse #29



To Auxiliary Control Valve Pilot Pump



Front Side of Base Machine Stabilizer Cylinder (Front-Right) Check Valve (Stabilizer)



From Auxiliary Control Valve



T2-1-75



T1GL-02-01-041



SYSTEM / Control System Parking Brake Control Function: The parking brake in the transmission is applied or released by operating the brake switch. Operation: 1. When the travel system is operable after the engine is started and once the current from terminal ST on the key switch magnetizes parking brake relay 3, the current from fuse #6 magnetizes parking brake relay 1. Then, the current from fuse #20 is routed to parking brake relay 2 via parking brake relay 1. Accordingly, the parking brake solenoid valve is shifted depending on whether the parking brake relay 2 is turned ON or OFF as far as the engine is running. (Refer to the SYSTEM / Electric System group.) 2. When the parking brake switch is turned to the parking position, the current from fuse #20 is grounded through the parking brake switch, magnetizing parking brake relay 2. 3. Thereby, parking brake relay 2 cuts the current from #20 to the parking brake solenoid valve. 4. Then, the parking brake solenoid valve is demagnetized, shifting the parking brake solenoid valve spool. 5. When the solenoid valve spool is shifted, the pressure oil flow from the pilot pump is blocked at the solenoid valve. 6. When the pressure oil flow from the pilot pump is blocked, no pressure oil is supplied to the transmission so that the disc brake and the disc clutch are engaged. 7. Therefore, the transmission output shaft is locked, causing the parking brake to be applied.



T2-1-76



SYSTEM / Control System



Key Switch



From Alternator Terminal L



From Battery



Monitor Controller



A2 Fuse #6



C5 C4



B14



From Alternator Brake Switch: Parking Position Fuse #20 Parking Brake Relay 3



Parking Brake Relay 1



Parking Brake Relay 2



Parking Brake Solenoid Valve Pilot Pump



Output Shaft Transmission



T1GL-02-01-044



Disc Clutch



Disc Brake



T2-1-77



SYSTEM / Control System Parking Brake Holding System Function: When the parking is released, this system holds the parking brake ON for 1 seconds until each operating system is shifted to other mode. Operation: 1. When the travel system is operable after the engine is started and once the current from terminal ST on the key switch magnetizes parking brake relay 3, the current from fuse #6 magnetizes parking brake relay 1. Then, the current from fuse #20 is routed to parking brake relay 2 via parking brake relay 1. Accordingly, the parking brake solenoid valve is shifted depending on whether the parking brake relay 2 is turned ON or OFF as far as the engine is running. (Refer to the SYSTEM / Electric System group.) 2. The monitor controller recognizes that the brake switch is shifted to other position from the parking position by change in the input signal to terminal B14 on the monitor controller from the brake switch. 3. Then the monitor controller ground the circuit connected to terminal C4 in the monitor controller for 1 second. 4. Thereby, parking brake relay 2 is magnetized. 5. As long as parking brake relay 2 is kept magnetized, the current from fuse #29 doesn’t flow to the parking brake solenoid valve. 6. Therefore, the parking brake solenoid valve is kept demagnetized, holding the parking brake ON for one second.



T2-1-78



SYSTEM / Control System



Key Switch



From Alternator Terminal L



From Battery



Monitor Controller



A2 Fuse #6



C5 C4



B14



From Alternator Brake Switch: Parking Position Fuse #20 Parking Brake Relay 3



Parking Brake Relay 1



Parking Brake Relay 2



Parking Brake Solenoid Valve Pilot Pump



Output Shaft Transmission



T1GL-02-01-045



Disc Clutch



Disc Brake



T2-1-79



SYSTEM / Control System Travel Mode Control Function: Operating the shift lever shifts the transmission changeover solenoid valve, causing the transmission to select the fast or slow (D or L) mode, and turning the indicator ON in the column box. Operation: Shift Lever: N Position 1. When the shift lever is turned to neutral (N), the current from fuse #28 magnetizes the neutral relay and is grounded via the shift lever. 2. As the neutral relay is magnetized, the current from fuse #28 flows through the neutral relay and turns indicator (N) ON in the column box. Shift Lever: D Position 1. When the shift lever switch is turned to the D position, the neutral relay and the Hi/Low selection relay are demagnetized. 2. Therefore, the current from fuse #28 flows through the neutral relay and the Hi/Low selection relay and turns indicator (D) ON in the column box. 3. The pressure oil from the pilot pump is routed to the Hi port on the transmission via the transmission changeover solenoid valve. 4. Then, the oil pressure releases the disc brake in the transmission, allowing the transmission to shift to the Hi (D) side.



Shift Lever: L Position 1. When the shift lever is turned to the L position, the current from fuse #28 magnetizes the Hi/Low selection relay and is grounded via the shift lever. In addition, the current turns indicator (L) ON in the column box. 2. When the Hi/Low selection relay is magnetized, the current from fuse #28 flows through the neutral relay and the Hi/Low selection relay and magnetizes the transmission changeover solenoid valve. 3. When the transmission changeover solenoid valve is magnetized, the pressure oil from the pilot pump is routed to the Low port on the transmission via the transmission changeover solenoid valve. 4. Then, the oil pressure releases the disc clutch in the transmission, allowing the transmission to shift to the Low (L) side.



T2-1-80



SYSTEM / Control System



Column Box (Indicator) N D



Shift Lever



L



Hi/Low Selection Relay



Neutral Relay



From fuse #28



Transmission Control Valve



Pilot Pump



Transmission Changeover Solenoid Valve



Low Hi



Disc Clutch



T1GL-02-01-043



Disc Brake



NOTE: The illustration indicates the system operation when the brake switch is not in the P position and the shift lever is in the L position.



T2-1-81



SYSTEM / Control System (Blank)



T2-1-82



SYSTEM / Hydraulic System OUTLINE The hydraulic system is broadly divided into four circuits, the pilot circuit, the service brake circuit, the main circuit and the steering circuit. Pilot Circuit: Power Source Pilot Pumps



→



Controller Pilot Valves



Pilot Circuit →



Pump Regulator



Front Attachment Operation Control Circuit Pump Control Circuit



Solenoid Valve Unit



Swing Parking Brake Release Circuit



Max. Pump 1 Flow Rate Limit



Valve Control Circuit



Solenoid Valve



Hydraulic Oil Heat Circuit



Max. Pump 2 Flow Rate Limit



Travel Operation Control Circuit



Solenoid Valve



Travel Motor Displacement Angle Control



Torque Control Solenoid Valve Max. Pump 1 Flow Rate Shift



Circuit Work Brake Circuit



Solenoid Valve



Blade/Stabilizer Operation Control Circuit



Blade/Stabilizer Signal Shift Valve Signal Control Valve Service Brake Circuit: Power Source Pilot Pumps



Controller →



Actuator



Accumulator Charging



→



Valves



Front Brake Rear Brake



Brake Valve Main Circuit: Power Source Main Pumps



Controller →



Control Valves



Actuator →



Motors Cylinders Front Attachments (Optional)



Steering Circuit: Power Source Steering Pumps →



Controller Steering Valves



Actuator →



T2-2-1



Steering Cylinders



SYSTEM / Hydraulic System PILOT CIRCUIT Outline: Pressure oil from the pilot pump is used to operate as follows. • Operation Control Circuit (Front Attachment, Travel, Blade/Stabilizer) Left Pilot Valve



Travel Pilot Valve



• Travel Motor Displacement Angle Control Circuit • Work Brake Circuit



Positioning / Auxiliary Pilot Valve



Right Pilot Valve



Blade/Stabilizer Pilot Valve



Swing Motor



Travel Shockless Valve Shuttle Valve Pilot Shut-Off Valve



To Auxiliary Control Valve Spools



Signal Control Valve



SA To Control Valve Spools



Blade/Stabilizer Solenoid Valve (Rear)



Blade/Stabilizer Signal Shift Valve



Max. Pump 1 Flow Rate Limit Control Solenoid Valve



1



2



Regulator



Blade/Stabilizer Solenoid Valve (Front)



Bypass Shut-Out Valve Work Brake Circuit



Brake Valve



Control Valve



SG SC SE



Hydraulic Oil Tank



SI Solenoid Valve Unit Travel Motor Displacement Angle Control Circuit



Suction Filter



Travel Motor



Pilot Pump Relief Valve Accumulator Charging Valve



Pilot Filter T1F3-02-02-015



T2-2-2



SYSTEM / Hydraulic System • Swing Parking Brake Release Circuit • Hydraulic Oil Heat Circuit



Left Pilot Valve



Travel Pilot Valve



• Pump Control Circuit • Valve Control Circuit



Right Pilot Valve



Positioning/ Auxiliary Pilot Valve



Swing Motor Max. Pump 1 Flow Rate Limit Control Solenoid Valve Pump Control Circuit Max. Pump 2 Flow Rate Limit Control Solenoid Valve



Pilot Shut-Off Valve



Torque Control Solenoid Valve



Signal Control Valve



To Control Valve Spools



1 Max. Pump 1 Flow Rate Shift Control Solenoid Valve



Hydraulic Oil Heat Circuit



Regulator



Bucket Flow Rate Control Valve Boom Anti-Drift Valve



Hose-Rupture Safety Valve (Positioning)



Arm Anti-Drift Valve SG



Bypass Shut-Out Valve



SC



Arm Regenerative Valve



2



Hose-Rupture Safety Valve (Arm) Hose-Rupture Safety Valve (Boom)



SE Control Valve SI



Hydraulic Oil Tank



Solenoid Valve Unit



Valve Control Circuit



Suction Filter



Pilot Pump Relief Valve Accumulator Charging Valve



Pilot Filter T1F3-02-02-014



T2-2-3



SYSTEM / Hydraulic System Front Attachment, Travel, Blade/Stabilizer Operation Control Circuit • Each pilot valve controls the pressure oil from the pilot pump to operate the spools in the control valve. • A signal control valve is located in the circuit between the front attachment and travel pilot valves and the control valve. The shockless valve built in the boom raise circuit in the signal control valve buffers the movement of the spool in the control valve. (Refer to the COMPONENT OPERATION / Signal Control Valve group.) • A travel shockless valve is located in the travel operation circuit to buffer the movement of the travel spools in the control valve. • An auxiliary solenoid valve is located in the positioning operation circuit between the signal control valve and the control valve. One auxiliary pilot valve can operate two kinds of the attachments by shifting the auxiliary solenoid.



T2-2-4



SYSTEM / Hydraulic System Travel Pilot Valve



Pilot Valve (Left)



Pilot Valve (Right)



Positioning /Auxiliary



Travel Shockless Valve



Blade/ Stabilizer



61



60



Shockless Valve



Signal Control Valve



11



12 4 1



3 2



Auxiliary Solenoid Valve



7 6 5



8



14 13 10 9



10



9



12



8



14



13



11



7 2



1



1 Auxiliary Control Valve 4



3



3



60 5



61



6 Control Valve



Pilot Pump T1F3-02-02-005



1234-



Boom Raise Boom Lower Arm Roll-Out Arm Roll-In



5678-



Swing Left Swing Right Bucket Roll-In Bucket Roll-Out



910 11 12 -



T2-2-5



Positioning Raise Positioning Lower Travel Reverse Travel Forward



13 14 60 61 -



Auxiliary Auxiliary Blade/Stabilizer Raise Blade/Stabilizer Lower



SYSTEM / Hydraulic System Travel Motor Displacement Angle Control Circuit (Refer to the COMPONENT OPERATION / Travel Device group.) • The pilot pressure oil from solenoid valve unit (SI) regulates the travel motor displacement angle control valve. Work Brake Circuit • The pilot pressure oil from the solenoid valve unit (SG) shifts the brake valve.



• Then, the pressure oil from the accumulator charging valve is routed to the front and rear brakes via the brake valve, operating both brakes. Swing Parking Brake Release Circuit (Refer to the COMPONENT OPERATION / Swing Device group.) • When the front attachment and/or swing function is operated, the pilot pressure oil selected by the shuttle valves in the signal control valve shifts the swing parking brake release spool. • Consequently, the release signal pressure oil is routed to the swing motor, releasing the swing parking brake. Hydraulic Oil Heat Circuit (Refer to the COMPONENT OPERATION / Others (Upperstructure) group.) • When the pilot shut-off valve is closed, the pilot pressure oil is routed to the signal control valve so that hydraulic oil is warmed while passing through the orifice in the signal control valve. • The warmed pilot pressure oil flows to the signal control valve and pilot valves so that the pilot system components are warmed.



T2-2-6



SYSTEM / Hydraulic System Arm RollIn



Swing RollOut Right Left



Boom



Bucket



Roll- RollLower Raise In Out



Positioning /Auxiliary



Blade/ Stabilizer



Pilot Shut-Off Valve Shuttle Valve



Swing Parking Brake Release Spool



Shuttle Valve



Solenoid Valve Unit



SG



SI



Travel Motor



Displacement Angle Control Valve



Swing Motor



Brake Valve Front Brake



Accumulator Charging Valve



Rear Brake



T1F3-02-02-008



T2-2-7



SYSTEM / Hydraulic System Pump Control Circuit (Refer to the COMPOMENT OPERATION / Pump Device group.)



• Pump Flow Rate Control by Flow Rate Control



Pressure Pi • Pressure oil from the pilot valve is selected by the shuttle valves in the signal control valve. Then, the selected pressure oil is routed further to either the pump 1 flow rate control valve or the pump 2 flow rate control valve in the same signal control valve, shifting either of the flow rate control valves. • The selected pilot pressure oil flow from the blade/stabilizer pilot valve by the separately installed shuttle valve shifts the pump 1 flow rate control valve in the signal control valve. • When either the pump 1 flow rate control valve or the pump 2 flow rate control valve is shifted, the pilot pressure oil from the pilot pump is routed to either main pump 1 or main pump 2 as flow rate control pressure Pi. NOTE: When the boom (raise/lower), arm (roll-in/out), bucket (roll-in/out), travel (forward/reverse), positioning/auxiliary and/or blade/stabilizer function is operated, flow rate control pressure Pi is routed to main pump 1. When the boom (raise), arm (roll-in/out), swing (right/left), and/or positioning/auxiliary function is operated, flow rate control pressure Pi is routed to main pump 2.



• Torque Control (Speed Sensing) by Torque Control



Solenoid Valve • After the pilot pressure oil from the pilot pump is regulated by the torque control solenoid valve, the regulated pilot pressure oil is routed to main pump 1 and 2 as speed sensing pressure Ppc.



• Maximum Pump Flow Rate Control by Maximum



Pump 1 Flow Rate Solenoid Valve • The pilot oil pressure from the pilot pump is routed to pump 1 as the maximum pump 1 flow rate shift pressure after being regulated by the maximum pump 1 flow rate solenoid valve.



T2-2-8



SYSTEM / Hydraulic System Travel



Arm



Boom



Swing



Bucket



Positioning/ Auxiliary



Blade/ Stabilizer



Shuttle Valve



Pump 1 Flow Rate Control Valve



Pump 2 Flow Rate Control Valve



Control Valve



Maximum Pump 2 Flow Rate Limit Solenoid Valve Torque Control Solenoid Valve Pump 1 Pump 2



Maximum Pump 1 Flow Rate Limit Solenoid Valve Maximum Pump 1 Flow Rate Shift Solenoid Valve



T2-2-9



T1F3-02-02-006



SYSTEM / Hydraulic System Valve Control Circuit (Refer to the COMPONENT OPERATION / Control Valve and Travel Device groups.) • The following valves are controlled by pressure oil from the pilot valves, solenoid valve unit (SC) and the bucket flow rate control valve control spool.



• Boom Lower Pilot Pressure: Boom Anti-Drift Valve, Hose-Rupture Safety Valve (Boom)



• Arm Roll-In Pilot Pressure: Arm Anti-Drift Valve, Hose-Rupture Safety Valve (Arm), Bucket Flow Rate Control Valve Control Spool



• Blade/Stabilizer Pilot Pressure: Blade/Stabilizer Signal Shift Valve, Bypass Shut-Out Valve



• Positioning Lower Pilot Pressure: Hose-Rupture Safety Valve (Positioning)



• Solenoid Valve SC: Arm Regenerative Valve • Bucket Flow Rate Control Valve Control Spool: Bucket Flow Rate Control Valve



T2-2-10



SYSTEM / Hydraulic System Arm Roll- RollIn Out



Travel Reverse Forward



Hose-Rupture Safety Valve (Positioning)



Boom



Swing



Bucket Roll- Roll- Positioning Right Left Lower Raise In Out /Auxiliary



Blade/ Stabilizer



4 9



2



Blade/Stabilizer Signal Shift Valve Bucket Flow Rate Control Valve Control Spool



Hose-Rupture Safety Valve (Arm)



9



Bucket Flow Rate Control Valve



2



Solenoid Valve



4 Boom Anti-Drift Valve



SC



Hose-Rupture Safety Valve (Boom) Arm Anti-Drift Valve



Bypass Shut-Out Valve Arm Regenerative Valve T1F3-02-02-007



T2-2-11



SYSTEM / Hydraulic System SERVICE BRAKE CIRCUIT • Pressure oil from the pilot pump is routed to the brake valve via the accumulator charging valve.



• When the brake pedal is operated, the pressure oil from the accumulator charging valve is supplied to the front and rear brakes, operating the brakes. NOTE: The accumulator charging valve is located in the circuit between the pilot pump and the pilot relief valve so that the pressure oil has priority to flow to the brake circuit than the priority circuit. (Refer to the COMPONENT OPERATION / Others (Upperstructure) group.) NOTE: Even if the engine stalls, the oil pressure in the service brake is kept maintained for a specified period of time due to functions of the accumulators and check valves.



Brake Valve Accumulator Front Brake



To the pilot relief valve



Rear Brake Check Valve Accumulator Charging Valve



Pilot Pump



T1GL-02-02-014



T2-2-12



SYSTEM / Hydraulic System STEERING CIRCUIT The pressure oil from the steering pump flows into the steering valve via the steering filter. The steering valve is actuated by the rotation of the steering wheel to make the pressure oil flow to the steering cylinder, so that the front wheels change their directions. Steering Cylinder



Steering Valve



Steering Filter



Steering Pump



T1GL-02-02-009



T2-2-13



SYSTEM / Hydraulic System MAIN CIRCUIT Outline • Main pumps (1 and 2) draw hydraulic oil from the hydraulic oil tank. Main pump 1 and main pump 2 deliver pressure oil to the 4-spool control valve and the 5-spool control valve respectively.



• The pressure oil from the main circuit in 4-spool control valve is routed to the auxiliary control valve. • Delivered pressure oil is routed to the motor(s) or cylinder(s) in response to operation(s) of the spool(s) in the control valve(s). • The return oil from the motor(s) and/or cylinder(s) flows back to the hydraulic oil tank via the control valve and/or the oil cooler. • When the oil temperature is low (high viscosity), the oil flow resistance increases in the oil cooler, which opens the bypass check valve, allowing hydraulic oil to return directly to the hydraulic oil tank without passing through the oil cooler.



T2-2-14



SYSTEM / Hydraulic System



Positioning Cylinder



Travel Motor Bucket Cylinder



Front Attachment (s)



Control Valve



Boom Cylinder 4-Spool Side



Arm Cylinder Positioning



Travel



Auxiliary



Bucket



Boom 2



Boom 1



Arm 1



Arm 2



Auxiliary Control Valve



Swing



Blade/ 5-Spool Side



Stabilizer



Bypass Check Valve Swing Motor



Main Pump 2



Main Pump 1



Oil Cooler



Suction Filter



T2-2-15



Hydraulic Oil Tank



Blade/Stabilizer Cylinder



SYSTEM / Hydraulic System Neutral Circuit • When the control lever is in neutral, pressure oil from the main pump passes through the control valve and returns to the hydraulic oil tank. Single Operation Circuit • Pressure oil from main pump 1 is routed to the 4-spool control valve and is further routed to each spool of the travel, bucket, boom 1, and arm 2. • Pressure oil from main pump 2 is routed to the 5-spool control valve and is further routed to each spool of the swing, arm 1, boom 2, auxiliary, and positioning. • The boom and arm are actuated by pressure oil from two main pumps. Pressure oil from each main pump is combined and supplied together.



T2-2-16



SYSTEM / Hydraulic System Positioning Cylinder Travel Motor Positioning Control Valve



Front Attachment Travel Bucket Cylinder



Auxiliary



Bucket Arm Cylinder Boom 1



Boom Cylinder



Boom 2



Swing Motor



Arm 2



Arm 1



Auxiliary Control Valve



Swing



Blade/Stabilizer Pump 2



Pump 1



T1F3-02-02-009



T2-2-17



SYSTEM / Hydraulic System Combined Operation Circuit



• Swing and Boom Raise Operation



• When the boom is raised while swinging, the pilot oil pressure shifts the swing, boom 1, and boom 2 spools. • Pressure oil from pump 1 flows into the boom cylinders via the parallel circuit and the boom 1 spool, raising the boom. • Pressure oil from pump 2 flows into the swing motor via the swing spool. • At the same time, pressure oil from pump 2 flows through the parallel circuit and after being combined with pressure oil from pump 1, flows into the boom cylinders, raising the boom together with pressure oil from pump 1.



T2-2-18



SYSTEM / Hydraulic System



Parallel Circuit



Boom 2



Boom 1



Boom Cylinder



Swing Motor



Swing Parallel Circuit



Pump 2



Pump 1



T1F3-02-02-010



T2-2-19



SYSTEM / Hydraulic System Auxiliary Flow Combiner Circuit (Only available on the machines equipped with optional auxiliary flow combiner circuit.) • When an attachment such as a hydraulic breaker is operated, the pilot pressure oil from the positioning/auxiliary pilot valve shifts the auxiliary flow combiner valve and the bypass shut-out valve. • Accordingly, the neutral circuit in the 4-spool side control valve is blocked so that the pressure oil from main pump 1 is routed to the auxiliary spool via the auxiliary flow combiner valve. NOTE: When each operation of boom (raise/lower), arm (roll-in/out), bucket (roll-in/out), and/or travel (forward/reverse) is made, each pilot control pressure is routed to the auxiliary flow combiner valve (port SN) through the signal control valve (port SN). Therefore, the auxiliary flow combiner valve is shifted by this pilot control pressure, blocking the oil flow from main pump 1. However, the combining flow rate can be adjusted by reducing the control pressure with the reducing valve.



T2-2-20



SYSTEM / Hydraulic System Pilot Pressure Routed Pilot Pressure Routed from the from the Positioning/ Signal Control Auxiliary Pilot Valve Valve *Auxiliary Flow Combiner Shift Solenoid Valve



*Reducing Valve



*Shuttle Valve



Auxiliary Flow Combiner Valve SN



SM



Auxiliary



Bypass Shut-Out Valve



Pump 2



Pump 1



T1F3-02-02-011



NOTE:* Available on only machines equipped with optional auxiliary flow combiner circuit.



T2-2-21



SYSTEM / Hydraulic System Blade/Stabilizer Circuit



• When the blade/stabilizer is operated, the pilot pressure oil from the blade/stabilizer pilot valve shifts the bypass shut-out valve. • Accordingly, the neutral circuit in the 4-spool side control valve is blocked so that the pressure oil from main pump 1 is routed to the auxiliary control valve. NOTE: One check valve, which is operated by the signal pressure from the 2-spool solenoid valve (blade/stabilizer), is installed on each cylinder port. When the check valve is closed, the cylinder is inoperable even though the blade/stabilizer pilot valve is operated. Operable cylinder is determined depending on whether the corresponding check valve is opened or closed when the blade/stabilizer pilot valve is operated. (Refer to the SYSTEM / Control System group.)



T2-2-22



SYSTEM / Hydraulic System



From the Blade/Stabilizer Pilot Valve



Auxiliary Control Valve



Bypass Shut-Out Valve



Check Valve Pump 1



Check Valve



Blade/Stabilizer Cylinder



T2-2-23



T1F3-03-03-020



SYSTEM / Hydraulic System (Blank)



T2-2-24



SYSTEM / Electrical System OUTLINE The electrical circuit is broadly divided into the main circuit, the monitor circuit, control circuit, and the column box circuit.



• Main Circuit The engine and accessory operation related circuit.



• Monitor Circuit The electrical circuit group consists of the monitors, sensors, and switches, and displays the machine operation status.



• Control Circuit (Refer to the SYSTEM / Control System group.) The control circuit is categorized into the engine, pump, and valve control circuits. Each circuit consists of the actuators such as solenoid valves, MC (main controller), switch boxes, sensors and pressure switches.



• Column Box Circuit The column box circuit is used for traveling, and consisted of the headlight, turn signal, tail light and column box.



T2-3-1



SYSTEM / Electrical System MAIN CIRCUIT The major functions and circuits in the main circuit are as follows.



• Electric Power Circuit: Supplies all electric power to all electrical systems on this machine. [Key Switch, Batteries, Fuses (Fuse Boxes, Fusible Links), and Battery Relay]



• Indicator Light Check Circuit Checks all indicator bulbs for burning.



• Accessory Circuit Becomes operative when the key switch is turned to the ACC position.



• Preheat Circuit Assists the engine to start in cold weather. [Key Switch, QOS Controller, Coolant Switch, Glow Plug Relay, and Glow Plugs]



• Starting Circuit Starts the engine. [ Key Switch, Starter, and Starting Relay]



• Charging Circuit Charges the batteries. [Alternator, and Regulator]



• Parking Brake Circuit Operates the parking brake.



• Serge Voltage Prevention Circuit Prevents the occurrence of serge voltage developed when stopping the engine. [ Load Damp Relay]



• Engine Stop Circuit Stops the engine using the EC motor. [MC, and EC Motor]



T2-3-2



SYSTEM / Electrical System ELECTRIC POWER SWITCH: OFF)



CIRCUIT



(KEY



The battery ground terminal is connected to the vehicle frame. The current from the battery plus terminal flows as (shown) below when the key switch is OFF. Battery ↓ Fusible Link



→Glow Plug Relay (Power) →Key Switch (B) →Load Damp Relay →Fuse Box



→Terminal #1: Radio (Backup Power) Monitor (Backup Power) ICX Controller (Backup Power) →Terminal #2: MC (Power) →Terminal #3: MC (EC Motor Power) →Terminal #10: Optional →Terminal #24: Hazard Flasher



Battery Load Damp Relay



Monitor



Hazard Flasher



Fusible Link



Glow Plug Relay Fuse Box



Optional MC MC Radio, Monitor, ICX Controller T1GL-02-03-001



T2-3-3



SYSTEM / Electrical System INDICATOR LIGHT CHECK CIRCUIT (KEY SWITCH: ON) • When the key switch is turned ON, terminal B is connected to terminals ACC and M in the key switch.



• The current from key switch terminal M excites the battery relay.



• Therefore, the battery current enters the monitor controller via the battery relay and fuse #5 and checks the indicator bulbs.



Key Switch



Battery



Battery Relay



Fuse Box



Monitor Controller T1GL-02-03-002



T2-3-4



SYSTEM / Electrical System ACCESSORY CIRCUIT • When the key switch is turned to the ACC position, terminal B is connected to terminal ACC in the key switch.



• The current from key switch terminal ACC flows to horn, radio, lighter, cab light and auxiliary through the fuse box, making each accessory operable.



Horn Radio Lighter Cab Light Auxiliary



T1GL-02-03-003



T2-3-5



SYSTEM / Electrical System PREHEAT CIRCUIT (KEY SWITCH: ON / START) • When the key switch is turned ON or to the START position, terminal B is connected to terminal M in the key switch. The current from terminal M is routed to QOS controller terminal #1 through fuse #19.



• When the key switch is ON or in the START position with the coolant switch OFF (when the coolant temperature is 10 °C (50 °F) or below), QOS controller terminal #4 is connected to terminal #5 (ground).



• Accordingly, the glow plug relay is turned ON, routing the current to the glow plugs so that preheating begins.



• When preheating begins, QOS controller terminal #6 is connected to terminal #5 for 8 seconds, turning the preheat indicator ON. (When preheating is not performed, the preheat indicator comes ON for 2 seconds for indicator light check.)



T2-3-6



NOTE: After preheating has been performed, heating will continue for approx. 30 seconds after the engine starts.



SYSTEM / Electrical System



Monitor Power



Coolant Temperature Switch



Preheat Indicator QOS Controller



Key Switch



Fuse Box



Glow Plug Relay



Glow Plug T1GL-02-03-004



T2-3-7



SYSTEM / Electrical System STARTING CIRCUIT (KEY SWITCH: START) Brake Switch at work or parking position



Starter Relay Operation



• When the key switch is turned to the START



• When the key switch is turned to the START



position, terminal B on the key switch is connected to terminals M and ST in the switch. The current from terminal M magnetizes the battery relay, leading the battery current to terminals B on the starter and starter relay via the battery relay. Terminal ST of the key switch is connected to terminal S on the starter relay so that the battery current flows through the coil in the starter relay, allowing the relay to close the circuit. Then, the battery current can flow to terminal C on the starter, closing the inner starter relay. Thereby, the starter begins to rotate. The current from terminal M flows to the MC, instructing that the key switch is positioned at ON or START. When this signal arrives at the MC, the MC actuates the EC motor, which moves the governor lever.



position, key switch terminal B and terminal ST have continuity in the key switch. Then, the current flows to the base of transistor (Q2) via resistance R4 in the starter relay, switching transistor (Q2) ON. Thereby, the current flows through coil (L), closing the circuit between starter terminals B and C. Then, the starter begins to rotate.



•



•



• • •



• Once the engine is started, the alternator begins to charge the batteries so that the voltage at starter relay terminal R rises. When the voltage at terminal R reaches 21 to 22 V, zener diode (Z) becomes ON. Accordingly, transistor (Q1) is switched ON so that the base current to transistor (Q2) is cut, switching transistor (Q2) OFF. At this time, continuity between starter terminal B and C is opened. Then, the starter is switched OFF. Capacitor C1 shown in the figure is used to stabilize the operating voltage. Diode D4 protects the circuit from damage when the batteries are inversely connected.



Starter Relay B



S D3 (1) R3



From Alterrater Terminal L



R



R2



Z



L



R4



C



(1) C



D2 Q1



C1



C



(2) Q2



M



B



(2) Starter



E D4



B ST Key Switch



Engine Starter Relay



12V Batteries 12V



T1F3-02-03-001



T2-3-8



SYSTEM / Electrical System



Key Switch



Battery Battery Relay Starter



Engine Starter Relay



C



Fuse Box



Starter Relay



Brake Switch (Work or Parking position)



EC Motor MC T1GL-02-03-005



T2-3-9



SYSTEM / Electrical System Brake Switch at OFF or AXLE LOCK Position



• Start Safety Circuit (Engine Starter Relay) • When the key switch is turned to the ON or START • • • •



position, the current from the key switch energizes the battery relay. By the battery relay energizes, the current from the battery flows to the engine starter relay via #28 fuse. When the brake switch is at the off or axle lock position, the current from #28 fuse excites the engine starter relay via the brake switch. As the engine starter relay is energized, the circuit between the key switch and the starter relay is cut. For this reason, when the brake switch is in the off or axle lock position, the starter will not start even if the key switch is turned to the START position.



Starter Relay S



B D3 (1) R3



From Alternator Terminal L



R2



R



Z



L



R4



C (2)



D2 Q1



C1



C



(1)



C M



Q2



B



(2) Starter



E D4



12V



B ST Key Switch



Engine Starter Relay



Batteries 12V



T1F3-02-03-002



T2-3-10



SYSTEM / Electrical System



Key Switch



Battery Battery Relay Starter



Engine Starter Relay



C



Fuse Box



Starter Relay



Brake Switch (OFF or Axle Lock Position)



EC Motor MC T1GL-02-03-006



T2-3-11



SYSTEM / Electrical System CHARGING CIRCUIT (KEY SWITCH: ON) • After the engine starts and the key switch is released, the key switch moves to the ON position.



• Then, key switch terminal B is connected to terminals ACC and M in the key switch.



• The Power From Terminal M flows to the battery relay, so that the battery relay keeps ON.



• When the alternator starts generating electricity, the current flows from alternator terminal B to the batteries via the battery relay, charging the batteries.



• The current from alternator terminal L flows to the monitor controller and the ICX controller, turning the alternator indicator OFF.



Key Switch



Battery Monitor Controller ICX Controller



Battery Relay



Alternator B



L



T1GL-02-03-007



T2-3-12



SYSTEM / Electrical System (Blank)



T2-3-13



SYSTEM / Electrical System Alternator Operation • The alternator consists of field coil FC, stator coil SC, and diodes D. The regulator consists of transistors (T1 and T2), Zener diode ZD, and resistances (R1 and R2).



• At the beginning, no current is flowing through field coil FC. When the rotor starts turning, alternate current is generated in stator coil SC by the rotor residual magnetism.



• Alternator terminal B is connected to base B of



• When the current starts to flow through field coil



transistor T1 through the circuit [B → R → RF → (R) → (R1)].



FC, the rotor is further magnetized so that the generating voltage increases. Thereby, the current flowing through field coil FC increases and the generating voltage is increased further, to charge the batteries.



• When battery relay is ON, the battery voltage is applied to base B of transistor T1 so that collector C is connected to emitter E. Therefore, field coil FC is grounded via transistor T1.



Alternator



B



Battery Relay



R RF



L



Regulator



(R)



R3



R5



R4 R6



D



ZD Battery



R2



B



SC



E



R1 FC D1 (F)



E



C B C



T2 E T1



(E)



T157-04-02-008



T2-3-14



SYSTEM / Electrical System Regulator Operation • When the generating voltage increases more than the set-voltage of Zener diode ZD, the current is routed to base B of transistor T2, connecting collector C to emitter E.



• When the generating voltage decreases lower than the set-voltage of Zener diode ZD, transistor T2 is turned OFF, causing transistor T1 to turn ON again.



• Then, the current which was routed to base B of



• Then, the current flows through field coil FC,



transistor T1 disappears, turning transistor T1 OFF.



increasing the generating voltage at the stater coil. The above operation is repeated so that the alternator generating voltage is kept constant.



• Therefore, no current flows through filed coil FC, reducing the generating voltage at stator coil SC.



Battery Relay



RF



R3



R4



R5



R6 Battery



ZD R2



B



SC A



E



C FC R1



(F)



E



D1



C



B



T2 E T1



(E)



T157-04-02-009



T2-3-15



SYSTEM / Electrical System PARKING BRAKE CIRCUIT • When the key switch is turned to the START position, terminal B is connected to terminals M and ST in the key switch. • The current from terminal ST magnetizes parking brake relay 3. • When parking brake relay 3 is magnetized, the current from fuse #6 flows to the coil in parking brake relay 1 through parking brake relay 3. NOTE: The current from fuse #6 flows to the coil in parking brake relay 3 after passing through parking brake relay 3 and diverging at junction A. Accordingly, parking brake relay is magnetized continuously until the current from fuse #6 disappears.



• After the engine starts running and the alternator



•



• • •



•



starts generating, the generating current flows to monitor controller terminal A2 from alternator terminal L. When the current from the alternator arrives at the monitor controller, the monitor controller judges that the engine has started so that the travel system is operable. Then, the monitor controller grounds the circuit connected from parking brake relay 1 to monitor controller terminal C5 in the monitor controller. Thereby, the current from fuse #20 is supplied to parking brake relay 2 through parking brake relay 1. Unless the brake switch is in the parking brake position, the current from fuse #20 activates the parking brake solenoid valve after passing through parking brake relays 1 and 2. When the parking brake solenoid valve is activated, the parking brake is released. (Refer to the SYSTEM / Control System group.)



T2-3-16



SYSTEM / Electrical System Key Switch



Fuse #6



A2 Fuse #20 Fuse Box



Monitor Controller



C5



Junction A



Alternator



Parking



Parking Brake Relay 3



Parking Brake Relay 1



Parking Brake Relay 2



Work



Parking Brake Solenoid Valve



T2-3-17



Axle Lock



OFF



Brake Switch



T1GL-02-03-009



SYSTEM / Electrical System SERGE VOLTAGE PREVENTION CIRCUIT • When the engine is stopped (key switch: OFF),



• When the alternator is generating electricity, the



the current from key switch terminal M is disconnected, turning the battery relay OFF.



• The engine continues to rotate due to inertia force



generating current from alternator terminal L flows to monitor controller terminal #A-2 (ZAXIS135UR: Terminal #A-13) so that the monitor controller connects terminal #C-3 to the ground.



just after the key switch is turned OFF so that the alternator continues to generate electricity.



• Then, the current flows through the load damp



• As the generating current cannot flow to the



relay exciting circuit, turning the load damp relay ON.



battery, the surge voltage arises in the circuit, possibly causing failures of the electronic components, such as the controller. To prevent the occurrence of the surge voltage, the surge voltage prevention circuit is provided.



• Accordingly, even if the key switch is turned OFF while the engine is rotating, the battery current continues to excite the battery relay via the load damp relay until the alternator stops generating. Therefore, the battery relay is kept ON, allowing the generating current to flow to the batteries. Key Switch



Battery Battery Relay Load Damp Relay



Alternator Monitor Controller



T1SM-02-04-007



T2-3-18



SYSTEM / Electrical System ENGINE STOP CIRCUIT • When the key switch is turned from the ON position to the OFF position, the signal current indicating that the key switch is ON stops flowing from terminal M to MC terminal #C31



• Then, the MC drives the EC motor to the engine stop position.



Key Switch



EC Motor MC



T1GL-02-03-008



T2-3-19



SYSTEM / Electrical System (Blank)



T2-3-20



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SECTION 3



COMPONENT OPERATION Group 1 Pump Device



CONTENTS



Group 5 Travel Device



Outline ...................................................... T3-1-1



Outline ......................................................T3-5-1



Main Pump................................................ T3-1-2



Transmission .............................................T3-5-2



Regulator .................................................. T3-1-4



Front and Rear Propeller Shaft................T3-5-17



Torque Control Solenoid Valve ................ T3-1-32



Front Axle................................................T3-5-18



Pilot Pump, Steering Pump ..................... T3-1-34



Steering Cylinder.....................................T3-5-20



N Sensor (Engine Speed Sensor) ........... T3-1-34



Differential Gear ......................................T3-5-22



Pump Delivery Pressure Sensor ............. T3-1-34



Reduction Gear .......................................T3-5-26



Pump Control Pressure Sensor .............. T3-1-35



Rear Axle ................................................T3-5-28 Travel Motor ............................................T3-5-31



Group 2 Swing Device Outline ...................................................... T3-2-1 Swing Reduction Gear .............................. T3-2-2 Swing Motor.............................................. T3-2-3 Swing Parking Brake................................. T3-2-4 Valve Unit ................................................. T3-2-6



Rotor Section ..........................................T3-5-32 Regulator ................................................T3-5-34 Brake Valve .............................................T3-5-45



Group 6 Signal Control Valve Outline ......................................................T3-6-1 Pilot Port ...................................................T3-6-2



Group 3 Control Valve Outline ...................................................... T3-3-1 Hydraulic Circuit ..................................... T3-3-16 Main Relief Valve .................................... T3-3-22 Overload Relief Valve ............................. T3-3-24 Anti-Drift Valve ........................................ T3-3-26 Regenerative Valve................................. T3-3-28 Flow Rate Control Valve ......................... T3-3-30 Bypass Shut-Out Valve ........................... T3-3-32 Auxiliary Flow Combiner Valve................ T3-3-34



Shuttle Valve .............................................T3-6-5 Shockless Valve ........................................T3-6-8 Pump 1 and Pump 2 Flow Rate Control Valves .......................................T3-6-10 Bucket Flow Rate Control Valve Control Spool, Flow Combiner Valve Control Spool, Swing Parking Brake Release Spool, Arm Flow Rate Control Valve Control Spool.........................................T3-6-12



Group 4 Pilot Valve Outline ...................................................... T3-4-1 Operation .................................................. T3-4-4



CBBT-3-1



Group 7 Steering Valve Outline ...................................................... T3-7-1 Construction ............................................. T3-7-4 Operation .................................................. T3-7-5 Relief Valve............................................... T3-7-8 Overload Relief Valve ............................... T3-7-9 Make-Up Valve.......................................... T3-7-9



Group 8 Brake Valve Outline ...................................................... T3-8-1 Operation .................................................. T3-8-2



Group 9 Transmission Control Valve Outline ...................................................... T3-9-1 Operation .................................................. T3-9-4



Group 10 Others (Upperstructure) Pilot Shut-Off Valve................................. T3-10-1 Solenoid Valve Unit................................. T3-10-2 Travel Shockless Valve ........................... T3-10-6 Pilot Relief Valve ..................................... T3-10-8 Accumulator............................................ T3-10-9 Accumulator Charging Valve ................. T3-10-10 Hose-Rupture Safety Valve ................... T3-10-14 EC Motor .............................................. T3-10-18



Group 11 Others (Undercarriage) Swing Bearing......................................... T3-11-1 Center Joint ............................................ T3-11-2 Slip Ring ................................................. T3-11-3 Cylinder .................................................. T3-11-5



CBBT-3-2



COMPONENT OPERATION / Pump Device OUTLINE The pump device consists of main pump [pump 1 (9) and pump 2 (10)], pilot pump (2) and steering pump (4). The main pump is a swash plate type variable displacement 2-tandem plunger pump, supplying the high pressure hydraulic oil to the main circuits.



Pilot pump (2) and steering pump (4) are gear pumps. Pump delivery pressure sensors (6 and 8), pump control pressure sensors (5 and 7), and N sensor (engine speed sensor) (1) are provided to control pump and valve operations.



8



7



6



9



1 - N Sensor (Engine Speed Sensor) 2 - Pilot Pump 3 - Torque Control Solenoid Valve



45-



4



3



2



1



T1F3-01-02-007



5



T1F3-03-01-002



10



Steering Pump



7-



Pump 2 Control Pressure Sensor 6 - Pump 2 Delivery Pressure Sensor



Pump 1 Control Pressure Sensor 8 - Pump 1 Delivery Pressure Sensor



T3-1-1



9-



Pump 1



10 - Pump 2



COMPONENT OPERATION / Pump Device MAIN PUMP The main pump is a swash plate type 2-tandem plunger pump. The two shafts (1) are connected with gear (6). The same type pump is mounted on each shaft (1). Shaft (1) is splined to cylinder block (5), and plungers (4) are inserted in cylinder block (5). Engine rotation is transmitted to shaft (1) via the coupling. As shaft (1) is rotated, plungers (4) rotate along with cylinder block (5). Plungers (4) slide along the surface of shoe plate (3) so that plungers (4) reciprocate in the cylinder block (5) bores as swash plate (2) is positioned at an angle toward plungers (4). Plunger (4) reciprocation functions to draw and discharge the hydraulic oil.



Main Pump 2



Main Pump 1



1



2



3



4



4 5



6



5



4



3



2 T1F3-03-01-003



T3-1-2



COMPONENT OPERATION / Pump Device Flow Rate Increasing / Decreasing Operation The flow rate of the pump is varied by changing the angle of the swash plate, which changes the stroke of the plunger. The servo piston is moved by the pressure oil routed from the regulator. As the swash plate is connected to the servo piston, the swash plate angle is changed in accordance with the movement of the servo piston, so that the pump flow rate is changed.



Servo Piston



Shaft



Valve Plate Cylinder Block Plunger Swash Plate



T3-1-3



T117-02-01-003



COMPONENT OPERATION / Pump Device REGULATOR The regulator controls the main pump flow rate in response to the various command signal pressures so that the pump driving power doesn’t exceed the engine power. Pump 1 and pump 2 are provided with one regulator each. The major parts of the regulator are lever 2 (5), pilot piston (3), pin (7), feedback lever (9), lever 1 (15), compensating piston (22), sleeve (12), spool (13) and stopper (1).



The torque control solenoid valve is located on the pump 2 regulator.



Torque Control Solenoid Valve



Pump 1 Regulator



T1F3-01-02-007



Pump 2 Regulator



Component Layout Pump 1



Pump 2



19



9 5



1



3



7 Pump 1 Regulator



Pump 2 Regulator



22 1 - Stopper 3- Pilot Piston 5- Lever 2



15 7 - Pin 9- Feedback Lever 12- Sleeve



13



12



13 - Spool 15- Lever 1



T3-1-4



T1F3-03-01-012



Torque Control Solenoid Valve 19- Servo Piston 22- Compensating Piston



COMPONENT OPERATION / Pump Device Pump 1 Regulator 3



1



5



7



9 T1F3-03-01-004



12



15



13



19



22



T1F3-03-01-005



Pump 2 Regulator



7



5



3



9



T1F3-03-01-007



T3-1-5



COMPONENT OPERATION / Pump Device Cross Section (Pump 1 Regulator)



B



A



A



B



T1F3-03-01-034



Cross Section A-A 1



2



3



4



5



6



8



7



9



T1F3-03-01-004



10 1 - Stopper 2 - Piston 3 - Pilot Piston



4 - Pin 5 - Lever 2 6 - Pin



7 - Pin 8 - Pilot Piston



T3-1-6



9 - Feedback Lever 10 - Pin



COMPONENT OPERATION / Pump Device Cross Section B-B



11



13



12



14



15



16



18



17



T1F3-03-01-005



23



11121314-



Return Spring Sleeve Spool Pin



22



15 - Lever 1 16 - Pin 17 - Outer Spring



20



21



18 - Inner Spring 19 - Servo Piston 20 - Pin



T3-1-7



19



21 - Compensating Rod 22 - Compensating Piston 23 - Piston



COMPONENT OPERATION / Pump Device Cross Section (Pump 2 Regulator) B



A



A



B



T1F3-03-01-009



Cross Section A-A



3



4



5



6



8



7



9 10 34-



Pilot Piston Pin



56-



Lever 2 Pin



7 - Pin 8 - Pilot Spring



T3-1-8



9 - Feedback Lever 10 - Pin



T1F3-03-01-007



COMPONENT OPERATION / Pump Device Cross Section B-B 11



23 11121314-



Return Spring Sleeve Spool Pin



22



21



12



13



14



15



17



18



19



20



15- Lever 1 16- Pin 17- Outer Spring



16



T1F3-03-01-008



18- Inner Spring 19- Servo Piston 20- Pin



T3-1-9



21- Compensating Rod 22- Compensating Piston 23- Piston



COMPONENT OPERATION / Pump Device Link Mechanism Movement of pilot piston (3) is transmitted to lever 2(5) via pin (4), rotating lever 2 (5) around pin (7) held in the supporting plug. Movement of compensating rod (21) is transmitted to lever 1 (15) via pin (20), rotating lever 1 (15) around pin (14) held in the casing. Pin (6) is installed into feedback lever (9) and both ends of pin (6) are inserted into the holes on lever 1 (15) and lever 2 (5). 14 Casing



20



Accordingly, when lever 1 (15) or lever 2 (5) rotates, pin (6) comes in contact with the hole inside on the rotated lever, causing feedback lever (9) to rotate around pin (10) on servo piston (19). On the other hand, when servo piston (19) is moved, feed back lever (9) is moved via pin (10). Since lever 1 (15) and lever 2 (5) do not move at this time, feedback lever (9) rotates around pin (6), moving spool (13).



NOTE:



15



:Decreasing displacement angle :Increasing displacement angle



Hole



9



21



16 6 5 Hole



7



4 Supporting Plug



13



10 3 19 3456-



Pilot Piston Pin Lever 2 Pin



7 - Pin 9 - Feedback Lever 10 - Pin



T117-02-01-009



14 - Pin 15 - Lever 1 16 - Pin



T3-1-10



19 - Servo Piston 20 - Pin 21 - Compensating Rod



COMPONENT OPERATION / Pump Device Regulator Functions The regulator has the following five control functions.



• Control by Pump Control Pressure



When a control lever is operated, the pump flow rate control valve in the signal control valve regulates pump control pressure Pi in response to the lever stroke. Then, when the regulator receives pump control pressure Pi, the regulator controls the pump flow rate in proportion to pump control pressure Pi. When a control lever is operated, pump control pressure Pi increases Thereby, the regulator increases the pump flow rate. When the control lever is returned to neutral, pump control pressure Pi decreases, causing the regulator to reduce the pump flow rate.



Flow Rate (Q)



0



• Control by Own or Partner Pump Delivery Pressure



Pump Control Pressure (Pi)



Flow Rate (Q)



The regulator receives own pump delivery pressure P1 and partner pump delivery pressure P2 as control signal pressures. If the two average pressures increase over the set P-Q line, the regulator reduces both pump flow rates by the excess pressure from the P-Q line so that the total pump output is returned to the set P-Q line. Thereby, the engine is protected from being overloaded. The P-Q line has been designated to jointly regulate both pump operations Therefore, both pump flow rates are regulated almost equally to each other. Accordingly, although the higher-pressure side pump is loaded more than the lower-pressure side pump, the total pump output matches with the engine output. (Total Horsepower Control)



Pressure Increase Flow Rate Decrease



0



Pressure (P) P1



Pump 1



P2 Pump 2



Pi2



Pi1



PG



Pic



Pf Torque Control Solenoid Valve P1 - Pump 1 Delivery Pressure Pi1 - Pump 1 Control Pressure (from maximum pump 1 flow rate limit solenoid valve) Pic - Maximum Pump 1 Flow Rate Shift Pressure (from maximum pump 1 flow rate shift solenoid valve) PG - Primary Pilot Pressure (from pilot pump)



T3-1-11



T1F3-03-01-012



P1 - Pump 2 Delivery Pressure Pi2 - Pump 2 Control Pressure (from maximum pump 2 flow rate limit solenoid valve) Pf - Torque Control Pressure (from torque control solenoid valve)



COMPONENT OPERATION / Pump Device • Control by Pilot Pressure from Torque Control



Solenoid Valve The main controller (MC) operates based on both the engine target speed input data and actual speed information signals and outputs signals to the torque control solenoid valve. In response to the signals from the MC, the torque control solenoid valve delivers torque control pilot pressure Pps to the regulator. Upon receiving pilot pressure Pps, the regulator reduces the pump flow rate.(Speed Sensing Control: Increasing torque at a slow speed) (Refer to the CONTROL SYSTEM section.)



Flow Rate (Q)



0



Pressure (P)



• Control by the pilot pressure from the flow rate limit



solenoid valve When signals from the work mode switch, and/or the pressure sensor (auxiliary) or the attachment mode switch (optional) arrive at the MC (main controller), the MC sends a signal to the pump maximum flow rate limit solenoid valve. In response to this signal, the pump maximum flow rate limit solenoid valve reduces pump control pressure Pi, limiting the pump maximum flow rate. (Pump flow rate limit control) (Refer to the Control System group.)



Flow Rate (Q)



0



Pump Control Pressure (Pi)



Flow Rate (Q)



0



T3-1-12



Pressure (P)



COMPONENT OPERATION / Pump Device • Control by the maximum flow rate shift solenoid



valve (only pump 1 side) When signals from the engine control mode switch, the travel mode switch, the brake switch, the travel pilot pressure, and/or the N sensor (travel) arrive at the MC, the MC judges that the machine must be traveling. Then, the MC sends the signal to the pump 1 maximum flow rate shift solenoid valve. In response to this signal, the pump 1 maximum flow rate shift solenoid valve reduces the p1 maximum flow rate shift pressure Pic so that the pump 1 maximum flow rate is increased. (Travel pump 1 maximum flow rate shift control) (Refer to the Control System group.) NOTE: Minimum Flow Rate Signal Priority Control When more than two control signals are delivered to the regulator at the same time, the regulator is controlled by the minimum flow rate signal. Smaller Swash Angle Smaller (Flow Rate) Signal Priority Control



Increased Maximum Flow Rate



Flow Rate (Q)



Normal Pump P-Q Curve



0



Pressure (P) P1



Pump 1



P2 Pump 2



Pi2



Pi1



PG



Pic



Pf Torque Control Solenoid Valve P1 - Pump 1 Delivery Pressure Pi1 - Pump 1 Control Pressure (from maximum pump 1 flow rate limit solenoid valve) Pic - Maximum Pump 1 Flow Rate Shift Pressure (from maximum pump 1 flow rate shift solenoid valve) PG - Primary Pilot Pressure (from pilot pump)



T3-1-13



T1F3-03-01-012



P1 - Pump 2 Delivery Pressure Pi2 - Pump 2 Control Pressure (from maximum pump 2 flow rate limit solenoid valve) Pf - Torque Control Pressure (from torque control solenoid valve)



COMPONENT OPERATION / Pump Device (Blank)



T3-1-14



COMPONENT OPERATION / Pump Device Regulator Operation Although the pump 1 regulator is slightly different from the pump 2 regulator, the operational principles are the same except for the maximum flow rate sift control section. Therefore, both regulator operation is described using only pump1 regulator.



3



1



5



Swash Plate Inclination



8 Increase



19



Decrease



Pi1



10 Pic



9



7 P1 P2 Pf T1F3-03-01-013



22



1 - Stopper 3 - Pilot Piston 5 - Lever 2 7 - Pin



P1 - Pump 1 Delivery Pressure



8910 11 -



15



Pilot Spring Feedback Lever Pin Return Spring



18



12



13



11



12 - Sleeve 13 - Spool 15 - Lever 1



Pi1 - Pump 1 Control Pressure (from maximum pump 1 flow rate limit solenoid valve)



Pic - Maximum Pump 1 Flow Rate Shift Pressure (from maximum pomp 1 flow rate shift solenoid valve)



P2 - Pump 2 Delivery Pressure



T3-1-15



18 - Inner Spring 19 - Servo Piston 22 - Compensating Piston



Pf - Torque Control Pressure (from torque control solenoid valve)



COMPONENT OPERATION / Pump Device Control by Pump Control Pressure The pump control pressure control has two functions, the flow rate increase and decrease functions. The secondary pilot oil pressure proportional to the control lever stroke is routed to the pump regulator after being converted to pressure Pi at the selector valve. Thereby, the pump regulator is informed of the control lever conditions so that the regulator controls the pump swash angle.



• Flow Rate Increase Operation 1. When a control lever is operated, flow rate control pressure Pi acts on piston (2). As pressure Pi increases, piston (2) and pilot piston (3) is moved to the right until Pi pressure force comes in balance with pilot spring (8) force. 2. Pilot piston (3) moves lever 2 (5) via pin (4). Lever 2 (5) rotates around pin (7) (secured in the supporting plug) counterclockwise. 3. As pin (6) installed in feedback lever (9) is inserted into the hole on lever 2 (5). Feedback lever (9) is rotated around pin (10) by lever 2 (5) counterclockwise, moving spool (13) to the left. 4. When spool (13) is moved, the large chamber of servo piston (19) is connected to the hydraulic oil tank through spool (13). Since the pump delivery oil pressure (P) is routed into the small chamber, servo piston (19) moves to the left. 5. According to servo piston (19) moving, the pump swash angle increases so that the pump flow rate increases.



6. As servo piston (19) moves, feedback lever (9) is moved via pin (10). Since pilot piston (3) and lever 2 (5) do not move, feedback lever (9) is rotated around pin (6) clockwise, moving spool (13) to the right. Then, when the notches on spool (13) and sleeve (12) close thoroughly, the large chamber of servo piston (19) isn’t connected to the hydraulic oil tank, then servo piston (19) stops moving. 7. Consequently, the pump flow rate increases in proportion to the control lever stroke (Pi pressure increase).



Flow Rate (Q)



0



3



Pump Control Pressure (Pi)



Swash Plate Inclination



5



Decrease



Increase



Pi



19 10 9



7



P



T1F3-03-01-031



8



T3-1-16



13



12



COMPONENT OPERATION / Pump Device Animation



2



3



4



5



6



7



8



9



Pi



10



12



To Hydraulic Oil Tank



T1F3-03-01-016



13



P



19 234-



Piston Pilot Piston Pin



5 - Lever 2 6 - Pin 7 - Pin



8 - Pilot Spring 9 - Feedback Lever 10 - Pin



T3-1-17



T1F3-03-01-023



12 - Sleeve 13 - Spool 19 - Servo Piston



COMPONENT OPERATION / Pump Device • Flow Rate Decrease Operation 1. When a control lever is returned to neutral and flow rate control pressure Pi is reduced, pilot piston (3) is moved to the left until pilot piston (3) balances with spring (8). 2. Pilot piston (3) moves lever 2 (5) via pin (4). Lever 2 (5) rotates around pin (7) (secured in the supporting plug) clockwise. 3. As pin (6) installed in feedback lever (9) is inserted into the hole on lever 2 (5). Feedback lever (9) is rotated around pin (10) by lever 2 (5) clockwise, moving spool (13) to the right. 4. When spool (13) is moved, pump delivery oil pressure (P) is routed into the large chamber of servo piston (19) through spool (13). Although the same oil pressure (P) is routed into the small chamber, servo piston (19) moves to the right due to the difference in pressure receiving area between the servo piston ends. 5. According to servo piston (19) moving, the pump swash angle is reduced so that the pump flow rate is reduced. 6. As servo piston (19) moves, feedback lever (9) is moved via pin (10). Since pilot piston (3) and lever 2 (5) do not move, feedback lever (9) is rotated around pin (6) counterclockwise, moving spool (13) to the left. Then, when the notches on spool (13) and sleeve (12) close thoroughly, the pump delivery oil pressure (P) isn’t routed into the large chamber of the servo piston (19), then servo piston (19) stops moving. 7. Consequently, the pump flow rate decreases in proportion to the control lever stroke (Pi pressure decrease).



Flow Rate (Q)



0



3



5



Pump Control Pressure (Pi)



Swash Plate Inclination



8



Decrease



Increase



19



Pi



10 9



7



T3-1-18



13 P



T1F3-03-01-030



12



COMPONENT OPERATION / Pump Device Animation



3



4



5



6



7



8



9



Pi



10 T1F3-03-01-019



13



12



P



19 345-



Pilot Piston Pin Lever 2



678-



Pin Pin Pilot Spring



9 - Feedback Lever 10 - Pin 12 - Sleeve



T3-1-19



T1F3-03-01-025



13 - Spool 19 - Servo Piston



COMPONENT OPERATION / Pump Device Control by Own or Partner Pump Delivery Pressure NOTE: The pump control, which is performed using its own delivery pressure and partner pump delivery pressure, has the following two functions. Overload Prevention Operation As load (pressure) increases, the pump delivery flow rate is reduced so that the engine is not overloaded. Flow Rate Recover Operation As load (pressure) decreases, the pump delivery flow rate is increased so that the engine output can be effectively utilized.



• Flow Rate Reduction (Overload Prevention) Function 1. When pump delivery pressure (P1: its own delivery pressure, and P2: partner pump delivery pressure) increases, compensation piston (22) moves compensation rod (21) to the right until the pump delivery pressure force comes in balance with outer spring (17) force and inner spring (18) force. 2. Compensating rod (21) moves lever 1 (15) via pin (20). Lever 1 (15) is rotated around pin (14) (secured in the casing) counterclockwise. 3. As pin (6) installed in feedback lever (9) is inserted into the hole on lever 1 (15). Feedback lever (9) is rotated around pin (10) by lever 1 (15) clockwise, moving spool (13) to the right. 4. When spool (13) is moved, pump delivery oil pressure (P) is routed into the large chamber of servo piston (19) through spool (13). Although the same oil pressure (P) is routed into the small chamber, servo piston (19) moves to the right due to the difference in pressure receiving area between the servo piston (19) ends. 5. According to servo piston (19) moving, the pump swash angle is reduced so that the pump flow rate is reduced.



6. As servo piston (19) moves, feedback lever (9) is moved via pin (10). Since compensating rod (21) and lever 1 (15) do not move, feedback lever (9) is rotated around pin (6) counterclockwise, moving spool (13) to the left. Then, when the notches on spool (13) and sleeve (12) close. Thoroughly the oil pressure isn’t routed into the large chamber of servo piston (19), then servo piston (19) stops moving. 7. Consequently, the pump flow rate decreases from Q1 to Q2, reducing the pump loads.



Flow Rate (Q)



0



Pressure (P) Swash Plate Inclination Increase



Decrease



19 10 9



22 P1 P2



T1F3-03-01-028



15 18



T3-1-20



12



COMPONENT OPERATION / Pump Device Animation



12



13



17



15



14



18



P1



P2



21



22



20



19



12



10 13



21



15



19



9



6



T1F3-03-01-035



6



10



9 T1F3-03-01-038



6 - Pin 9 - Feedback Lever 10 - Pin



12 - Sleeve 13 - Spool 14 - Pin



15 - Lever 1 17 - Outer Spring 18 - Inner Spring



T3-1-21



19 - Servo Piston 21 - Compensating Rod 22 - Compensating Piston



COMPONENT OPERATION / Pump Device • Flow Rate Increase (Flow Rate Recovery) Function 1. When pump delivery pressure (P1: its own delivery pressure, and P2: partner pump delivery pressure) decreases, compensation piston (22) and compensation rod (21) is moved to the left until the pump delivery pressure force comes in balance with outer spring (17) force and inner spring (18) force. 2. Compensating rod (21) moves lever 1 (15) via pin (20). Lever 1 (15) is rotated around pin (14) (secured in the casing) clockwise. 3. As pin (6) installed in feedback lever (9) is inserted into the hole on lever 1 (15). Feedback lever (9) is rotated around pin (10) by lever 1 (15) counterclockwise, moving spool (13) to the left. 4. When spool (13) is moved, the large chamber of servo piston (19) is connected to the hydraulic oil tank through spool (13). As pump delivery oil pressure (P) is routed into the small chamber, servo piston (19) moves to the left. 5. According to servo piston (19) moving, the pump swash angle increases so that the pump flow rate increases. 6. As servo piston (19) moves, feedback lever (9) is moved via pin (10). Since compensating rod (21) and lever 1 (15) do not move, feedback lever (9) is rotated around pin (6) clockwise, moving spool (13) to the right. Then, when the notches on spool (13) and sleeve (12) close thoroughly, the large chamber of servo piston (19) isn’t connected to the hydraulic oil tank, then servo piston (19) stops moving. 7. Accordingly, the pump flow rate increases.



Flow Rate (Q)



0



Pressure (P)



Swash Plate Inclination Decrease



Increase



19 10 9



22 P1 P2



T1F3-03-01-033



15 18



T3-1-22



13



12



COMPONENT OPERATION / Pump Device Animation



To Hydraulic Oil Tank



12



13



14



17



15



18



P1 P2



22



21



6



9



10



20



19



T1F3-03-01-036



12



13



21



19



6



15



10



9 T1F3-03-01-039



6 - Pin 10 - Feedback Lever 11 - Pin



12 - Sleeve 13 - Spool 14 - Pin



15 - Lever 1 17 - Outer Spring 18 - Inner Spring



T3-1-23



19 - Servo Piston 20 - Compensating Rod 21 - Compensating Piston



COMPONENT OPERATION / Pump Device Control by Pilot Pressure from Torque Control Solenoid Valve The pump flow rate is reduced when torque control pressure Pf is supplied from the torque control solenoid valve. 1. Torque control pressure Pf acts on the end face of pin (23). Then, compensating piston (22), and compensating rod (21) move to the right until they balance with outer spring (17) and inner spring (18). 2. Compensating rod (21) moves lever 1 (15) via pin (20). Lever 1 (15) is rotated around pin (14) (secured in the casing) counterclockwise. 3. As pin (6) installed in feedback lever (9) is inserted into the hole on lever 1 (15). Feedback lever (9) is rotated around pin (10) by lever 1 (15) clockwise, moving spool (13) to the right. 4. When spool (13) is moved, pump delivery oil pressure (P) is routed into the large chamber of servo piston (19) through spool (13). Although the same oil pressure (P) is routed into the small chamber, servo piston (19) moves to the right due to the difference in pressure receiving area between the servo piston (19) ends. 5. According to servo piston (19) moving, the pump swash angle is reduced so that the pump flow rate is reduced.



6. As servo piston (19) moves, feedback lever (9) is moved via pin (10). Since compensating rod (21) and lever 1 (15) do not move, feedback lever (9) is rotated around pin (6) counterclockwise, moving spool (13) to the left. Then, when the notches on spool (13) and sleeve (12) close thoroughly, the pump delivery oil pressure (P) isn’t routed into the servo piston (19), then servo piston (19) stops moving. 7. Therefore, torque constant control (overload prevention operation and flow rate recover operation) is performed conforming with the varied P-Q curve.



Flow Rate (Q)



0



Pressure (P) Swash Plate Inclination



19



Increase



Decrease



10 9 22



13



P



Pf T1F3-03-01-029



15



T3-1-24



18



12



COMPONENT OPERATION / Pump Device Animation



Pf



13



14



15



17 18



12



P



23



22



21



19



20



9



10



6 T1F3-03-01-037



13



15



6



12



21 6910 12 -



Pin Feedback Lever Pin Sleeve



13 - Spool 14 - Pin 15 - Lever 1



19



10 17 - Outer Spring 18 - Inner Spring 19 - Servo Piston



T3-1-25



9



T1F3-03-01-040



21 - Compensating Rod 22 - Compensating Piston 23 - Pin



COMPONENT OPERATION / Pump Device Control by Pilot Pressure from Pump 2 Flow Rate Limit Solenoid Valve NOTE: Control operation performed by the pilot pressure from the pump maximum flow rate limit solenoid valve is identical to the control operation (flow rate increase) performed by the pump control pressure.



• Limiting Maximum Flow Rate 1. The maximum pump flow rate control solenoid valve in the pump control pressure Pi circuit is activated by the signals from the MC. 2. The maximum pump flow rate control solenoid valve functions as a reducing valve, limiting pump control pressure Pi. 3. When a control lever is operated, flow rate control pressure Pi acts on pilot piston (3). As pressure Pi increases, piston (2) and pilot piston (3) is moved to the right until Pi pressure force comes in balance with pilot spring (8) force. 4. Pilot piston (3) moves lever 2 (5) via pin (4). Lever 2 (5) rotates around pin (7) (secured in the supporting plug) counterclockwise. 5. As pin (6) installed in feedback lever (9) is inserted into the hole on lever 2 (5). Feedback lever (9) is rotated around pin (10) by lever 2 (5) counterclockwise, moving spool (13) to the left. 6. When spool (13) is moved, the large chamber of servo piston (19) is connected to the hydraulic oil tank through spool (13). Since the pump delivery oil pressure (P) is routed into the small chamber, servo piston (19) moves to the left. 7. According to servo piston (19) moving, the pump swash angle increases so that the pump flow rate increases.



8. As servo piston (19) moves, feedback lever (9) is moved via pin (10). Since pilot piston (3) and lever 2 (5) do not move, feedback lever (9) is rotated around pin (6) clockwise, moving spool (13) to the right. Then, when the notches on spool (13) and sleeve (12) close thoroughly, the large chamber of servo piston (19) isn’t connected to the hydraulic oil tank, then servo piston (19) stops moving. 9. Consequently, the pump flow rate increases in proportion to the control lever stroke (Pi pressure increase). However, as the maximum pump control pressure is limited so that the movement of pilot piston (3) is reduced. Therefore, the maximum flow rate is reduced to less than normal. Flow Rate (Q)



0



Pump Control Pressure (Pi)



Flow Rate (Q)



0



T3-1-26



Pressure (P)



COMPONENT OPERATION / Pump Device 2



3



4



5



7



6



8



9



Reducing Pi Pressure



10 T1F3-03-01-019



12



To Hydraulic Oil Tank



13



P



19 T1F3-03-01-023



234-



Piston Pilot Piston Pin



567-



Lever 2 Pin Pin



8 - Pilot Spring 9 - Feedback Lever 10 - Pin



T3-1-27



12 - Sleeve 13 - Spool 19 - Servo Piston



COMPONENT OPERATION / Pump Device Control by Maximum Flow Rate Shift Solenoid Valve (Only Pump 1) NOTE: Control operation performed by the maximum flow rate shift solenoid valve is almost identical to the control operation (flow rate increase) performed by the pump control pressure.



• Flow Rate Increase (Pump 1 Maximum Flow Rate) 1. When the pump 1 maximum flow rate shift solenoid is activated, pump 1 maximum flow rate shift pressure Pic acting on stopper (1) is routed to the hydraulic oil tank. 2. Pump control pressure Pi is pushing piston (2) to the right. As pump 1 maximum flow rate shift pressure Pic is reduced to the hydraulic oil tank pressure, stopper (1) moves piston (2) to the right. 3. Then, piston (2) moves pilot piston (3) to the right until the pressure Pi force comes in balance with spring (8) force. 4. Pilot piston (3) moves lever 2 (5) via pin (4). Lever 2 (5) rotates around pin (7) (secured in the supporting plug) counterclockwise. 5. As pin (6) installed in feedback lever (9) is inserted into the hole on lever 2 (5). Feedback lever (9) is rotated around pin (10) by lever 2 (5) counterclockwise, moving spool (13) to the left. 6. When spool (13) is moved, the large chamber of servo piston (19) is connected to the hydraulic oil tank through spool (13). Since the pump delivery oil pressure (P) is routed into the small chamber, servo piston (19) moves to the left. 7. According to servo piston (19) moving, the pump swash angle increases so that the pump flow rate increases.



8. As servo piston (19) moves, feedback lever (9) is moved via pin (10). Since pilot piston (3) and lever 2 (5) do not move, feedback lever (9) is rotated around pin (6) clockwise, moving spool (13) to the right. Then, when the notches on spool (13) and sleeve (12) close thoroughly, the large chamber of servo piston (19) isn’t connected to the hydraulic oil tank, then servo piston (19) stops moving. 9. As stopper (1) moves to the right, pilot piston (3) is moved to the right more than usual, causing the maximum pump 1 flow rate to increase. Increased Maximum Flow Rate



Flow Rate (Q)



Normal pump P-Q Curve



0



3



1



7



Pressure (P)



5 Increase



Swash Plate Inclination



Decrease



19 Pi



10



Pic



9



P



T1F3-03-01-032



8



T3-1-28



13



12



COMPONENT OPERATION / Pump Device Animation



1



2



4



3



5



7



6



8



9



Pi



Pic (To Hydraulic Tank)



10



Oil



12



T1F3-03-01-017



To Hydraulic Oil Tank



13



P



19 T1F3-03-01-024



1234-



Stopper Piston Pilot Piston Pin



5 - Lever 2 6 - Pin 7 - Pin



8 - Pilot Spring 9 - Feedback Lever 10 - Pin



T3-1-29



12 - Sleeve 13 - Spool 19 - Servo Piston



COMPONENT OPERATION / Pump Device Smaller Swash Angle Smaller (Flow Rate) Signal Priority Control When both pump flow rate increase and decrease signals arrive at the same time, this regulator operates so that the priority is given to the flow rate decrease signal. 1. The pump displacement angle control signals supplied from the pump control pressure and the pilot pressure from the torque control solenoid valve is transferred to feedback lever (9) and spool (13) via the holes on lever 1 (15) and lever 2 (5), and pin (6). [Refer to T3-1-12 (Control by Pump Control Pressure) and T3-1-20 (Control by Pilot Pressure from Torque Control Solenoid Valve)] 2. Pin (6) comes in contact with the flow rate decrease side hole on lever 1 (15) or lever 2 (5) so that priority is given to flow rate and power decrease control.



T3-1-30



COMPONENT OPERATION / Pump Device Flow Rate Increase Directive Signal:



5



6



9



Pi



T1F3-03-01-016



Flow Rate Decrease Directive Signal: Pf



13



15



6



P



T1F3-03-01-022



56-



Lever 2 Pin



9-



Feedback Lever



13 - Spool



T3-1-31



15- Lever 1



COMPONENT OPERATION / Pump Device TORQUE CONTROL SOLENOID VALVE The torque control solenoid valve is located on the pump 2 regulator. The torque control solenoid valve supplies the torque control pressure Pps to both the pump 1 and pump 2 regulators to reduce the pump flow rate. Operation 1. When neutral, port T is connected to the output port through the notch on the spool. Pressure oil from port P is completely blocked by the spool. 2. When the current flows to the solenoid from the MC, the solenoid is magnetized, pushing spring 1. 3. The output port is connected to port P via the notch on spool. Then, the pressure oil is routed to the output port from port P. 4. The spring chamber is opened to port T via the passage in the spool. Since the left side spool stap flange diameter (A) is larger than the right side spool stap flange diameter (B), the spool is returned to the left side.



T3-1-32



COMPONENT OPERATION / Pump Device When Neutral: Solenoid



Spring



Hole



Port P



Spool



Port T Spring Chamber



Output T1F3-03-01-010



When Operating: Solenoid



Spring



Port P



Hole



Spool



T1F3-03-01-018



Spring Chamber



Output



T3-1-33



A



B



COMPONENT OPERATION / Pump Device PILOT PUMP, STEERING PUMP Drive gear (1) is driven by the engine via the transmission which in turn rotates driven gear (2) as they are meshed together. 1 - Drive Gear



1



Inlet Port



2



2 - Driven Gear



Outlet Port



T137-02-03-005



N SENSOR (ENGINE SPEED SENSOR) The N sensor detects the engine speed, which is used to control various operations. The N sensor is located close to the transmission teeth so that the sensor converts the number of teeth passing by the sensor into pulse signals, effectively sensing the engine speed. 3 - Tooth 4 - Output



4



5



3



5 - Output



T178-03-01-020



PUMP DELIVERY PRESSURE SENSOR This sensor detects the pump delivery pressures, which are used to control various operations. When oil pressure is applied onto diaphragm (9), the diaphragm is deformed. The deformation of the diaphragm is detected as electrical signals. 6 - Ground 7 - Output



8 - Power Source (5V) 9 - Pressure Receiving Area (Diaphragm)



6



T3-1-34



7



T157-02-03-010



8



9



COMPONENT OPERATION / Pump Device PUMP CONTROL PRESSURE SENSOR This sensor detects the pump control pressures, which are used to control various operations. When oil pressure is applied onto diaphragm (10), the diaphragm is deformed. The deformation of the diaphragm is detected as electrical signals. 10 - Pressure Receiving Area (Diaphragm) 11 - Ground



12 - Output



T176-03-01-023



10



13 - Power Source (5V)



T3-1-35



11 12



13



COMPONENT OPERATION / Pump Device (Blank)



T3-1-36



COMPONENT OPERATION / Swing Device OUTLINE The swing device consists of the valve unit, swing motor, and swing reduction gear. The valve unit prevents cavitation in the swing circuit from occurring and protects the circuit from being overloaded. The swing motor is a swash plate type axial plunger motor with a built-in swing parking brake. The swing motor is driven by pressure oil delivered from the pump, and drives the swing reduction gear.



The swing reduction gear converts the swing motor output into slow large torque to rotate the shaft. Thereby, the upperstructure is rotated.



Valve Unit



Swing Motor



Swing Reduction Gear



T178-03-02-001



T3-2-1



COMPONENT OPERATION / Swing Device SWING REDUCTION GEAR The swing reduction gear is a two stage reduction planetary gear type. The ring gear is formed on the internal surface of the housing so that they are integrated. As the housing is bolted on the upperstructure, the ring gear doesn’t rotate. The swing motor shaft rotates the first stage sun gear. Then, its torque is transmitted to the second stage sun gear via the first stage planetary gear and carrier. The second stage sun gear rotates the shaft via the second stage planetary gear and carrier.



The shaft meshes with the swing bearing internal gear secured to the undercarriage, causing the upperstructure to rotate.



Swing Motor Shaft First Stage Sun Gear First Stage Planetary Gear



First Stage Carrier



Ring Gear



Second Stage Sun Gear



Second Stage Planetary Gear



Second Stage Carrier



Shaft T178-03-02-006



T3-2-2



COMPONENT OPERATION / Swing Device SWING MOTOR The swing motor consists of the swash plate, rotor, plungers, valve plate, housing and swing parking brake (springs, brake piston, plates, friction plates, and swing parking brake switch valve). The rotor in which the plungers are inserted is splined onto the shaft.



When pressure oil is supplied from the pump, the pressure oil pushes the plungers. Since the swash plate is inclined, the shoes on top of the plungers slide along the swash plate, causing the rotor and shaft to rotate. The shaft tip end is splined into the first stage sun gear in the swing reduction gear so that shaft rotation is transmitted to the swing reduction gear.



Spring Valve Plate Brake Piston Plate



Rotor



Swing Parking Brake Switch Valve



Housing



Friction Plate



Shoe



Plunger Retainer



Swash Plate



Shaft T178-03-02-002



T3-2-3



COMPONENT OPERATION / Swing Device SWING PARKING BRAKE The swing parking brake is a wet-type multi-disc brake. The brake is released when brake release pressure enters into the brake piston chamber (negative brake type). Brake release pressure is supplied from the pilot pump only when a front attachment and/or swing operation is made. During operations other than swing and/or front attachment or while the engine is stopped, brake release pressure is returned to the hydraulic oil tank so that the brake is automatically applied by spring. Releasing Brake: 1. When the swing and/or front attachment control levers are operated, the swing parking brake release spool in the signal pilot pressure control valve is shifted. Thereby, the pilot pressure oil from the pilot pump is routed to port SH. 2. Pilot pressure at port SH pushes to open the check valve and flows into the brake piston chamber. 3. Then, the brake piston is raised, breaking contact between the plates and friction plates so that the brake is released.



Applying Brake: 1. When the swing and/or front attachment control levers are released, the swing parking brake release spool in the signal pilot pressure control valve is returned to neutral so that the pilot pressure routed to port SH is reduced. 2. Therefore, the check valve is closed, allowing brake release pressure to flow into the swing motor housing through the orifice. 3. Consequently, spring force is applied to plates and friction plates, which are meshed with the outer diameter of the rotor and inner diameter of the housing respectively via the brake piston. Then, the rotor outer diameter is held with friction force. While the engine is stopped, no pilot pressure is routed to port SH, allowing the brake to be automatically applied.



T3-2-4



COMPONENT OPERATION / Swing Device



Spring Brake Piston Orifice



Check Valve



Friction Plate



Port SH (Brake Release Pressure) Plate Brake Piston Chamber



T178-03-02-003



T3-2-5



COMPONENT OPERATION / Swing Device VALVE UNIT The valve unit consists of the make-up valves and the relief valves. The make-up valves prevents cavitation in the circuit. The relief valves prevent surge pressure and overloads in the circuit. Make-Up Valve During swing stop operation, the swing motor is driven by inertia force of the upperstructure. The motor is rotated by inertia force more than by pressure oil delivered from the pump, causing cavitation to develop in the circuit. To prevent cavitation, when pressure in the swing circuit is reduced more than the return circuit (port M) pressure, the poppets are opened so that hydraulic oil is drawn into the circuit from the hydraulic oil tank to compensate for the lack of oil in the circuit.



Relief Valve



Make-Up Valve



Port M



Control Valve T107-02-04-013



Control Valve



Poppet



Make-Up Valve



Make-Up Valve



Port M



Relief Valve



T3-2-6



T178-03-02-004



COMPONENT OPERATION / Swing Device Relief Valve During starting or stopping swing operation, oil pressure in the swing circuit becomes high. The relief valve prevents the circuit pressure from rising higher than the set-pressure. Low Pressure Relief Operation (Shock Reducing Function): 1. Pressure at port HP (swing circuit) is routed into oil chamber C through the poppet orifice. 2. Pressure oil in oil chamber C is further routed into oil chambers A and B via passages A and B respectively. 3. The pressure receiving area in oil chamber B is larger than oil chamber A so that the piston moves to the left. 4. As long as the piston keeps moving, a pressure difference is developed between the front and the rear of the poppet. When this pressure difference is increased more than spring force, the poppet is unseated, allowing pressure oil to flow to port LP. 5. When the piston is moved full stroke, the pressure difference between the front and the rear of the poppet disappears, causing the poppet to be seated.



Poppet



Orifice



Spring



High Pressure Relief Operation (Overload Prevention): 1. After the piston is moved full stroke, the spring is compressed so that the circuit pressure is increased to the set-pressure. 2. If pressure in port HP increases more than the spring set-pressure, the poppet is unseated, causing pressure oil to flow to port LP from port HP. 3. When pressure in port HP is reduced to the specified level, the poppet is seated by spring force.



Passage A



Passage B



Piston



HP



LP Oil Chamber C Oil Chamber B Oil Chamber A



T3-2-7



T178-03-02-005



COMPONENT OPERATION / Swing Device (Blank)



T3-2-8



COMPONENT OPERATION / Control Valve OUTLINE The control valve controls pressure oil, flow rate, and oil flow direction in the hydraulic circuit. The major parts of the control valve are the main relief valve, overload relief valve, flow combiner valve, anti-drift valve, flow rate control valve, regenerative valve, auxiliary flow combiner valve, bypass shut-out valve, and spools. The spools are operated by pilot pressure oil.



The spool arrangements are as follows from the machine front side. 4-Spool Side: Travel, Bucket, Boom 1, Arm 2 5-Spool Side: Positioning, Auxiliary, Boom 2, Arm 1, Swing



Control Valve



Swing Arm 1 Boom 2 Auxiliary Positioning



Arm 2 Boom 1



5-Spool Side



Bucket Travel



Front



4-Spool Side



Auxiliary Control Valve



T176-03-03-035



Front



T1F3-03-03-018



T3-3-1



COMPONENT OPERATION / Control Valve Component Layout



1



2



3



4



5



6



7



9



10



11



35 12 34 33 32 31 30



13



14 15 16



29 28



17



27



26



25



24 23 22



21



20 19 18



T1F3-03-03-014



T3-3-2



COMPONENT OPERATION / Control Valve



16 26



4 29



18, 19 7



21



12 9, 10



Front



T176-03-03-038



1 - Load Check Valve (Positioning Tandem Circuit) 2 - Load Check Valve (Positioning Parallel Circuit) 3 - Check Valve (Main Relief Circuit) 4 - Main Relief Valve 5 - Auxiliary Flow Combiner Valve 6 - Check Valve (Auxiliary Flow Combining Circuit) 7 - Check Valve (Main Relief Circuit) 9 - Bucket Flow Rate Control Valve (Selector Valve) 10 - Bucket Flow Rate Control Valve (Poppet Valve)



11 - Bucket Regenerative Circuit



20 - Load Check Valve (Arm 2 Tandem Circuit)



29 - Overload Relief Valve (Arm Rod Side)



12 - Overload Relief Valve (Bucket Rod Side)



21 - Bypass Shut-Out Valve



30 - Arm Anti-Drift Valve (Check Valve)



13 - Overload Relief Valve (Bucket Bottom Side) 14 - Load Check Valve (Boom 1 Parallel Circuit) 15 - Boom Regenerative Circuit



22 - Check Valve (Orifice) (Arm 2 Parallel Circuit) 23 - Load Check Valve (Arm 1 Parallel Circuit) 24 - Load Check Valve (Arm 1 Tandem Circuit) 25 - Load Check Valve (Swing Circuit)



31 - Arm Anti-Drift Valve (Selector Valve) 32 - Load Check Valve (Boom 2 Parallel Circuit) 33 - Aux. Flow Rate Control Valve (Poppet Valve) 34 - Aux. Flow Rate Control Valve (Selector Valve)



17 - Overload Relief Valve (Boom Rod Side) 18 - Boom Anti-Drift Valve (Check Valve)



26 - Arm Regenerative Valve (Selector Valve) 27 - Arm Regenerative Circuit



35 - Load Check Valve (Bucket Parallel Circuit)



19 - Boom Anti-Drift Valve (Selector Valve)



28 - Overload Relief Valve (Arm Bottom Side)



16 - Overload Relief Valve (Boom Bottom Side)



T3-3-3



COMPONENT OPERATION / Control Valve



1



2



3



4



5



6



7



9



10



11



35 12 13



34 33 32 31 30



14 15 16



29 28



17



27



26



25



24 23 22



21



20 19 18



T1F3-03-03-014



T3-3-4



COMPONENT OPERATION / Control Valve



30, 31



33, 34



28



Front



17



5 6



1-



2-



345-



Load Check Valve (Positioning Tandem Circuit) Load Check Valve (Positioning Parallel Circuit) Check Valve (Main Relief Circuit) Main Relief Valve



Auxiliary Flow Combiner Valve 6- Check Valve (Auxiliary Flow Combining Circuit) 7- Check Valve (Main Relief Circuit) 9 - Bucket Flow Rate Control Valve (Selector Valve) 10 - Bucket Flow Rate Control Valve (Poppet Valve)



T176-03-03-036



13



35



11- Bucket Regenerative Circuit



20- Load Check Valve (Arm 2 Tandem Circuit)



29- Overload Relief Valve (Arm Rod Side)



12- Overload Relief Valve (Bucket Rod Side)



21- Bypass Shut-Out Valve



30- Arm Anti-Drift Valve (Check Valve)



13- Overload Relief Valve (Bucket Bottom Side) 14- Load Check Valve (Boom 1 Parallel Circuit) 15- Boom Regenerative Circuit



22- Check Valve (Orifice) (Arm 2 Parallel Circuit) 23- Load Check Valve (Arm 1 Parallel Circuit) 24- Load Check Valve (Arm 1 Tandem Circuit) 25- Load Check Valve (Swing Circuit)



31- Arm Anti-Drift Valve (Selector Valve) 32- Load Check Valve (Boom 2 Parallel Circuit) 33- Aux. Flow Rate Control Valve (Poppet Valve) 34- Aux. Flow Rate Control Valve (Selector Valve)



17- Overload Relief Valve (Boom Rod Side) 18- Boom Anti-Drift Valve (Check Valve)



26- Arm Regenerative Valve (Selector Valve) 27- Arm Regenerative Circuit



35- Load Check Valve (Bucket Parallel Circuit)



19- Boom Anti-Drift Valve (Selector Valve)



28- Overload Relief Valve (Arm Bottom Side)



16- Overload Relief Valve (Boom Bottom Side)



T3-3-5



COMPONENT OPERATION / Control Valve



1



2



3



4



5



6



7



9



10



11



35 12 13



34 33 32 31 30



14 15 16



29 28



17



27



26



25



24 23 22



21



20 19 18



T1F3-03-03-014



T3-3-6



COMPONENT OPERATION / Control Valve Cross Section A



F E



D



4



C B



7 A



3 35



6



5



a



NOTE: Valve (a) is not used.



T176-03-03-035



1-



2-



345-



Load Check Valve (Positioning Tandem Circuit) Load Check Valve (Positioning Parallel Circuit) Check Valve (Main Relief Circuit) Main Relief Valve



Auxiliary Flow Combiner Valve 6- Check Valve (Auxiliary Flow Combining Circuit) 7- Check Valve (Main Relief Circuit) 9- Bucket Flow Rate Control Valve (Selector Valve) 10- Bucket Flow Rate Control Valve (Poppet Valve)



T1F3-03-03-013



11- Bucket Regenerative Circuit



20- Load Check Valve (Arm 2 Tandem Circuit)



29- Overload Relief Valve (Arm Rod Side)



12- Overload Relief Valve (Bucket Rod Side)



21- Bypass Shut-Out Valve



30- Arm Anti-Drift Valve (Check Valve)



13- Overload Relief Valve (Bucket Bottom Side) 14- Load Check Valve (Boom 1 Parallel Circuit) 15- Boom Regenerative Circuit



22- Check Valve (Orifice) (Arm 2 Parallel Circuit) 23- Load Check Valve (Arm 1 Parallel Circuit) 24- Load Check Valve (Arm 1 Tandem Circuit) 25- Load Check Valve (Swing Circuit)



31- Arm Anti-Drift Valve (Selector Valve) 32- Load Check Valve (Boom 2 Parallel Circuit) 33- Aux. Flow Rate Control Valve (Poppet Valve) 34- Aux. Flow Rate Control Valve (Selector Valve)



17- Overload Relief Valve (Boom Rod Side) 18- Boom Anti-Drift Valve (Check Valve)



26- Arm Regenerative Valve (Selector Valve) 27- Arm Regenerative Circuit



35- Load Check Valve (Bucket Parallel Circuit)



19- Boom Anti-Drift Valve (Selector Valve)



28- Overload Relief Valve (Arm Bottom Side)



16- Overload Relief Valve (Boom Bottom Side)



T3-3-7



COMPONENT OPERATION / Control Valve



1



2



3



4



5



6



7



9



10



11



35 12 13



34 33 32 31 30



14 15 16



29 28



17



27



26



25



24 23 22



21



20 19 18



T1F3-03-03-014



T3-3-8



COMPONENT OPERATION / Control Valve Cross Section B



Cross Section C Travel



Bucket



Positioning



Auxiliary



12



1



2



10



33



9 11 13



34



T1F3-03-03-012



T176-03-03-004



1-



2-



345-



Load Check Valve (Positioning Tandem Circuit) Load Check Valve (Positioning Parallel Circuit) Check Valve (Main Relief Circuit) Main Relief Valve



Auxiliary Flow Combiner Valve 6- Check Valve (Auxiliary Flow Combining Circuit) 7- Check Valve (Main Relief Circuit) 9- Bucket Flow Rate Control Valve (Selector Valve) 10- Bucket Flow Rate Control Valve (Poppet Valve)



11- Bucket Regenerative Circuit



20- Load Check Valve (Arm 2 Tandem Circuit)



29- Overload Relief Valve (Arm Rod Side)



12- Overload Relief Valve (Bucket Rod Side)



21- Bypass Shut-Out Valve



30- Arm Anti-Drift Valve (Check Valve)



13- Overload Relief Valve (Bucket Bottom Side) 14- Load Check Valve (Boom 1 Parallel Circuit) 15- Boom Regenerative Circuit



22- Check Valve (Orifice) (Arm 2 Parallel Circuit) 23- Load Check Valve (Arm 1 Parallel Circuit) 24- Load Check Valve (Arm 1 Tandem Circuit) 25- Load Check Valve (Swing Circuit)



31- Arm Anti-Drift Valve (Selector Valve) 32- Load Check Valve (Boom 2 Parallel Circuit) 33- Aux. Flow Rate Control Valve (Poppet Valve) 34- Aux. Flow Rate Control Valve (Selector Valve)



17- Overload Relief Valve (Boom Rod Side) 18- Boom Anti-Drift Valve (Check Valve)



26- Arm Regenerative Valve (Selector Valve) 27- Arm Regenerative Circuit



35- Load Check Valve (Bucket Parallel Circuit)



19- Boom Anti-Drift Valve (Selector Valve)



28- Overload Relief Valve (Arm Bottom Side)



16- Overload Relief Valve (Boom Bottom Side)



T3-3-9



COMPONENT OPERATION / Control Valve



1



2



3



4



5



6



7



9



10



11



35 12 34 33 32 31 30



13



14 15 16



29 28



17



27



26



25



24 23 22



21



20 19 18



T1F3-03-03-014



T3-3-10



COMPONENT OPERATION / Control Valve Cross Section D Boom 1



Cross Section E Boom 2



Arm 2



19



Arm 1



31 16



29 30



18



14



32



20



22



23



24 27



15



28



17 T176-03-03-006



T176-03-03-005



1-



2-



345-



Load Check Valve (Positioning Tandem Circuit) Load Check Valve (Positioning Parallel Circuit) Check Valve (Main Relief Circuit) Main Relief Valve



Auxiliary Flow Combiner Valve 6- Check Valve (Auxiliary Flow Combining Circuit) 7- Check Valve (Main Relief Circuit) 9- Bucket Flow Rate Control Valve (Selector Valve) 10- Bucket Flow Rate Control Valve (Poppet Valve)



11- Bucket Regenerative Circuit



20- Load Check Valve (Arm 2 Tandem Circuit)



29- Overload Relief Valve (Arm Rod Side)



12- Overload Relief Valve (Bucket Rod Side)



21- Bypass Shut-Out Valve



30- Arm Anti-Drift Valve (Check Valve)



13- Overload Relief Valve (Bucket Bottom Side) 14- Load Check Valve (Boom 1 Parallel Circuit) 15- Boom Regenerative Circuit



22- Check Valve (Orifice) (Arm 2 Parallel Circuit) 23- Load Check Valve (Arm 1 Parallel Circuit) 24- Load Check Valve (Arm 1 Tandem Circuit) 25- Load Check Valve (Swing Circuit)



31- Arm Anti-Drift Valve (Selector Valve) 32- Load Check Valve (Boom 2 Parallel Circuit) 33- Aux. Flow Rate Control Valve (Poppet Valve) 34- Aux. Flow Rate Control Valve (Selector Valve)



17- Overload Relief Valve (Boom Rod Side) 18- Boom Anti-Drift Valve (Check Valve)



26- Arm Regenerative Valve (Selector Valve) 27- Arm Regenerative Circuit



35- Load Check Valve (Bucket Parallel Circuit)



19- Boom Anti-Drift Valve (Selector Valve)



28- Overload Relief Valve (Arm Bottom Side)



16- Overload Relief Valve (Boom Bottom Side)



T3-3-11



COMPONENT OPERATION / Control Valve



1



2



3



4



5



6



7



9



10



11



35 12 34 33 32 31 30



13



14 15 16



29 28



17



27



26



25



24 23 22



21



20 19 18



T1F3-03-03-014



T3-3-12



COMPONENT OPERATION / Control Valve Cross Section F



Swing



26



25



21 T176-03-03-007



1-



2-



345-



Load Check Valve (Positioning Tandem Circuit) Load Check Valve (Positioning Parallel Circuit) Check Valve (Main Relief Circuit) Main Relief Valve



Auxiliary Flow Combiner Valve 6- Check Valve (Auxiliary Flow Combining Circuit) 7- Check Valve (Main Relief Circuit) 9- Bucket Flow Rate Control Valve (Selector Valve) 10- Bucket Flow Rate Control Valve (Poppet Valve)



11- Bucket Regenerative Circuit



20- Load Check Valve (Arm 2 Tandem Circuit)



29- Overload Relief Valve (Arm Rod Side)



12- Overload Relief Valve (Bucket Rod Side)



21- Bypass Shut-Out Valve



30- Arm Anti-Drift Valve (Check Valve)



13- Overload Relief Valve (Bucket Bottom Side) 14- Load Check Valve (Boom 1 Parallel Circuit) 15- Boom Regenerative Circuit



22- Check Valve (Orifice) (Arm 2 Parallel Circuit) 23- Load Check Valve (Arm 1 Parallel Circuit) 24- Load Check Valve (Arm 1 Tandem Circuit) 25- Load Check Valve (Swing Circuit)



31- Arm Anti-Drift Valve (Selector Valve) 32- Load Check Valve (Boom 2 Parallel Circuit) 33- Aux. Flow Rate Control Valve (Poppet Valve) 34- Aux. Flow Rate Control Valve (Selector Valve)



17- Overload Relief Valve (Boom Rod Side) 18- Boom Anti-Drift Valve (Check Valve)



26- Arm Regenerative Valve (Selector Valve) 27- Arm Regenerative Circuit



35- Load Check Valve (Bucket Parallel Circuit)



19- Boom Anti-Drift Valve (Selector Valve)



28- Overload Relief Valve (Arm Bottom Side)



16- Overload Relief Valve (Boom Bottom Side)



T3-3-13



COMPONENT OPERATION / Control Valve



1



Auxiliary Control Valve



2 3



T1F3-03-03-014



T3-3-14



COMPONENT OPERATION / Control Valve Cross Section X-X X



2



1



3



T1GL-03-03-004



X T1GL-03-03-003



1 - Load Check Valve (Blade/Stabilizer Tandem Circuit)



2-



Overload Relief Valve (Blade/Stabilizer Rod Side)



T3-3-15



3-



Overload Relief Valve (Blade/Stabilizer Bottom Side)



COMPONENT OPERATION / Control Valve HYDRAULIC CIRCUIT Main Circuit The pressure oil from main pump 1 flows to the 4-spool side control valve and the pressure oil from main pump 2 flows to the 5-spool side control valve. Both right and left main circuits are provided with the parallel circuits, making combined operations possible. The boom and arm circuits are provided with the flow combining circuits so that the pressure oil from main pump 1 and 2 can be supplied together to each cylinder when a single operation is made. The main relief valve is located in the main circuit (between the pumps and actuators), preventing the oil pressure in the main circuit from increasing over the set-pressure during operation (when any control lever is operated). The overload relief valves are located in the boom, arm, and bucket circuits (between the control valve and actuators). The overload relief valve prevents the surge pressure, which is developed in the actuator circuit due to external loads, from increasing more than the set-pressure.



T3-3-16



COMPONENT OPERATION / Control Valve Positioning



Travel Motor Main Relief Valve



4-Spool Side Parallel Circuit 4-Spool Side



5-Spool Side



Attachment



Bucket Cylinder



Arm Cylinder Overload Relief Valve



Overload Relief Valve



Swing Motor Boom Cylinder



Flow Combining Circuit Auxiliary Control Valve



5-Spool Side Parallel Circuit Pump2



Pump1



T1F3-03-03-015



T3-3-17



COMPONENT OPERATION / Control Valve Blade/Stabilizer Circuit



• When the blade/stabilizer is operated, the pilot pressure oil from the blade/stabilizer pilot valve shifts the bypass shut-out valve. • Accordingly, the neutral circuit in the 4-spool side control valve is blocked so that the pressure oil from main pump 1 is routed to the auxiliary control valve. NOTE: One check valve, which is operated by the signal pressure from the 2-spool solenoid valve (blade/stabilizer), is installed on each cylinder port. When the check valve is closed, the cylinder is inoperable even though the blade/stabilizer pilot valve is operated. Operable cylinder is determined depending on whether the corresponding check valve is opened or closed when the blade/stabilizer pilot valve is operated. (Refer to the Control System group.)



T3-3-18



COMPONENT OPERATION / Control Valve From the blade/stabilizer pilot valve



Auxiliary Control Valve



Bypass Shut-Out Valve



Check Valve Pump 1



Check Valve



Blade/Stabilizer Cylinder



T3-3-19



T1F3-03-03-020



COMPONENT OPERATION / Control Valve Pilot Operation Circuit The pilot pressure oil (shown by figure letters) from the pilot valve is routed to the spool end faces in the control valve, moving the spools. Besides moving the spools, the pilot pressure oil operates the control valve at the same time in the following operations: • When arm roll-in operation (4) is made, the pilot pressure oil moves the spools and shifts the arm anti-drift valve selector valve and the hose-rupture safety valve (arm) spool. • When boom lower operation (2) is made, the pilot pressure oil moves the spools and shifts the boom anti-drift valve selector valve and the hose-rupture safety valve (boom) spool. • When positioning lower operation (10) is made, the pilot pressure oil moves the spools and shifts the hose-rupture safety valve (positioning) spool. As the air bleed circuit is provided in the upper section of the control valve so that any air trapped in the control valve will automatically be bled.



External Pilot Pressure Oil Control Circuit • The arm regenerative valve is shifted by the pilot pressure oil delivered from solenoid valve unit (SC). • The bucket flow rate control valve is shifted by the pilot pressure oil from the bucket flow rate control valve control spool in the signal control valve. • The bypass shut-out valve is shifted by the pilot pressure oil delivered from blade/stabilizer pilot valve. • The aux. flow combiner valve and bypass shut-out valve are shifted by the pilot pressure oil from positioning/auxiliary pilot valve. (Only the machines equipped with the optional auxiliary flow combining system.) • The aux. flow rate control valve is shifted by the pilot pressure oil from the aux. flow rate control solenoid valve. (Only the machines equipped with the optional auxiliary flow combining system.) NOTE: Normally, the auxiliary flow combiner valve and the auxiliary flow control valve are routed to the circuit. The auxiliary flow control solenoid valve is provided only on the machines equipped with the optional auxiliary flow combining system.



T3-3-20



COMPONENT OPERATION / Control Valve Pilot Pressure Oil from Positioning/auxiliary Pilot Valve (only on the machines equipped with Pilot Pressure Oil from the optional auxiliary flow combining system) Bucket Flow Rate Control Valve Shift Spool in Signal Control Valve 60 Auxiliary Flow Combiner Valve



Auxiliary Flow Rate Control Valve



10



Pilot Pressure Oil Hose-Rupture Safety Valve (Positioning)



9



Pilot Pressure Oil from Auxiliary flow Rate Control solenoid Valve (only on the machines equipped with the optional auxiliary flow combining system)



Arm Regenerative Valve



11



12



Bucket Flow Rate Control Valve



14 13



8



7



2 1



1



Pilot Pressure oil to Hose-Rupture Safety Valve (Arm) Pilot Pressure Oil from Solenoid Valve Unit (SC)



61



Boom Anti-Drift Valve 4 3



3



Pilot Pressure Oil to Hose-Rupture Safety Valve (Boom)



Pilot Pressure Oil form Blade/Stabilizer (Positioning/Auxiliary) 5



6



Bypass Shut-Out Valve



Arm Anti-Drift Valve



T1F3-03-03-016



1234-



Boom Raise Boom Lower Arm Roll-Out Arm Roll-In



5678-



Left Swing Right Swing Bucket Roll-In Bucket Roll-Out



9- Positioning Raise 10- Positioning Lower 11- Travel Reverse



T3-3-21



12 - Travel Forward 60 - Blade/Stabilizer Raise 61 - Blade/Stabilizer Lower



COMPONENT OPERATION / Control Valve MAIN RELIEF VALVE The main relief valve prevents pressure in the main circuit from increasing more than the set-pressure during operations of actuators such as the motors and the cylinders. Thereby, oil leakage from hoses and pipe joints and damage to the actuators are prevented. Operation 1. The oil pressure in port HP (main circuit) acts on the pilot poppet through orifice A in the main poppet and orifice B in the seat. 2. When the oil pressure in port HP increases more than the spring B set-force, the pilot poppet is unseated, allowing the pressure oil to flow to port LP (hydraulic oil tank) through passage A and around the outer diameter of sleeve. 3. At this time, a pressure difference arises between port HP and the spring chamber due to orifice A. 4. When this pressure difference increases more than the spring A set-force, the main poppet is unseated, causing the pressure oil in port HP to flow to port LP. 5. Thereby, the main circuit pressure decreases. 6. When the main circuit pressure decreases more than the specified pressure, the main poppet is seated by spring A.



T3-3-22



COMPONENT OPERATION / Control Valve When Normal: Main Poppet



Orifice A



Orifice B



Seat



Passage A



Spring B



HP



LP Sleeve



T176-03-03-010



Spring Chamber



Spring A



Pilot Poppet



When Relieving: Main Poppet



Orifice A



Orifice B



Seat



Passage A



Spring B



HP



LP Sleeve



T176-03-03-011



Spring Chamber



Spring A



T3-3-23



Pilot Poppet



COMPONENT OPERATION / Control Valve OVERLOAD RELIEF VALVE (with Make-Up Function) The overload relief valves are provided in the boom, arm, bucket and auxiliary control valve circuits. The overload relief valve prevents each actuator circuit pressure from rising excessively when the actuators are moved by external loads. In addition, when the actuator circuit pressure is reduced, draws the hydraulic oil from the hydraulic oil tank to prevent the occurrence of cavitation (make-up function).



Make-Up Operation 1. When pressure at port HP (actuator circuit) is reduced more than port LP (hydraulic oil tank), the sleeve is moved to the right. 2. Then, the hydraulic oil flows in port HP from port LP to prevent the cavitation. 3. When pressure in port HP increases more than the specified pressure, the sleeve is closed by spring C .



NOTE: The operations of overload relief valves in boom, arm, bucket, and auxiliary control valve are same. Accordingly, operation of the overload relief valve for the boom, the arm, and the bucket is explained on this page. Relief Operation 1. The oil pressure in port HP (main circuit) acts on the pilot poppet through orifice A in the main poppet and orifice B in the seat. 2. When the oil pressure in port HP increases more than the spring B set-force, the pilot poppet is unseated, allowing the pressure oil to flow to port LP (hydraulic oil tank) through passage A and around the outer diameter of sleeve. 3. At this time, a pressure difference arises between port HP and the spring chamber due to orifice A. 4. When this pressure difference increases more than the spring A set-force, the main poppet is unseated, causing the pressure oil in port HP to flow to port LP. 5. Thereby, the actuator circuit pressure is reduced. 6. When the actuator circuit pressure is reduced to the specified pressure, the main poppet is closed by spring A.



T3-3-24



COMPONENT OPERATION / Control Valve When Normal: Sleeve



Make-Up Valve



Main Poppet



Orifice Orifice A B



Seat



Passage A



Spring B



HP



LP Spring C



When Relieving: Sleeve



Spring Chamber



Main Poppet Orifice A



T176-03-03-012



Spring A Orifice B



Pilot Poppet Seat Passage A Spring B



HP



LP



T176-03-03-013



Spring Chamber



When Operating Make-Up:



Spring A



Pilot Poppet



Make-Up Valve



HP



LP



T1F3-03-03-021



Spring C



T3-3-25



COMPONENT OPERATION / Control Valve ANTI-DRIFT VALVE The anti-drift valves are located in the boom cylinder bottom and arm cylinder rod side circuits to reduce the cylinder drift. NOTE: The boom and arm anti-drift valves are identical in construction. Boom Cylinder



Blocking Operation 1. When the control lever (the spool) is in neutral, the anti-drift valve (selector valve) is not shifted. 2. Therefore, the pressure oil in the boom cylinder bottom (arm cylinder rod side) is applied to the anti-drift valve check valve via the control valve. 3. Consequently, the check valve is seated, blocking the return oil circuit from the cylinder so that the cylinder drift is reduced. Releasing Operation 1. When rolling the arm in or lowering the boom, the pressure oil from the pilot valve shifts the anti-drift valve (selector valve). 2. The hydraulic oil in the check valve spring chamber is returned to the hydraulic oil tank via the orifice in the Selector valve. 3. Accordingly, the check valve is unseated, allowing the return oil from the boom cylinder bottom side (arm cylinder rod side) to flow to the spool.



T176-03-03-028



Anti-Drift Valve (Selector Valve) Pressure Oil from Pump 1



Anti-Drift Valve (Check Valve) To Hydraulic Oil Tank Boom Cylinder



From Pilot Valve



To Hydraulic Oil Tank



T176-03-03-029



Anti-Drift Valve (Selector Valve)



T3-3-26



Anti-Drift Valve (Check Valve)



COMPONENT OPERATION / Control Valve When Blocking: Drain



Boom Cylinder To Pilot Valve Selector valve Sleeve



Spring B Seat Spring A Check Valve



To Spool T176-03-03-017



When Releasing: Drain



Boom Cylinder From Pilot Valve Selector Valve Sleeve



Spring B



Pressure Oil from Pump



Seat Spring A Check Valve



To spool T176-03-03-018



T3-3-27



COMPONENT OPERATION / Control Valve REGENERATIVE VALVE 3. Then, the return oil from the cylinder bottom side flows into the rod side so that the return pressure oil is regenerated, increasing the cylinder operating speed. 4. When the cylinder is fully stroked or digging loads increase, the oil pressure in the cylinder bottom circuit increases, causing the check valve to seat so that regeneration is stopped.



The regenerative valves are located in the boom lower and arm roll-in, accelerating the cylinder operating speeds, preventing the cylinders from making a pose in movement, and improving machine controllability. NOTE: Operational principles of each regenerative valve are almost identical. Therefore, the boom regenerative valve is used as an example.



NOTE: Arm Regenerative Valve (Selector Valve) Operation The arm regenerative valve (selector Valve) is shifted by the pilot pressure oil from solenoid valve unit (SC) so that the return oil circuit from the cylinder rod side to the hydraulic oil tank is blocked. (Refer to the SYSTEM / Control system group.)



Operation 1. When the boom is lowered, the return oil from the cylinder bottom side (the rod side in case of the arm cylinder) is routed the check valve via anti-drift valve and hole A on the spool. (Refer to T3-3-22 as for the operation of the anti-drift valve.) 2. At this moment, when the pressure oil in the cylinder rod side (the bottom side in case of the arm cylinder) is lower than the bottom side, the check valve is unseated.



Pressure Oil from Pump 1



Regenerative Valve



Boom 1 Spool



Boom Cylinder



Hole A



Anti-Drift Valve (Selector Valve)



Check Valve



Anti-Drift Valve (Check Valve)



From boom 2 spool (Pressure Oil from Pump 2 ) T1F3-03-03-022



T3-3-28



COMPONENT OPERATION / Control Valve When Operating:



Boom 1 Spool



Boom 2 Spool



Boom Cylinder



Anti-Drift Valve (Check Valve)



Hole A



Check Valve



T1F1-03-03-016



T3-3-29



COMPONENT OPERATION / Control Valve FLOW RATE CONTROL VALVE The flow rate control valve is located in the bucket and auxiliary circuits. When a combined operation is made, the flow rate control valve restricts the oil flow so that the other actuators are given priority to operate. When bucket (auxiliary) single operation is made: 1. The pressure oil from pump 1 acts on the check valve in the poppet via port P1. 2. Normally, the selector valve is kept open so that the pressure oil from pump 1 unseats the check valve and flows into the main spool through the selector valve. 3. Thereby, the poppet valve is opened, allowing the pressure oil to flow to the bucket spool. When the combined operation of the bucket (auxiliary), boom raise, and arm roll-in is made: 1. When the boom raise and arm roll-in functions are operated simultaneously, the selector valve is shifted so that the bucket flow rate control valve in the signal control valve is shifted by the boom raise pilot pressure. 2. Then, the oil pressure behind the poppet valve increases, and the force to close the poppet valve appears. 3. Consequently, the opening clearance of the poppet valve is reduced so that oil flow to the bucket spool is restricted, allowing the pressure oil to be routed to the high-pressure side of the boom raise circuit.



NOTE: The bucket flow rate control valve restricts the bucket circuit oil flow when the bucket, boom raise and arm roll-in operations are made simultaneously. The auxiliary flow rate control valve restricts the auxiliary circuit oil flow when a combined operation with the auxiliary and other front attachment is made. The bucket flow rate control valve is used here as an example.



Poppet Valve



Pressure Oil from Pump 1



Selector Valve



To Hydraulic Oil Tank



Bucket Cylinder



T176-03-03-030



Boom Raise Pilot Pressure



Pressure Oil from Pump 1



To Hydraulic Oil Tank



Poppet Valve



Selector Valve



Bucket Cylinder



T176-03-03-031



T3-3-30



COMPONENT OPERATION / Control Valve When Normal Operation: Poppet



Check Valve



Spring A Spring B



To Main Spool To Hydraulic Oil Tank Pressure Oil from Main Pump 1



P1



Selector Valve



Boom Raise Pilot Pressure



To Main Spool



Plug 2



T176-03-03-019



When Oil Flow is Restricted: Poppet



Check Valve



Spring A Spring B



To Main Spool



To Hydraulic Oil Tank Pressure Oil from Main Pump 1



Selector Valve P1



Boom Raise Pilot Pressure



To Main Spool



Plug 2



T3-3-31



T176-03-03-020



COMPONENT OPERATION / Control Valve BYPASS SHUT-OUT VALVE



Bypass Shut-Out Valve



The bypass shut-out valve is located after the 4-spool side circuit. When the blade/stabilizer is operated, the bypass shut-out valve is shifted, blocking the neutral passage in the 4-spool side circuit.



When Neutral: Spring



Spool



4-Spool Side Neutral Circuit



Operation 1. When the control levers are in neutral, the bypass shut-out valve is not shifted. The pressure oil from pump 1 returns back to the hydraulic oil tank through the neutral passage in the 4-spool side circuit. 2. When the blade/stabilizer is operated, the pilot pressure from the pilot valve is routed to port SJ so that the bypass shut-out valve is shifted. 3. Consequently, the neutral passage in the 4-spool side circuit is blocked, allowing the pressure oil from pump 1 to flow to the auxiliary control valve.



Return to Hydraulic Oil Tank



Port SJ



T176-03-03-022



When Operating: Spring



Spool



4-Spool Side Neutral Circuit



Return to Hydraulic Oil Tank



Port SJ



T3-3-32



T176-03-03-024



COMPONENT OPERATION / Control Valve From Blade/Stabilizer Pilot Valve



Neutral Circuit



SJ



Bypass Shut-Out Valve Auxiliary Control Valve Pump1



Blade/Stabilizer Cylinder



T1F3-03-03-020



T3-3-33



COMPONENT OPERATION / Control Valve AUXILIARY FLOW COMBINER VALVE



Auxiliary Flow Combiner Valve



The auxiliary flow combiner valve is located before the 4-spool side circuit. The auxiliary flow combiner valve operates differently depending on whether a single or combined operation is made. NOTE: The auxiliary flow combiner valve operates only on the machines equipped with the optional auxiliary flow combining system. Normally, port SN and port SM are connected to the hydraulic oil tank.



When Neutral: Port SN



To Auxiliary Spool



Check Valve Pressure Oil from Pump 1



Signal Operation When a single aux. pilot valve operation is made, the aux. flow combining valve allows the pressure oil from pump 1 to flow to the aux. spool together with the pressure oil from pump 2, increasing the attachment operating speed. 1. When an aux. pilot valve is operated, the pilot pressure oil is routed to port SM and port SJ so that both the aux. flow combining valve and bypass shut-out valve are shifted. 2. When the bypass shut-out valve is shifted, the neutral circuit in the 4-spool side is blocked. 3. At this moment, the aux. flow combiner valve is also shifted, allowing the pressure oil from the 4-spool side (pump 1) to flow to the aux. spool via the aux. flow combiner valve. 4. Therefore, pressure oil from both pumps 1 and 2 is supplied to the attachment, increasing attachment operation speed.



Spring B



Spool



Spring A Port SM



T176-03-03-021



When Operating: Port SN Spring B To Auxiliary Spool



Check Valve



Pressure Oil from Pump 1



Spool



Spring A Port SM



T176-03-03-023



T3-3-34



COMPONENT OPERATION / Control Valve



Reducing Valve



Signal Control Valve



Auxiliary Flow Combiner Valve SN



Pilot Pressure Oil from Positioning/Auxiliary Pilot Valve Auxiliary Flow Combining Solenoid Valve



SM



Neutral Circuit



Auxiliary Spool



4-Spool Side 5-Spool Side



SJ Pump2



Pump1



Bypass Shut-Out Valve



T1F3-03-03-019



NOTE: The reducing valve and the auxiliary flow combining solenoid valve are installed only on the machines equipped with the optional auxiliary flow combining system.



T3-3-35



COMPONENT OPERATION / Control Valve Combined Operation When the auxiliary pilot valve and the boom, arm, bucket, or travel functions are operated simultaneously, the auxiliary flow combiner valve is not shifted. Thereby, the specified operating speed of the boom, arm, bucket, or travel function is ensured. However, the combined oil flow is supplied to the auxiliary circuit when the pilot pressure to port SN is reduced by the reducing valve.



Auxiliary Flow Combiner Valve Port SN



To Auxiliary Spool



Spring B Check Valve



Pressure Oil from Pump 1



1. When the auxiliary pilot valve is operated, the pilot pressure oil is routed to port SM on the auxiliary flow combiner valve. 2. When the boom, arm, bucket, or travel is operated at the same time, the pilot pressure oil from the signal control valve is routed to port SN. 3. The pressure oil from port SM acts on the auxiliary flow combiner valve spool toward opening direction. The pressure oil from port SN and spring A act toward the closing direction. 4. Since the force to close the spool is larger than that to open the spool, the spool is kept closed. 5. When the pilot pressure to port SN is reduced by the reducing valve, the pilot pressure in port SM overcomes the pilot pressure in port SN and spring (A) force. Then, the auxiliary flow combiner valve is opened. Therefore, the pressure oil from pump 1 and pump 2 are combined and supplied together to the auxiliary spool.



T3-3-36



Spool



Spring A Port SM



T176-03-03-037



COMPONENT OPERATION / Control Valve Pilot Pressure Oil from Signal Control Valve Reducing Valve Auxiliary Flow Combiner Valve SN



Pilot Pressure Oil from Positioning/Auxiliary Pilot Valve Auxiliary Flow Combining Solenoid Valve



SM



Neutral Circuit



Auxiliary Spool



4-Spool Side 5-Spool Side



SJ Pump2



Pump1



Bypass Shut-Out Valve



T1F3-03-03-017



NOTE: The reducing valve and the auxiliary flow combining solenoid valve are installed only on the machines equipped with the optional auxiliary flow combining system.



T3-3-37



COMPONENT OPERATION / Control Valve (Blank)



T3-3-38



COMPONENT OPERATION / Pilot Valve OUTLINE The pilot valve controls the pilot pressure to move the control valve spools. The 4-port pilot valve is used for front attachment and swing operation. The 2-port pilot valve is used for travel, positioning/auxiliary and blade/stabilizer operation.



• Front and Swing Pilot Valve Port No.



Right



Left



1 2 3 4 1 2 3 4



HITACHI ISO Standard Standard Boom Lower ← Bucket Roll-Out ← Boom Raise ← ← Bucket Roll-In Right Swing Arm Roll-Out Arm Roll-In Right Swing Left Swing Arm Roll-In Arm Roll-Out Left Swing



Hydraulic Symbol



3 2



PT



4 1



3



1



PT



3 2



4 T566-03-05-002



P



4



2



T



1 T1F3-03-04-001



T3-4-1



COMPONENT OPERATION / Pilot Valve • Travel, Positioning/Auxiliary and Blade/Stabilizer Pilot Valve Port No. 1 Travel Forward Positioning Raise/Auxiliary Open Blade/Stabilizer Lower 2 Travel Reverse Positioning Lower/Auxiliary Close Blade/Stabilizer Raise



T T



P P



Hydraulic Symbol P



1



1



T



2



T1LA-03-04-001



2



1 T554-02-07-009



T3-4-2



2



COMPONENT OPERATION / Pilot Valve (Blank)



T3-4-3



COMPONENT OPERATION / Pilot Valve OPERATION • Front Attachment and Swing Pilot Valves In Neutral (Pusher Stroke: A to B on the Diagram) 1. When the control lever is in neutral, spool (6) completely blocks pressure oil from port P. The output port is open to port T via the notch on spool (6) so that the output port pressure is equal to pressure in the hydraulic oil tank. 2. When the control lever is moved slightly, cam (1) is tilted to push pusher (2). Pusher (2) is moved downward together with spring guide (3) while compressing return spring (5). 3. Spool (6) is pushed by balance spring (4) and is moved downward until clearance (A) becomes zero. 4. While moving downward, the output port is kept connected to port T so that pressure oil is not routed to the output port.



Full Stroke Operation (Pusher Stroke: E to F on the Diagram) 1. When the control lever is moved full stroke, pusher (2) is moved downward until spring guide (3) comes in contact with the stepped section of the casing. 2. Then, spool (6) is directly pushed by the bottom of pusher (2) at this moment. Accordingly, even if pressure in the output port increases, spool (6) cannot move upward. Then, the output port is kept connected to port P via the notch on spool (6). 3. Therefore, pressure in the output port is maintained at the same pressure in port P. The total lever stroke is decided by stroke C of the pusher.



NOTE: The lever stroke moved until clearance (A) becomes zero, corresponds to the lever play in the neutral position. Operation Corresponding to Control Lever Stroke (Pusher Stroke: C to D on the Diagram) 1. As the control lever is moved further, port P is connected to the output port via spool (6), increasing pressure in the output port. 2. The increase pressure in the output port acts on surface B of spool (6), causing spool (6) to move upward. 3. As long as this upward pressure force is lower than balance spring (4) force, balance spring (4) is not compressed. Therefore, port P is kept connected to the output port so that output port pressure continues to increase. 4. Then, the output port pressure increases further, force to push spool (6) upward increases. When this pushing force increases more than set-force of balance spring (4), spool (6) is moved upward while compressing balance spring (4). 5. As spool (6) is moved upward, the output port is disconnected from port P. Thereby, pressure oil is not supplied to the output port from port P, stopping the pressure increase in the output port. 6. As described, balance spring (4) is compressed by the same stroke as spool (6) is moved downward. The output port pressure at this time is equivalent to the pressure balancing with spring force applied to spool (6).



T3-4-4



E



F



Pilot Pressure D



C



A



B



Pusher Stroke T505-02-07-006



COMPONENT OPERATION / Pilot Valve Pusher Stroke: A to B



1 2



3 4 5 Notch Port T （A）



(Clearance A:0)



Port P



6



T577-03-04-002



Output Port



Pusher Stroke: C to D



T577-03-04-003



Pusher Stroke: E to F



2



（C）



4



3 Port T



Notch



6 Port P



Port P



6 Surface B



Output Port



1 - Cam 2 - Pusher



3 - Spring Guide 4 - Balance Spring



Output Port



T577-03-04-004



5 - Return Spring



T3-4-5



6 - Spool



T577-03-04-005



COMPONENT OPERATION / Pilot Valve • Travel, Positioning/Auxiliary and Blade/Stabilizer



Pilot Valves Control Pedal-In Neutral (Pusher Stroke: A to B) 1. When the control pedal is in neutral, spool (7) blocks the pressure oil in port P completely. The output port is connected to port T through the passage in spool (7), so the pressure at output port becomes equal to the hydraulic oil tank pressure. 2. When the control pedal is moved slightly, cam (1) moves and pusher (2) and spring guide (4) move downward together, compressing return spring (6). 3. At this time, balance spring (5) pushes spool (7) and spool (7) moves downward until clearance (A) becomes ZERO. 4. While spool (7) moves downward, the output port is connected to port T and the pressure oil does not flow into the output port.



Control Pedal-Full Stroke (Pusher Stroke: E to F) 1. When the control pedal is moved to full stroke, pusher (2) is moved down until it comes into contact with the top of plate (3). 2. Thereby, spool (7) is pressed directly by the bottom of pusher (2). As a result, notch (B) of spool (7) does not close even if the pressure at output port rises. 3. As a result, the pressure at output port becomes equal to the pressure at port P.



E



NOTE: The pedal stroke moved until clearance (A) becomes zero, corresponds to the pedal play in the neutral position.



F



Pilot Pressure



Control Pedal-Operated (Pusher Stroke: C to D Metering) 1. When the control pedal is moved further, the hole on spool (7) is connected to notch (B). 2. The pressure oil in port P flows into the output port via the hole in spool (7) from notch (B), so the pressure at output port increases. 3. The pressure at output port acts on the bottom of spool (7), to push spool (7) upward. 4. If the acting force on spool (7) is smaller than the spring force of balance spring (5), balance spring (5) will not be pressed. As a result, as port P is connected to the output port, the pressure at output port increases continuously. 5. If the pressure at output port increases further, the force to push up spool (7) increases. When this force becomes larger than the spring force of balance spring (5), spool (7) pushes balance spring (5), and moves upward. 6. When spool (7) moves upward, notch (B) closes, so the pressure oil does not flow into the output port from port P. Thereby, the pressure at port P stops raising. 7. Accordingly, the amount balance spring (5) is compressed is equal to the amount spool (7) is pressed down, so the balanced pressure between the spring force and the force acting on spool (7) becomes the pressure at output port.



T3-4-6



D



C



A



B



Pusher Stroke T505-02-07-006



COMPONENT OPERATION / Pilot Valve Pusher Stroke: A to B



1 2 3 4 5 Port T



6 (A)



Clearance (A): 0 Port P



Hole



7 Passage T1LA-03-04-002



Output Port



Pusher Stroke: C to D



T1LA-03-04-003



Pusher Stroke: E to F



1



2



3 5 Port T



Port T



Notch (B)



Notch (B)



Port P



Port P



Hole



7 Output Port



1 - Cam 2 - Pusher



3 - Plate 4 - Spring Guide



7



T1LA-03-04-004



Output Port



5 - Balance Spring 6 - Return Spring



T3-4-7



7 - Spool



T1LA-03-04-005



COMPONENT OPERATION / Pilot Valve (Blank)



T3-4-8



COMPONENT OPERATION / Travel Device OUTLINE The travel device consists of the travel motor, the transmission, the front propeller shaft, the rear propeller shaft, the front axle and the rear axle. The travel motor is a variable displacement bent axis type axial plunger motor. The motor is driven by the pressure oil from the pump and rotates the transmission. A regulator is provided on the travel motor to regulate the torque, which is transferred to the transmission. The travel modes (Hi and Low) are selected at the transmission by the pressure oil from the pilot pump. Travel motor rotation is transferred to the propeller shafts and axles.



Rear Axle



Rear Propeller Shaft



Front Propeller Shaft



Travel Motor



Transmission



Front Axle



T1F3-03-05-002



T3-5-1



COMPONENT OPERATION / Travel Device TRANSMISSION The transmission setup consists of the shift interlock controller and the Hi/Low travel speed reduction gear. The shift interlock controller prevents the shift lever from moving from the D (Hi) position to the L (Low) position during travel operation. (See the shift interlock control description pages.) The major components of the shift interlock controller are gearshift piston (1), relief valve (2) and rotary pump (3).



The Hi/Low travel speed reduction gear is controlled by the pressure oil supplied from port P1 (high speed) or port P2 (low speed) so that either the disc brake or the disc clutch is released, selecting which the gears are to be driven. The major components of the Hi/Low travel speed reduction gear are final gears (4), planetary gears (6), ring gear (7), disc brake (8), disc clutch (9), sun gear (10), shaft (11), clutch piston (12), disc springs (13), brake piston (14), throttle check valves (15) and accumulator (16). In addition, the travel motor drain pressure sensor and the N sensor (travel speed sensor) are provided.



Hi/Low Travel Speed Reduction Gear



Low Hi Speed Speed



16



P2



Shift Interlock Controller



P1



1



15



N Sensor (Travel)



14



2



13 12



3



Travel Motor



11



4



E



10



Propeller Shaft Travel Motor Drain Pressure Sensor



9 1234-



Gearshift Piston Relief Valve Rotary Pump Final Gear



5678-



Carrier Planetary Gear Ring Gear Disc Brake



8



6



7 910 11 12 -



T3-5-2



Disc Clutch Sun Gear Shaft Clutch Piston



T1F3-03-05-003



5 13 14 15 16 -



Disc Spring Brake Piston Throttle Check Valve Accumulator



COMPONENT OPERATION / Travel Device



Shift Interlock Controller



Hi/Low Travel Speed Reduction Gear



6



12



14



16



5



2



1



15 3



4



11 13



9



8



10



7



T1F3-03-05-001



T3-5-3



COMPONENT OPERATION / Travel Device Low Speed Selection



• Releasing Disc Clutch



5. Since disc brake (8) is kept applied, ring gear (7) cannot rotate. 6. Thereby, the rotation of the travel motor is transmitted to the propeller shaft via shaft (11), sun gear (10), planetary gears (6), carrier (5) and final gears (4). 7. At this time, the travel motor rotation speed is reduced at the stages of planetary gears (6) and final gears (4). Then, the output shaft speed (propeller shaft side) is slower than the input shaft speed (travel motor side). 8. Consequently, the output shaft rotates at a slow speed.



1. When the shift lever is moved to the L (Low) position, the transmission control valve allows the pressure oil to flow from the pilot pump to port P2. (Refer to the COMPONENT OPERATION / Transmission Control valve group.) 2. The pressure oil is routed into clutch piston (12) chamber from port P2 via gearshift piston (1) and throttle check valve (15). 3. Then, the pressure oil pushes clutch piston (12) to the left, releasing disc clutch (9). 4. When the Low mode is selected, no pressure oil is routed into brake piston (14) chamber so that brake piston (14) is kept pushed to the right by disc spring (13). Therefore, disc brake (8) remains applied.



Low Speed P2



1



15 14 13



12 Travel Motor



11



4



10 Propeller Shaft



9



8



T1F3-03-05-004



7



T3-5-4



6



5



COMPONENT OPERATION / Travel Device 12



14



6



5



1



From Travel Motor



15



4



11 13



To Propeller Shaft



8



9



10



7



11



7



T1F3-03-05-001



6 10 5 From Travel Motor



4



9 8 To Propeller Shaft



To Propeller Shaft



T1F3-03-05-037



1456-



Gearshift Piston Final Gear Carrier Planetary Gear



789-



Ring Gear Disc Brake Disc Clutch



10 - Sun Gear 11 - Shaft 12 - Clutch Piston



T3-5-5



13 - Disc Spring 14 - Brake Piston 15 - Throttle Check Valve



COMPONENT OPERATION / Travel Device Hi Speed Selection



• Releasing Disc Brake



5. Sun gear (10) is coupled to shaft (11) through the spline joint. 6. Thereby, the travel motor, ring gear (7), sun gear (10), planetary gears (6) and carrier (5) rotate as one unit. 7. Consequently, the input shaft (travel motor side) rotation is reduced only at final gears (4) so that the output shaft (propeller shaft side) rotates at a high speed.



1. When the shift lever is moved to the D (Hi) position, the transmission control valve allows the pressure oil to flow from the pilot pump to port P1. (Refer to the COMPONENT OPERATION / Transmission Control Valve group.) 2. The pressure oil is routed into brake piston (14) chamber from port P1 via gear shift piston (1) and throttle check valve (15). 3. Then, the pressure oil pushes brake piston (14) to the left, releasing disc brake (8). 4. When the Hi mode is selected, no pressure oil is routed into clutch piston (12) chamber so that clutch piston (12) is kept pushed to the right by disc spring (13). Therefore, disc clutch (9) remains engaged.



Hi Speed P1



1



15 14 13



12 Travel Motor



4



11 10



Propeller Shaft



9



8



7



T3-5-6



6



5



T1F3-03-05-005



COMPONENT OPERATION / Travel Device 12



14



6



5



1



From Travel Motor



15



4



11 13 To Propeller Shaft



9



8



10



7



11



7



T1F3-03-05-001



6 10 5 From Travel Motor



4 9 8



To Propeller Shaft



To Propeller Shaft



T1F3-03-05-038



1456-



Gearshift Piston Final Gear Carrier Planetary Gear



789-



Ring Gear Disc Brake Disc Clutch



10 - Sun Gear 11 - Shaft 12 - Clutch Piston



T3-5-7



13 - Disc Spring 14 - Brake Piston 15 - Throttle Check Valve



COMPONENT OPERATION / Travel Device Parking Brake 1. When the brake switch is turned to the parking brake position, the transmission control valve blocks the pressure oil from the pilot pump. (Refer to the COMPONENT OPERATION / Transmission Control valve group.) 2. The pressure oil in the clutch piston (12) and brake piston (14) is allowed to flow back to the hydraulic oil tank. 3. Therefore, clutch piston (12) and brake piston (14) are moved by disc springs (13) force to the right so that disc clutch (9) is engaged and disc brake (8) is applied. 4. Consequently, all gears are locked, holding shaft (11) stationary.



14 13



12



11



9



T1F3-03-05-003



8



T3-5-8



COMPONENT OPERATION / Travel Device 14



12



11 13



8



9



T1F3-03-05-001



9 8



T1F3-03-05-039



89-



Disc Brake Disc Clutch



11 - Shaft 12 - Clutch Piston



13 - Disc Spring



T3-5-9



14 - Brake Piston



COMPONENT OPERATION / Travel Device Shift Interlock Control The shift interlock controller prevents the shift lever from moving from the D (Hi) position to the L (Low) position during travel operation, protecting the travel motor from being damaged. Even if the shift lever is moved from the D (Hi) position to the L (Low) position while traveling in the high travel mode, the machine continues to travel in the high travel mode. Then, after the travel speed is reduced to the gear-shift speed range (about 75 % of the maximum speed), the transmission is automatically shifted to the low travel mode. NOTE: The shift interlock controller doesn’t prevent the machine from running away while traveling on a down slope. The travel motor brake valve makes travel speed control on a down slope. 1. As the travel speed is accelerated with the shift lever in the D position, the travel motor rotation speed increases so that the delivery pressure of rotary pump (3) increases. 2. When the delivery pressure of the rotary pump overcomes the spring force, gearshift piston (1) is shifted. 3. Thereby, even if the shift lever is moved to the L position at this time, as the travel motor continues to rotate at a high speed, the delivery pressure from rotary pump (3) is kept at a high pressure. 4. Then, gearshift piston (1) remains in the shifted position so that the machine travel speed remains unchanged in the D mode even if the shift lever is in the L position. 5. After the machine travel speed decreases to the gearshift speed range, gearshift piston (1) is returned to the original position by the spring force so that the machine travel speed mode is automatically shifted. 6. Consequently, the travel motor is prevented from running at an excessive speed.



T3-5-10



COMPONENT OPERATION / Travel Device



Low Hi Speed Speed P2



Spring



P1



1



3



T1F3-03-05-006



T3-5-11



COMPONENT OPERATION / Travel Device Shockless Function Accumulator (16) is provided in the transmission high speed control circuit. Accumulator (16) maintains the oil pressure in the high speed control circuit so that activation time-lag is created between disc clutch (9) and disc brake (8), reducing shock developed when shifting the travel mode.



• Shifting Low Mode to Hi Mode



1. The pressure oil from port P1 opens throttle check valve (15) and is routed into brake piston (14) chamber and accumulator (16). 2. As pressure oil is routed into the both brake piston (14) chamber and accumulator (16), brake piston (14) slowly compresses disc springs (13). 3. Accordingly, disc brake (8) is slowly released. 4. The pressure oil in clutch piston (12) chamber flows back to the hydraulic oil tank through the orifice. 5. Then, clutch piston (12) is slowly moved by disc springs (13), preventing disc clutch (9) from engaging too quickly. 6. Therefore, when the high travel mode is selected, the travel motor is prevented from quickly increasing the rotation speed, reducing the shock due to travel mode change operation.



T3-5-12



COMPONENT OPERATION / Travel Device



Low Speed



16 Orifice



P2



Hi Speed P1



15



14 13 12



9



T1F3-03-05-007



8



T3-5-13



COMPONENT OPERATION / Travel Device • Shifting Hi Mode to Low Mode



1. The pressure oil from port P2 opens throttle check valve (15) and is routed into clutch piston (12) chamber. 2. The pressure oil moves clutch piston (12) to the left causing disc clutch (9) to disengage. 3. On the other hand, port P1 is connected to the hydraulic oil tank. 4. Then, brake piston (14) is moved to the right by disc spring (13) so that pressure oil in brake piston (14) chamber and accumulator (16) flows together back to the hydraulic oil tank. 5. As the return oil flows through the orifice at this time, brake piston (14) is not quickly moved so that disc brake (8) is slowly applied. 6. Therefore, when the low travel mode is selected, the travel motor is prevented from quickly increasing the rotation speed, reducing the shock due to travel mode change operation.



T3-5-14



COMPONENT OPERATION / Travel Device



Low Speed



16 Orifice



P2



Hi Speed P1



15



14 13 12



9



T1F3-03-05-008



8



T3-5-15



COMPONENT OPERATION / Travel Device Disconnect Device The disconnect device is activated when towing the machine. When the manual-operated lock lever is moved to the OFF position, the parking brake is released.



Underside of Base Machine The lock lever is secured with a bolt in position.



Lock Lever



1. When the lock lever is in the ON position, carrier (5) is coupled to final gear (4) via the disconnect device. 2. Accordingly, when the parking brake is applied, all gears are locked so that final gears (4) cannot rotate. 3. When the lock lever is placed in the OFF position, the disconnect device is activated, freeing final gears (4) to rotate. 4. Therefore, the transmission is shifted to neutral, which allows the machine to be towed at a desired speed.



T1F3-03-05-047



OFF



ON



5



Disconnect Device



4



T1F3-03-05-003



T3-5-16



COMPONENT OPERATION / Travel Device FRONT AND REAR PROPELLER SHAFT Joint The most common type universal joint is used for the joint. The universal joint consists of a pair of forks (1) and spider (2). Fork (1) is connected to spider (2) with bearings (3). Propeller Shaft



T1GL-03-05-003



1



2



3



T1GL-03-05-005



T3-5-17



COMPONENT OPERATION / Travel Device FRONT AXLE Front axle consists of bodies (1), steering cylinders (2), differential gear (3), and reduction gears (4). The front axle functions to change the machine travel direction, to support the machine weight, and to transfer the front propeller shaft power to the wheels. The front axle is connected to the base machine via the axle lock cylinders. When the axle lock cylinders are released, the front axle is allowed to oscillate so that the machine vibration is reduced during traveling (axle lock release control). (Refer to the SYSTEM / Control System group.)



Front Axle



A



Axle Lock Cylinder



T1F3-01-02-002



1



View A



2



4 3



T1F3-03-05-015



T3-5-18



COMPONENT OPERATION / Travel Device Construction 3



1



1



2



2 T1F3-03-05-013



4 2 1



T1F3-03-05-017



1-



Body



2-



Axle Shaft



3-



T3-5-19



Steering Cylinder



4-



Double Joint Shaft



COMPONENT OPERATION / Travel Device STEERING CYLINDER The steering valve operates the steering cylinder. When the steering wheel is turned to either the right or left, the pressure oil from the steering valve is routed into the steering cylinder. Then, the piston rod in the steering cylinder is moved so that the front wheels are steered to either the right or left. Construction



4



6



5



7



8



11 12 9 10



13



3 2



1



23



24



25



26 27



7



6



22



14 1234567-



Castle Nut Cotter Pin Tie Rod Clamp Bolt O-Ring Stopper



15



16



17 18



16 15 19 17



8910 11 12 13 14 -



O-Ring Ring Scraper Ring Guide O-Ring Cylinder Snap Ring



14



20 20 21 T1F3-03-05-014



15 16 17 18 19 20 21 -



T3-5-20



Snap Ring Split Ring Disc O-Ring Piston Backup Ring Seal Ring



22 23 24 25 26 27 -



Piston Rod Shim Guide Bolt Ring Scraper Ring



COMPONENT OPERATION / Travel Device (Blank)



T3-5-21



COMPONENT OPERATION / Travel Device DIFFERENTIAL GEAR The differential gear allows the right and left drive wheels to rotate at different speeds each other when the machine changes the travel direction, or when the machine travels on uneven road surfaces. Construction



1 2



3 4 5 6 7 8 9 10 11



12



T1F3-03-05-018



18 18



19



19



17 16 23



123456-



Lock Plate Nut Washer Flange Guard Seal



22



17



21



78910 11 12 -



Bearing Ring Shim Bearing Pinion Shaft Ring Gear



19



18



20



19



16



12



15



14



13



18 T1F3-03-05-019



13 14 15 16 17 18 -



T3-5-22



Spring Pin Spring Pin Half Case Gasket Side Gear Shim



19 20 21 22 23 -



Idle Gear Spider Half Gear Plane Washer Socket Bolt



COMPONENT OPERATION / Travel Device Function



• Purpose of Differential



1. When the machine is steered, the rear wheels move along the circular having its center point on the extension line of the rear wheel drive shaft. Therefore, the outer wheel must rotate faster than the inner wheel. 2. Let study the case when the rear wheels are driven by a propeller shaft via an axle having no differential gear. 3. In this case, both outer and inner wheels rotate at the same speed. If the machine is steered, the outer wheel must move faster than the inner wheel, resulting in sliding and/or premature wearing of the tire. In addition, the axle will be twisted, not allowing the constant transmission of driving force. 4. When a differential gear is installed, the outer wheel can rotate at different speed from that of the inner wheel so that the problem as mentioned above doesn’t occur.



Extension Line of Rear Wheel Drive Shaft



When the Machine is Steered:



When the Machine Travels on an Uneven Road Surface:



T3-5-23



T202-03-05-005



COMPONENT OPERATION / Travel Device • Basic Operational Principle of Differential Gear The operational principle of differential gear is explained using a pair of racks and a pinion gear. 1. When handle (C) is moved upward by distance (H) while applying equal loads (W) onto both rack (A) and rack (B) respectively, both racks (A and B) move by distance (H) together with the pinion gear. 2. When handle (C) is moved upward without applying load (W) onto rack (B), the pinion gear is moved upward while rotating along rack (A) to which load (W) is kept applied. 3. Rack (B) to which no load is applied is moved upward as the pinion gear rotates. 4. At this time, the moving distance of rack (B) is longer than the moving distance of the pinion gear that rotates along rack (A). 5. The moving distance of rack (B) can be obtained as H + H = 2H. This is equal to the operational principle of the differential gear.



W



W



W C



C H



H



H



2H



Rack (B) Rack (A) Pinion



Pinion



T202-03-05-006



T3-5-24



COMPONENT OPERATION / Travel Device • Operational Principle of Differential Gear 1. The axle shafts are coupled to side gears (17) through the spline joints. When equal loads are applied to axle shafts on both side, or when the machine is traveling straight on a flat surface, idle gears (19) don’t rotate. 2. Half cases (15 and 21) are connected to ring gear (12). Since idle gears (19) mesh with side gears (17) and mutual movement is kept stationary, half cases (15 and 21) rotate together with ring gear (12). 3. As mentioned above, as long as all parts are rotating as one unit, differential gear function doesn’t work. Therefore, side gears (17), idle gears (19) and spider (20) work as a joint connecting the axles. 4. When the machine is steered, uneven resistance forces are applied to the driving wheels. Depending on the difference in resistance force applied to the inner and outer wheels, idle gears (19) start revolving along side gears (17) while rotating around spider (20). 5. In case the resistance force applied to axle shaft (A) is larger than that applied to axle shaft (B), idle gears (19) revolve along side gears (17) in the same direction as ring gear (17) rotates while rotating around spider (20). Then, the rotation speed on axle shaft (A) is reduced. To the contrary, the rotation speed on axle shaft (B) is increased so that the differential gear function operates. 6. Supposing that ring gear (12) is driven by pinion shaft (11) at the speed of 100, the both side driving wheels rotate at the same speed as long as the machine travel straight. 7. When the machine is steered and the travel speed on the right side driving wheel is reduced to 90, the left side travel speed is increased by 10 (100-90) so that the machine is steered with the left side driving wheel rotating at the speed of 110. 8. Consequently, when ring gear (12) rotates at the speed of 100, the total rotation speed of both side wheels is kept constantly at 200 irrespective of difference in speed between both side wheels.



T3-5-25



12



11



19



Axle Shaft



17



17



15



20



Axle Shaft



21



T202-03-05-007



12



11



19



Axle Shaft (B)



17 15



17 20



Axle Shaft (A)



21



T202-03-05-008



COMPONENT OPERATION / Travel Device REDUCTION GEAR The reduction gear is a planetary gear type one-stage reduction gear that transfers the driving force from the differential gear to the wheels. The brake equipped is a wet type multi disc brake. The major components are knuckle (1), hub (2), internal gear (3), piston (4), gear (5), friction plate (6), plate (7), plate carrier (8), sun gear shaft (9), planetary gear (10), and planetary carrier (11). Construction 2



1



5 4 3



11 9 8



6



1 - Knuckle 2 - Hub 3 - Internal Gear



10



7



4 - Piston 5 - Gear 6 - Friction Plate



7 - Plate 8 - Plate Carrier 9 - Sun Gear Shaft



T3-5-26



T1F3-03-05-012



10 - Planetary Gear 11 - Planetary Carrier



COMPONENT OPERATION / Travel Device Brake Operation 1. When the brake pedal is stepped on, the pressure oil from the brake valve is routed onto piston (4) in the reduction gear. 2. Then, piston (4) is moved by the pressure oil so that friction plates (6) come in contact with plates (7). 3. Accordingly, the rotation speeds of sun gear shaft (9) and planetary carrier (11) is reduced, thereby reducing the machine travel speed.



Brake Valve



Brake Pedal



NOTE: When the machine is traveling, the pressure is routed into the hydraulic oil tank. Therefore, the disc brake is kept released.



11



9



4



7



6



Front Brake



Pilot Pump



Rear Brake



Hydraulic Oil Tank



T1F3-03-05-048



T3-5-27



COMPONENT OPERATION / Travel Device REAR AXLE The rear axle consists of bodies, a differential gear, and a pair of reduction gears. The rear axle transfers the driving force from the rear propeller shaft to the wheels while supporting the machine weight.



NOTE: The rear axle construction is identical to that of the front axle. Therefore, only the construction of the bodies, differential gear, and reduction gears are illustrated.



Rear Axle



Body Differential Gear



T1F3-03-05-016



Reduction Gear



Body



1



2



T1F3-03-05-011



1 - Body



2-



Axle Shaft



T3-5-28



COMPONENT OPERATION / Travel Device Defferential Gear 14



23



1



2



21



22



19



18



19



20



18 17



13



16 15



12 3



16 17



4 5



6



7



8



9



19



18



19



18



10 11



T1F3-03-05-026



123456-



Lock Plate Nut Washer Flange Guard Seal



78910 11 12 -



Bearing Ring Shim Bearing Piston Shaft Ring Gear



13 14 15 16 17 18 -



T3-5-29



Spring Pin Spring Pin Half Case Gasket Side Gear Shim



19 20 21 22 23 -



Idle Gear Spider Half Gear Plain Washer Socket Bolt



COMPONENT OPERATION / Travel Device Reduction Gear 1



3 2



5



6



7



4



9 8 11



10 T1F3-03-05-010



1 - Knuckle 2 - Hub 3 - Internal Gear



4 - Piston 5 - Gear 6 - Friction Plate



7 - Plate 8 - Plate Carrier 9 - Sun Gear Shaft



T3-5-30



10 - Planetary Gear 11 - Planetary Carrier



COMPONENT OPERATION / Travel Device TRAVEL MOTOR The travel motor consists of the motor section, and brake valve. The motor section is rotated by the pressure oil from the pump and transfers the motor rotation to the transmission. The regulator controls the motor displacement angle so that the motor is rotated at the displacement angle in proportion to the pilot pressure oil. Overload relief valves provided on the regulator prevent surge pressure due to overloads from occurring in the motor circuit. Brake Valve



The travel brake valve consists of the counterbalance valve, load check valves, check valves, and shuttle valve and prevents the machine from running away. NOTE: The make-up valve in the control valve prevents occurrence of cavitation in the motor circuit.



Motor



Counterbalance Valve



Load Check Valve/ Check Valve



Overload Relief Valve T1F3-03-05-020



Regulator



Component Layout



Check Valve



Pilot Piston T



B Counterbalance Valve Connected Transmission



Shuttle Valve



Load Check Valve A X Overload Relief Valve



Servo Piston



T3-5-31



T1F3-03-05-023



COMPONENT OPERATION / Travel Device ROTOR SECTION FV



The rotor section consists of valve plate (1), rotor (2), drive shaft (3) and plungers (4). When the pressure oil is routed to port AM on valve plate (1), the pressure oil flows into the half side of rotor (2) so that plungers (4) are pushed. The component force (FV) of plunger pushing force (F) rotates drive shaft (3). As drive shaft (3) rotates, rotor (2) is also rotated. Then, when plunger (4) is rotated up to port BM in sequence, the pressure oil in the rotor is returned to the hydraulic oil tank. Supplying the pressure oil to either port AM or BM can achieve forward and reverse travel direction change.



F FR



4



AM 1



3



2



BM



T216-03-05-015



1



2



3



T1F3-03-05-021



4



1-



Valve Plate



2-



Rotor



3-



T3-5-32



Drive Shaft



4-



Plunger



COMPONENT OPERATION / Travel Device (Blank)



T3-5-33



COMPONENT OPERATION / Travel Device REGULATOR The major components of the regulator are pilot piston (1), sleeve (2), piston (3), spring (4), bushing (5), collar (6), spring (7), return spring (8), pin (9) and servo piston (10). Corresponding to various signal pressures delivered to the regulator, the regulator opens or closes the circuit to the servo piston so that the tilt angle of the rotor is adjusted, controlling the travel motor rotation.



NOTE: The motor system pressure is constantly routed into the small chamber of servo piston (10).



2



1



Port T



Port B



Port A



Port X



10



Port A: Travel Forward Side



Port B: Travel Reverse Side



Port T: Hydraulic Oil Tank Return Side



T3-5-34



T1F3-03-05-023



PortX: Pilot Pressure [From 4-Spool Solenoid Valve Unit (SI)]



COMPONENT OPERATION / Travel Device 1 2 3 Rotor



4 5 6 7 8 9 10



T1F3-03-05-025



1 - Pilot Piston 2 - Sleeve 3 - Piston



4 - Spring 5 - Bushing 6 - Collar



7 - Spring 8 - Return Spring



T3-5-35



9 - Pin 10 - Servo Piston



COMPONENT OPERATION / Travel Device (Blank)



T3-5-36



COMPONENT OPERATION / Travel Device Control Function of Regulator The pressure oil routed to pilot piston (1) controls the displacement angle of the travel motor. Pilot piston (1) controls the pressure oil routed into the large diameter chamber of servo piston (10) to control the motor displacement angle. The regulator is controlled by the following two methods.



Motor Displacement Angle



• Control by motor driving oil pressure



When the motor driving oil pressure increases to more than the set-pressure, the regulator increases the motor displacement angle to reduce the motor rotation speed so that the machine travels at a slow speed. When the motor driving oil pressure decreases to lower than the set-pressure, the regulator decreases the motor displacement angle to increase the motor rotation speed so that the machine travels at a fast speed. • Control by pilot pressure oil When solenoid valve (SI) is shifted by the signal from MC (main controller), the pilot oil pressure is routed to the regulator so that the motor displacement angle is increased. Then, the machine travel speed is reduced (Superfine travel speed control) (Travel motor excessive speed rotation preventive control) (Refer to the SYSTEM / Control System group.)



Driving Oil Pressure



To Hydraulic Oil Tank



1



T



Motor Driving Oil Pressure A



B



X



10



T3-5-37



Pilot Pressure Oil [From Solenoid Valve Unit (SI)]



T1F3-03-05-027



COMPONENT OPERATION / Travel Device Control by Motor Driving Oil Pressure



• Small Displacement Angle (Fast Speed)



1. When the control valve travel spools are in neutral, no pressure oil is routed into the small diameter chamber of servo piston (10) so that servo piston (10) moves downward by return spring (8) force, decreasing the motor displacement angle (fast speed). 2. As pilot piston (1) is being pushed upward by springs (4 and 7), the pressure oil in the large diameter chamber of servo piston (10) flows to the hydraulic oil tank through the notch on pilot piston (1). 3. When travel operation is made, the motor driving pressure oil from the control valve is routed into the small diameter chamber of servo piston (10) and on the pilot piston (1). 4. Since the oil pressure in the large diameter chamber of servo piston (10) is equal to that in the hydraulic oil tank, servo piston (10) doesn’t move. 5. Consequently, the travel motor displacement angle is reduced, causing the travel motor speed to increase.



1 Motor Driving Oil Pressure



T3-5-38



10



T1F3-03-05-028



COMPONENT OPERATION / Travel Device In Neutral:



During Traveling:



1



1



4



4



7



7



To Hydraulic Oil Tank



To Hydraulic Oil Tank



8



8 Motor Driving Oil Pressure



Motor Driving Oil Pressure



10 10



Small Diameter Chamber



Large Diameter Chamber T1F3-03-05-041



T3-5-39



T1F3-03-05-042



COMPONENT OPERATION / Travel Device • Large Displacement Angle (Slow Speed) 1. The motor driving oil pressure is routed into the small diameter chamber of servo piston (10) and onto pilot piston (1). 2. The pressure receiving area at section (B) on pilot piston (1) is larger than that at section (A). 3. When the motor driving oil pressure increases to more than springs (4 and 7) force with servo piston (10) in the minimum displacement angle position, the pressure oil pushes pilot piston (1) downward. 4. Then, the motor driving pressure oil flows into the large diameter chamber of servo piston (10) after passing through the notch on pilot piston (1) and the inner passage. 5. Although the motor driving pressure oil is routed into the small diameter of servo piston (10), servo piston (10) is moved upward because the pressure force in the large diameter chamber is large than that in the small diameter chamber due to difference in pressure acting area. 6. Therefore the motor displacement increases, causing the machine to drive at a slow speed.



1 Motor Driving Oil Pressure



T3-5-40



T1F3-03-05-024



10



COMPONENT OPERATION / Travel Device During Travel:



During Parking:



1



1 A



3



3



B



4 4 7 7 8



8



Motor Driving Oil Pressure



Motor Driving Oil Pressure



10 10



Small Diameter Chamber



Large Diameter Chamber



T1F3-03-05-043



T3-5-41



T1F3-03-05-044



COMPONENT OPERATION / Travel Device Control by Pilot Oil Pressure 1



• Large Displacement Angle (Slow Speed)



1. When the signal arrives from the MC, solenoid valve (SI) is shifted, routing the pressure oil from the pilot pump to pilot piston (1). 2. Pilot piston (1) is moved downward by the pilot pressure oil. 3. Then, the pressure oil flows into the large diameter chamber of servo piston (10) after passing through the notch on pilot piston (1) and the inner passage. 4. Although the pressure oil is routed into the small diameter of servo piston (10), servo piston (10) is moved upward because the pressure force in the large diameter chamber is large than that in the small diameter chamber due to difference in pressure acting area. 5. Therefore the motor displacement decreases, causing the machine to drive at a slow speed.



Motor Driving Oil Pressure



10



T3-5-42



Pilot Pressure Oil



T1F3-03-05-029



COMPONENT OPERATION / Travel Device During Traveling:



During Parking:



From Solenoid Valve Unit (SI)



Motor Driving Oil Pressure



From Solenoid Valve Unit (SI)



1



1



3



3



4



4



7



7



8



8 Motor Driving Oil Pressure



10



10



T1F3-03-05-045



T3-5-43



T1F3-03-05-046



COMPONENT OPERATION / Travel Device Overload Relief Valve The regulator is equipped with the overload relief valves that prevents the surge pressure from occurring in the motor circuit. Circuit Protection 1. When the circuit oil pressure increases to higher than the set-pressure of the overload relief valve, the overload relief valve opens, allowing the surge pressure to relieve to the lower pressure side so that the travel motor is protected from being overloaded.



Overload Relief Valve



NOTE: When the motor runs faster than the oil volume supplied from the pump, the counterbalance valve is closed, increasing the return oil pressure from the motor.



Counterbalance Valve



A



B T1F3-03-05-036



When Relieving: 1



2



3



4



B



Ａ



1 - Spring 2 - Poppet



3 - Spring



To Housing (Hydraulic Oil Tank)



5



4-



T3-5-44



Check Valve



T1F3-03-05-035



5-



Piston



COMPONENT OPERATION / Travel Device BRAKE VALVE The travel brake valve is located on the head of the travel motor, and consists of the counterbalance valve, check valves and shuttle valve.



A



Counterbalance Valve: Ensures smooth start and stop travel operation, and prevents the machine from running away when traveling on a down slope. Check Valve: Blocks the return circuit from the travel motor. A



Shuttle Valve: Routes the travel motor driving high-pressure oil into the pilot piston and the small diameter chamber of the servo piston in the regulator.



Section A-A



T1F3-03-05-020



Counterbalance Valve



B



B Check Valve



Check Valve



Load Check Valve



Load Check Valve Section B-B



B



A Shuttle Valve



T3-5-45



T1F3-03-05-034



COMPONENT OPERATION / Travel Device When Traveling: 1. When the pressure oil from the control valve is supplied to port A, the pressure oil diverges into two directions. 2. The one oil flow opens check valve (6) and is routed to motor port AM and to counterbalance valve spool (1). 3. The other oil flow is routed onto the end face of spool (1) after passing through passage (7) and the inside of spool (1). 4. The return oil from the travel motor is routed to spool (1) and check valve (3) via motor port BM. However, both check valve (3) and spool (1) block the return oil flow. 5. When the oil pressure at port A increases higher than spring (2) force, spool (1) is moved to the right. 6. Then, the return oil from the travel motor flows to passage (8) through the notch on spool (1). 7. The return oil opens load check valve (4). Then, the return oil flows to port B. As the pressure oil starts flowing at this stage, the travel motor starts rotating. 8. When the travel levers are returned to neutral, spool (1) is returned to the original position by spring (2) force, closing the circuit so that the travel motor stops rotating.



When Traveling on a Down Slope: 1. While traveling on a down slope, the machine weight causes the travel to forcibly rotate so that the travel motor works as if it is a hydraulic pump. 2. Therefore, when the travel motor draws the hydraulic oil, the oil pressures at port A and motor port AM decrease. Then, spool (1) is moved to the left, restricting the return oil flow from the travel motor. 3. Therefore, the oil pressure at port BM increases, developing the brake force to the travel motor. 4. As the oil pressure at port A increases, spool (1) is moved back to the right. Repetition of this operation (hydraulic brake) prevents the machine from running away.



T3-5-46



COMPONENT OPERATION / Travel Device When Traveling: Notch



8



1



2



7 AM



BM



T1F3-03-05-022



6



5



A



4



B



3



When Traveling on a Down Slope: 1



AM



BM



T1F3-03-05-022



A 1 - Spool (Counterbalance Valve) 2 - Spring



3 - Check Valve



5 - Check Valve



7 - Passage



4 - Load Check Valve



6 - Load Check Valve



8 - Passage



T3-5-47



COMPONENT OPERATION / Travel Device (Blank)



T3-5-48



COMPONENT OPERATION / Signal Control Valve OUTLINE The signal control valve is provided in the pilot circuit between the pilot valve and the control valve and controls various kinds of the pilot signal pressure used to regulate the pumps and valves.



NOTE: The flow combiner control spool and the auxiliary spool in the signal control valve are not used.



The major components of the signal control valve are shuttle valves, shockless valve, pump 1 flow rate control valve, pump 2 flow rate control valve, flow combiner valve control spool, bucket flow rate control valve control spool, and swing parking brake release spool.



A



A



Pilot Valve Side



T178-03-06-016



Cross Section A-A



Shockless Valve



Bucket Flow Rate Control Valve



Auxiliary Spool



Pump 2 Flow Rate Control Valve



Pump 1 Flow Rate Control Valve



Swing Parking Brake Release Spool



Flow Combiner Valve Control Spool



T178-03-06-002



T3-6-1



COMPONENT OPERATION / Signal Control Valve PILOT PORT Pilot Valve Side C



PH A



E M D H B



F



SB G



PI



Pilot Valve Side



N



K



I SH



J DF SA



L T178-03-06-016



Pilot Valve Side Port Name Port A Port B Port C Port D Port E Port F Port G Port H Port I Port J Port K Port L Port M Port N Port SA Port SB Port PI Port PH Port SH Port DF



Connecting to Right Pilot Valve Right Pilot Valve Left Pilot Valve Left Pilot Valve Left Pilot Valve Left Pilot Valve Right Pilot Valve Right Pilot Valve   Travel Shocless Valve (Travel Pilot Valve) Travel Shocless Valve (Travel Pilot Valve) Positioning/Auxiliary Pilot Valve Positioning/Auxiliary Pilot Valve Pump 1 Regulator Pump 2 Regulator 4-Unit Solenoid Valve Unit Pilot Shut-Off Valve Shuttle Valve (Swing Parking Brake) Hydraulic Oil Tank



T3-6-2



Note Boom Raise Pilot Pressure Boom Lower Pilot Pressure Arm Roll-Out Pilot Pressure Arm Roll-In Pilot Pressure Left Swing Pilot Pressure Right Swing Pilot Pressure Bucket Roll-In Pilot Pressure Bucket Roll-Out Pilot Pressure Plug Plug Travel Reverse Pilot Pressure Travel Forward Pilot Pressure Positioning Raise/Auxiliary Open Pilot Pressure Positioning Lower/Auxiliary Close Pilot Pressure Pump 1 Control Pressure Pump 2 Control Pressure Primary Pilot Pressure Primary Pilot Pressure (Heating Circuit) Brake Release Pressure Returning to Hydraulic Oil Tank



COMPONENT OPERATION / Signal Control Valve



Control Valve Side 3



1



5



Pressure Sensor (Auxiliary)



13 4



2 SK



SE 8



Pressure Sensor (Swing)



14 Control Valve Side



7 9 6



10



SN



SL



11



12



Control Valve Side Port Name Port 1 Port 2 Port 3 Port 4 Port 5 Port 6 Port 7 Port 8 Port 9 Port 10 Port 11 Port 12 Port 13 Port 14 Port SE Port SN Port SP Port SL Port SK



Connecting to Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Hydraulic Oil Tank  Control Valve Control Valve Pilot Pressure Shift Valve Pilot Pressure Shift Valve   Shuttle Valve  Control Valve



SP



T1F3-03-06-003



Note Boom Raise Pilot Pressure Boom Lower Pilot Pressure Arm Roll-Out Pilot Pressure Arm Roll-In Pilot Pressure Left Swing Pilot Pressure Right Swing Pilot Pressure Bucket Roll-In Pilot Pressure Bucket Roll-Out Pilot Pressure Returning to Hydraulic Oil Tank Plug Travel Reverse Pilot Pressure Travel Forward Pilot Pressure Positioning Raise/Auxiliary Open Pilot Pressure Positioning Lower/Auxiliary Close Pilot Pressure Plug Plug Pump 1 Flow Rate Control Valve Control Pressure Plug Bucket Flow Rate Control Valve Control Pressure



T3-6-3



COMPONENT OPERATION / Signal Control Valve NOTE: Machines Equipped with Optional Auxiliary Flow Combining System Control Valve Side SM



Control Valve Side



SN



T1F3-03-06-004



Control Valve Side Port Name Port SM Port SN



Connecting to



Note



Auxiliary Flow Combiner Solenoid Valve Auxiliary Flow Combiner Reducing Valve



NOTE: The reducing valve and the auxiliary flow combiner solenoid valve are installed only on the machines equipped with the optional auxiliary flow combining system.



T3-6-4



Auxiliary Flow Combiner Valve Shift Pressure Auxiliary Flow Combiner Valve Shift Pressure



COMPONENT OPERATION / Signal Control Valve SHUTTLE VALVE The shuttle valve selects the pilot pressure used to perform each operation and routes it to the corresponding flow rate control valves and/or control spools. The flow rate control valves and/or control spools corresponding to each operation are as follows: Pump 1 Flow Rate Control Valve Boom Raise Boom Lower Arm Roll-In Arm Roll-Out Bucket Roll-In Bucket Roll-Out Right Swing Left Swing Travel Positioning/Auxiliary Blade/Stabilizer



Pump 2 Flow Rate Control Valve



-



-



T3-6-5



Bucket Flow Rate Control Valve Control Spool -



Swing Parking Brake Release Spool



-



COMPONENT OPERATION / Signal Control Valve 4 Travel



5



6



7



Arm



9 10



8 Swing



Boom



Bucket



11 Positioning/ Auxiliary



12 13 14 15 Blade/ Stabilizer



3 2 1



Pump 1 Flow Rate Control Valve



Pump 2 Flow Rate Control Valve



Bucket Flow Rate Control Valve Control Spool



Swing Parking Brake Release Spool



T3-6-6



T1F3-03-06-002



COMPONENT OPERATION / Signal Control Valve



B



B



Pilot Valve Side



T178-03-06-016



Cross Section B-B 7 3



6



5 14 15 13



11



9



12 8



4



10



1 2



T178-03-06-009



1 - Travel 2 - Boom/Arm/Bucket/Travel



56-



Boom/Arm Boom



3 - Arm



7-



Arm/Boom Raise



4 - Boom/Arm/Bucket/Travel/ Positioning/Auxiliary/ Blade/Stabilizer



8-



Boom Raise/Arm/Swing/ Positioning/Auxiliary



9 - Boom/Arm/Bucket 10 - Boom/Arm/Bucket/Swing/ Positioning/Auxiliary 11 - Arm/Boom Raise/Swing/ Positioning/Auxiliary 12 - Bucket



T3-6-7



13 - Swing 14 - Swing/Positioning/Auxiliary 15 - Positioning/Auxiliary



COMPONENT OPERATION / Signal Control Valve SHOCKLESS VALVE The shockless valve is provided in the boom raise circuit and functions during boom lowering operation. During Boom Raising Operation: 1. The boom raise pilot pressure is routed from port A and acts on the spool. 2. Immediately after the operation is started, the low pilot pressure oil flows to port 1 via clearance C between the spool and the housing, and inner passage 2. 3. The set-force of spring A is weaker than that of spring B. Therefore, when the pilot pressure increases, the spool is moved to the left. 4. As the spool is moved to the left, port A is connected to port 1, increasing the pressure in port 1 so that the spool in the control valve is moved.



During Boom Lowering Operation (Shock Reducing Operation) 1. When the boom is lowered, the return oil from the boom raise spool in the control valve is routed to port 1. 2. Since the spool blocks the oil passage between port 1 and port A, the return oil cannot flow directly to port A. 3. Port 1 is connected to spring A side via inner passage 1 and to the oil chamber via inner passage 2. 4. The pressure oil in the oil chamber flows out of clearance C between the spool and the housing, reducing the pressure in the oil chamber. Then, the spool is moved to the right by the pressure in the spring A side. Thereby, clearance C between the spool and the housing is closed, blocking the pressure oil flow. 5. When clearance C is closed, the pressure in the oil chamber increases, moving the spool to the left. Therefore, clearance C is opened again, allowing the pressure oil to flow to port A. 6. As operations in steps (4 and 5) are repeated, the pressure oil is gradually returned to port A so that the control spool returns slowly.



T3-6-8



COMPONENT OPERATION / Signal Control Valve



Pilot Valve Side Port A Inner Passage 1



Clearance C



Spring A



Inner Passage 2



Spool



Spring B



Oil Chamber



Port 1 T178-03-06-013



Control Valve Side



T3-6-9



COMPONENT OPERATION / Signal Control Valve PUMP 1 AND PUMP 2 FLOW RATE CONTROL VALVES The pump flow rate control valve delivers the pump control pressure Pi to the pump regulator in response to the pilot oil pressure from the pilot valve. 1. The pilot pressure from the pilot valve is routed into the spring chamber side in either the pump 1 or pump 2 flow rate control valve after being selected by the shuttle valves in the signal control valve. 2. Then, the spool is moved to the right, causing the primary pilot pressure to flow in either port SA or SB. 3. Therefore, the pressure in port SA or SB increases. 4. The oil pressure in port SA or SB acts on the right end of the spool. Thus, the spool is moved back to the left until the pressure force in port SA or SB balances with the pilot pressure force in the spring chamber so that the pressure in port SA or SB stops increasing.



T3-6-10



NOTE: The pump 1 flow rate control valve operates when the boom (raise or lower), arm (roll-in or out), bucket (roll-in or out), travel (forward or reverse), positioning/auxiliary, and blade/stabilizer functions are operated. The pump 2 flow rate control valve operates when the boom (raise), arm (roll-in or out), swing (right or left), and positioning/auxiliary functions are operated.



COMPONENT OPERATION / Signal Control Valve



Spring



Port SA, SB Spool



Primary Pilot Pressure Pilot Pressure



Shuttle Valve



T1F3-03-06-005



T3-6-11



COMPONENT OPERATION / Signal Control Valve BUCKET FLOW RATE CONTROL VALVE CONTROL SPOOL, SWING PARKING BRAKE RELEASE SPOOL NOTE: The three captioned spools are identical in operational principle.



Bucket Flow Rate Control Valve Control Spool: To Hydraulic Oil Tank



The bucket flow rate control valve control spool is shifted by the arm roll-in control pilot pressure, allowing the boom raise pilot pressure to flow to the bucket flow rate control valve in the control valve. The swing parking brake release spool is shifted by the boom, arm, bucket, swing or positioning/auxiliary pilot pressure, allowing the primary pilot pressure to flow to the swing motor.



Boom Raise Control Pilot Pressure



Spool



Spring



T178-03-06-014



Arm Roll-In Pi- To Bucket Flow Rate lot Pressure Control Valve



Swing Parking Brake Release Spool: To Hydraulic Oil Tank



Primary Pilot Pressure



Spool



Spring



T178-03-06-014



Pilot Pressure



T3-6-12



To Swing Parking Brake



COMPONENT OPERATION / Steering Valve OUTLINE The steering valve is located between the steering pump and the steering cylinders. The steering valve delivers the pressure oil from the steering pump to the steering cylinders corresponding to the rotation of the steering wheel. (Refer to the SYSTEM/Hydraulic System group.) Relief valve and overload relief valves are provided in the steering valve. The relief valve prevents the circuit pressure between the steering pump and the steering valve from being increased. When the steering valve is in neutral (when no steering operation is performed), the overload relief valve prevents the circuit pressure between the steering cylinders and the steering valve from being increased by external force to more than the set pressure.



Port L (Left Steering)



Port LS



Port R (Right Steering)



Steering Wheel



T487-03-02-001



Port T (To the Hydraulic Oil Tank)



T3-7-1



Port P (From the Steering Pump))



COMPONENT OPERATION / Steering Valve System Layout 1



2 3 4



5



9



1 - Gerotor



4 - Make-Up Valve



2 - Check Valve



5 - Port L (To the Steering Cylinder)



T1F3-03-07-005



6



8 7



6-



Port P (From the Steering Pump) 7 - Overload Relief Valve



8-



Port T (To the Hydraulic Oil Tank) 9 - Port R (To the Steering Cylinder)



3 - Relief Valve



5



9



A



B



8



6



T3-7-2



T487-03-02-001



COMPONENT OPERATION / Steering Valve View A



F



View B



C



F



D E



D



E



D



E E



D C



T487-03-02-005 T487-03-02-004



Section C-C



2



Section D-D



1



7



T487-03-02-007



Section E-E



4



T1F3-03-07-002



T487-03-02-006



Section F-F



T1F3-03-07-003



3



T3-7-3



COMPONENT OPERATION / Steering Valve CONSTRUCTION



8



The steering valve consists of gerotor (8), drive (7), sleeve (3), spool (4), pin (5), housing (1), and centering springs (2). When the steering wheel is rotated, spool (4) is rotated, opening the oil passage between spool (4) and sleeve (3). Then the pressure oil from the steering pump is routed into the steering cylinders via spool (4) and sleeve (3). Centering springs (2) are provided in both spool (4) and sleeve (3) so that sleeve (3) is returned to neutral when the steering wheel is released.



3



4 3



T1F3-03-07-005



2 T1F3-03-07-002



1



1 - Housing 2 - Centering Spring



5



34-



Sleeve Spool



4



3



56-



T3-7-4



7



Pin Plate



6



8



78-



Drive Gerotor



COMPONENT OPERATION / Steering Valve 8



7



OPERATION Sleeve (3), spool (4) are connected to drive (7) with pin (5). The pin hole in spool (4) is an oval hole so that there is play between spool (4) and sleeve (3). When the steering wheel spool (4) is rotated, the steering wheel exact rotation is transferred only to spool (4), creating a displacement angle between spool (4) and sleeve (3). Then, port P (from the steering pump) is connected to port R or L (to the steering cylinders) via sleeve (3) and spool (4).



2



5



4



T1F3-03-07-002



3 4



2 3



1 Port L Port R



Oval Hole



5 Port P



10 9



8



7



6 T1F3-03-07-004



1 - Housing 2 - Centering Spring 3 - Sleeve



4 - Spool 5 - Pin 6 - Plate



7 - Drive 8 - Gerotor



T3-7-5



9 - Spacer 10 - Cap



COMPONENT OPERATION / Steering Valve Left Steering: 1. When the steering wheel is turned counterclockwise, spool (4) is rotated. Then, the pressure oil from the steering pump is routed as follow: Port P → Sleeve (3) → Spool (4) → Sleeve (3) → Housing (1) → Gerotor (8) 2. The pressure oil from gerotor (8) is routed further as follow: Housing (1) → Sleeve (3) → Spool (4) → Sleeve (3) → Port L → Steering Cylinders. Then, the steering cylinders are operated so that the machine is turned to the left. 3. The return oil from the steering cylinders flows back to the hydraulic oil tank as follow: Housing (1) → Sleeve (3)→ Spool (4) → Sleeve (3) → Port T



4. When the pressure oil from the steering pump is routed through gerotor (8), gerotor (8) is rotated counterclockwise. The rotation of gerotor is transferred to sleeve (3) via drive (7), causing sleeve (3) to rotate to counterclockwise. When sleeve (3) is rotated by the same angle as spool (4) is rotated, the oil passage between sleeve (3) and spool (4) is closed so that the steering cylinder operation is stopped. Accordingly, gerotor (8) is rotated corresponding to the rotation of the steering wheel. Therefore the steering cylinders are operated corresponding to the rotation of the steering wheel.



Port R



Port L Overload Relief Valve



Relief Valve Make-Up Valve



Port T



1



8



Port P



Hydraulic Oil Tank



Steering Pump



7



4



2



3



T1F3-03-07-006



T3-7-6



COMPONENT OPERATION / Steering Valve Right Steering When the steering wheel is turned clockwise, the pressure oil from the steering pump as follows: Port P → Port R → Steering Cylinder The steering cylinders are operated so that the front wheel is turned to the right. The return oil from the steering cylinder flows back to the hydraulic oil tank via port L and port T.



T



L



R



P



T487-03-02-010



T



In Neutral When the steering wheel is in neutral, the pressure oil from the steering pump is routed to port T on the steering valve. However, port P is blocked by spool (4) so that the pressure oil cannot flow to the steering cylinders. Then, the steering cylinders are inoperative.



When Steering Pump Stops (When Engine Stops): When the steering wheel is turned to a certain angle, spool (4) touches pin (5), so that drive (7) rotates. Drive (7) rotates gerotor (8), and functions as the hand pump to send the oil to the steering cylinder. The oil is inhaled up from the tank port via the check valve. As results, the steering operation is performed even if the steering pump is completely stopped.



P



4



T



T487-03-02-011



Check Valve



4



5



T3-7-7



7



8



T1F3-03-07-002



COMPONENT OPERATION / Steering Valve RELIEF VALVE The relief valve is located in the steering valve, preventing the circuit oil pressure between the steering pump and the steering valve from increasing more than the set pressure. Thereby, oil leakage from hoses and pipe joints and damage to the actuators are prevented. Operation 1. The pressure oil from the steering pump acts on the poppet through the hole in the seat. 2. When the pressure oil from the steering pump increases more than the spring set-force, the poppet is unseated, allowing the pressure oil to flow to the hydraulic oil tank through around the outer diameter of the poppet.



3. Thereby, the main circuit pressure is reduced. 4. When the main circuit pressure is reduced to the specified pressure, the poppet is closed by the spring.



Relief Valve



Spring



Poppet Seat



Hydraulic Oil Tank



T1F3-03-07-010



Steering Pump



T1F3-03-07-008



T3-7-8



COMPONENT OPERATION / Steering Valve OVERLOAD RELIEF VALVE



MAKE-UP VALVE



The overload relief valves are located in the steering valve, preventing the circuit oil pressure between the steering cylinders and the steering valve from increasing more than the set pressure.



The make-up valves are located in the steering valve. If the circuit oil pressure between the steering cylinders and the steering valve decreases below the pressure in the hydraulic oil tank, the make-up valve draws the hydraulic oil through port T to prevent cavitation.



Operation: 1. In case an external force is applied in the left steering direction as illustrated below, surge oil pressure is developed in the circuit. 2. If the circuit pressure increases more than the set pressure in the overload relief valve, the ball and holder in the overload relief valve are moved upward so that the pressure oil is routed to the hydraulic oil tank via the oil passage around the holder. 3. When the circuit oil pressure decreases, the ball and holder are moved downward by the spring force, closing the overload relief valve.



Steering Cylinder



Overload Valve



Operation: 1. If the circuit oil pressure between the steering cylinders and the steering valve decreases below the pressure in the hydraulic oil tank, the pressure oil from port T moves the ball in the make-up valve upward, allowing the pressure oil to flow into the circuit between the steering cylinders and the steering valve. 2. When the circuit oil pressure increases, the ball is moved downward by the pressure oil, closing the make-up valve.



Relief Spring Holder Ball



Steering Valve



Orifice



T1F3-03-07-009



Make-Up Valve Ball Port T



Hydraulic Oil Tank Steering Pump



T1F3-03-07-007



T3-7-9



COMPONENT OPERATION / Steering Valve (Blank)



T3-7-10



COMPONENT OPERATION / Brake Valve OUTLINE The brake valve is operated with the brake pedal and the brake switch (work brake). (Refer to the descriptions for the valve and work brake control in the Control System Group in the Brake Switch: System Section.) The brake valve delivers pilot oil pressure in proportion to the brake pedal stroke which in turn activates both the front and rear wheel brakes. In addition, when the brake switch is turned to the work brake position, the pilot pressure from solenoid valve unit (SG) shifts the brake valve so that the brake is constantly activated.



Brake Pedal



Brake Valve



T1F3-03-09-001



T3-8-1



COMPONENT OPERATION / Brake Valve OPERATION



• When the pedal is operated: Output Diagram: Range A to B (Neutral) 1. When brake pedal (1) is not stepped on, spool (10) is pushed toward the left by spring (12) via retainer (11). 2. Therefore, piston (13) is moved toward the left by spool (10). 3. Spool (7) is pushed toward the left by spring (9) via retainer (8) together with the reaction force of spring (14). 4. Thereby, the balance spring is pushed toward the left. 5. Push rod (2) and pilot piston (3) are held toward the left by balance spring (6) via retainers (4 and 15). 6. Accordingly, when neutral, spools (7 and 10) completely block the pressure oil flow from ports PA and PB. Since ports BA and BB are connected to port T through the outer diameter around spools (7 and 10), the oil pressure at ports BA and BB becomes equal to the tank port T pressure. 7. When brake pedal (1) is slightly stepped on, push rod (2) and pilot piston (3) are moved in so that push rod (2), pilot piston (3), retainers (4 and 15) are moved as one assembly, pushing return spring (5) and balance spring (6) toward the right. 8. As the pressure at ports BA and BB is equal to the port T pressure and the resultant spring force [springs (9, 12, and 14)] pushing spools (7 and 10) toward the left is less than balance spring (6) force, spools (7 and 10) are moved toward the right. 9. This condition is kept maintained until notches on spool (7 and 10) become connected to ports BA and BB.



T3-8-2



D Pilot Pressure



C A B Pedal Stroke T1F3-03-09-004



COMPONENT OPERATION / Brake Valve



1



Port PP



3



2



15



2



1



5



4



8



10 11 12



9 Port BB



T1F3-03-09-002



Port T



14



4



3



7



6 Port BA



5



Port PA



6 Notch



7



13



Port PB



9 Notch



10



12



14



15



T1F3-03-09-002



Port BA (to the rear wheel brakes)



Port PP



1



Port BB (to the front wheel brakes)



12



2



1234-



Brake pedal Push Rod Pilot Piston Retainer



5678-



6



Return Spring Balance Spring Spool Retainer



7



Port PA



910 11 12 -



T3-8-3



14



Spring Spool Retainer Spring



10 Port PB



Port T



13 - Plunger 14 - Spring 15 - Retainer



T1F3-03-09-003



COMPONENT OPERATION / Brake Valve Output Diagram: Range C to D 1. When brake pedal (1) is further pressed, moving rod (2) and pilot piston (3), notches on spools (7 and 10) are connected to ports BA and BB, allowing pressure oil to flow in port BA and BB from ports PA and PB. 2. Oil pressure in ports BA and BB is routed into the inside of spools (7 and 10) through each spool hole, pushing each spool toward the left. 3. Until the force pushing spools (7 and 10) toward the left increases more than balance spring (6) force, balance spring will not be compressed. Therefore, spools (7 and 10) cannot move so that oil pressure in port BA and BB continues to increase. 4. As oil pressure in ports BA and BB increases further, the force pushing spools (7 and 10) toward the left increases. When this force overcomes balance spring (6) force, spools (7 and 10) compresses balance spring (6), causing balance spring (6) to move toward the left. 5. When spools (7 and 10) are moved toward the left, the notches are closed, blocking pressure oil flow to ports BA and BB from ports PA and PB. Thereby, oil pressure in ports BA and BB stops increasing. 6. As described above, balance spring (6) is compressed by the stroke of spools (7 and 10). During this operation, spring force increases in proportion to force to push spools (7 and 10). Oil pressure creating this force is equal to the oil pressure in ports BA and BB.



T3-8-4



D Pilot Pressure



C A B



Pedal Stroke T1F3-03-09-004



COMPONENT OPERATION / Brake Valve



Port BA



1



2



6



Port PP



3



Port BB



7



10



T1F3-03-09-002



Port T



10



Port BB



Notch



10



From Port PB



Port PB



Port PA



Port BB



Notch



Hole T1F3-03-09-005



T1F3-03-09-006



1 - Brake Pedal 2 - Push Rod



36-



Pilot Piston Balance Spring



7 - Spool



T3-8-5



10 - Spool



COMPONENT OPERATION / Brake Valve • When the work brake is operated: NOTE: The brake operates using the same mechanism as brake pedal (1) is stepped on except that the pilot oil pressure is routed from port PP. 1. The pilot oil pressure from port PP is routed into the pilot chamber in push rod (2) through the hole in push rod (2). 2. Then, the pilot oil pressure acts on the head of pilot piston (3). 3. When the pilot oil pressure force overcomes balance spring (6) force, pilot piston (3) is moved to the right. 4. While compressing balance spring (6) via retainer (15), pilot piston (3) moves pistons (7 and 10) to the right. 5. When spools (7 and 10) are moved until the notch on each spool is connected to port PA and port PB, the pressure oil is allowed to flow into port BA and BB from ports PA and PB. 6. Consequently, the brake is operated.



T3-8-6



COMPONENT OPERATION / Brake Valve



1



15



2



36-



Pilot Piston Balance Spring



Port BA



7



Port BB



10



T1F3-03-09-002



Port T



3



7



15



7 - Spool 10 - Spool



T3-8-7



Port PB



Port PA



Pilot Chamber Port PP



Hole



1 - Brake Pedal 2 - Push Rod



6



Port PP



3



2



Notch



6



10



Port PA



Notch



Port PB



15 - Retainer



T1F3-03-09-002



COMPONENT OPERATION / Brake Valve (Blank)



T3-8-8



COMPONENT OPERATION / Transmission Control Valve OUTLINE The transmission control valve consists of the parking brake solenoid valve, transmission changeover solenoid valve, reducing valve, and relief valve.



• Parking Brake Solenoid Valve



Operates when the brake switch is turned to the parking brake position so that the spool is moved to completely block the pressure oil flow from the pilot pump. • Transmission Changeover Solenoid Valve Operates when the travel mode switch is operated so that the spool is moved to change the travel mode control pilot oil port. (Refer to the SYSTEM / Control System group for Control of Parking Brake Solenoid Valve and Transmission Changeover Solenoid Valve.)



• Reducing Valve and Relief Valve



Maintains the circuit oil pressure constant by reducing or relieving the pressure when the oil pressure from the pilot pump increases to more than the set-pressure.



A Parking Brake Solenoid Valve



View A



Relief Valve



Transmission Changeover Solenoid Valve



Reducing Valve



Reducing Valve



Relief Valve



T1F3-03-03-002



Parking Brake Solenoid Valve



T3-9-1



T1F3-03-03-001



COMPONENT OPERATION / Transmission Control Valve Component Layout 9



11



10



8 7



1



2 3



5



6



12-



Port A (To Transmission Hi Side) Port B (To Transmission Low Side)



3-



Transmission Changeover Solenoid Valve) (S1) 4 - Parking Brake Solenoid Valve (S2)



56-



Port T (To Hydraulic Oil Tank) Relief Valve (R2)



7-



Port P (From Pilot Pump)



8-



Reducing Valve (R1)



T1F3-03-03-008



4



9 - Check Valve 10 - Port DS (To Parking Brake Pressure Switch) 11 - Port S (To Accumulator)



A



View A



E



１



3



2



5



D



8 6



F B



F



C



D



E



T1F3-03-03-002



4 T1F3-03-03-001



T3-9-2



COMPONENT OPERATION / Transmission Control Valve View B



View C



4



3



3



4 6



8



7



T1F3-03-03-004



10



11



T1F3-03-03-003



Section E-E



Section D-D



9



T1F3-03-03-005



T1F3-03-03-007



Section F-F



T1F3-03-03-006



T3-9-3



COMPONENT OPERATION / Transmission Control Valve OPERATION Reducing Valve (R1) 1. Spool (3) is pushed downward with spring (1) via spring seat (2) so that spool (3) comes in contact with plug (5). 2. The pilot pressure is routed to check valve (4) after passing through notch A and the internal passage. At the same time, the pilot pressure flows through orifice (6) and is routed to the bottom side of spool (3). 3. The pressure oil opens check valve (4) and flows further to parking brake solenoid valve (S2). 4. On the other hand, when the oil pressure acting on the bottom face of spool (3) increases more than the set-pressure of spring (1), spool (3) moves upward. 5. Then, notch B is connected to the internal passage. 6. Therefore, the pressure oil is routed into spool (3) through hole C provided at notch B. Then, the pressure oil flows to the hydraulic oil tank through spool (3) and hole D. 7. Consequently, the pressure oil acting on the bottom face of spool (3) is gradually reduced, causing spool (3) to be moved downward again by spring (1) force. 8. The oil pressure from the pilot pump is reduced as previously mentioned.



1



Hole D



2



Notch A



3 To Parking Brake Solenoid Valve (S2)



From Pilot Pump



6 Hole C



5



Notch B



4



T1F3-03-03-005



1



Hole D To Hydraulic Oil Tank



3 Notch B



Hole C T1F3-03-03-010



1 - Spring 2 - Spring Seat 3 - Spool



T3-9-4



4 - Check Valve 5 - Plug 6 - Orifice



COMPONENT OPERATION / Transmission Control Valve Parking Brake Solenoid Valve (S2) 1. When the brake switch is in the parking brake position. parking brake solenoid valve (S2) is not activated so that spool (2) is not shifted, blocking the reduced oil pressure from reducing valve (R1). The oil circuits in spools (1 and 2) are opened to hydraulic oil tank via holes on each spool and the valve internal passage. 2. When the brake switch is turned to another position from the parking brake position, spool (2) is shifted downward, allowing the notch to connect to the valve internal passage. 3. Then, the pressure oil is routed to spool (1) in transmission changeover solenoid valve (S1) through the valve internal passage. At the same time, the pressure oil flows to port S (to accumulator) and port DS (to parking brake pressure switch).



Parking Brake Solenoid Valve (S2)



Transmission Changeover Solenoid Valve (S1)



Hole Hole



2 Valve Internal Passage Port T From Reducing Valve (R1)



Port A Port B



1 T1F3-03-03-007



Port S Port DS (To Parking Brake (To Accumulator) Pressure Switch)



Parking Brake Solenoid Valve (S2)



Transmission Changeover Solenoid Valve (S1)



Notch Valve Internal Passage



2



1



From Pilot Pump



Port T Port A Port B



T1F3-03-03-007



Port S Port DS (To parking Brake (To Accumulator) Pressure Switch)



T3-9-5



COMPONENT OPERATION / Transmission Control Valve Transmission Changeover Solenoid Valve (S1) 1. Shift Lever: D (Hi) When the shift lever is in the D position, no signal is sent to transmission changeover solenoid valve (S1) so that spool remains unshifted. The pressure oil from reducing valve (R1) flows to port A (transmission Hi side) through around spool (1), shifting the transmission to the FAST mode. 2. Shift Lever: L (Low) When the shift lever is in the L position, spool (1) in transmission changeover solenoid valve (S1) is moved downward so that spool (1) blocks the oil circuit between port A and the valve inner passage completely. At the same time, the valve inner passage is connected to port B. 3. Then, the pressure oil flows to port B (transmission Low side) through around spool (1), shifting the transmission to the SLOW mode.



Parking Brake Solenoid Valve (S2)



Transmission Changeover Solenoid Valve (S1) Notch Valve Internal Passage



2



1



Port T



From Pilot Pump



Port A Port B



T1F3-03-03-007



Port S Port DS (To Parking Brake (To Accumulator) Pressure Switch) Parking Brake Solenoid Valve (S2)



Transmission Changeover Solenoid Valve (S1)



Valve Internal Passage



2



1



Port T From Pilot Pump



Port A Port B



T1F3-03-03-007



Port S Port DS (To Parking Brake (To Accumulator) Pressure Switch)



T3-9-6



COMPONENT OPERATION / Transmission Control Valve Relief Valve (R2) Accumulator



When the brake switch is turned from the parking brake position to other position, the pressure oil from the pilot pump is constantly routed to transmission changeover solenoid valve (S1), port S (to accumulator), and port DS (to parking brake pressure switch). 1. When the brake switch is turned to the parking brake position, spool (3) in parking brake solenoid valve (S2) is shifted, blocking the pressure oil from the pilot pump completely. 2. Then, the pressure oil stored in the accumulators flows to spool (2) in relief valve (R2) through port S and valve inner passage A. 3. When the oil pressure increases to more than set pressure [spring (1) force] in relief valve (R2), spool (2) moves upward while compressing spring (1). 4. Thereby, the hole on spool (2) is connected to valve inner passage B so that the pressure oil flows to port T (hydraulic oil tank) through valve inner passage B and spool (2). 5. Then, spool (2) is move downward again by spring (1) force. 6. Accordingly, the circuit pressure is maintained to the pressure set by relief valve (R2).



Parking Brake Solenoid Valve (S2) (Parking Position) S



Pilot Pump



To Parking Brake Pressure Switch Transmission DS Changeover Solenoid Valve (S1) (D (Hi) Position) To Transmission Hi Side



P



To Transmission Low Side



Valve Inner Passage A Relief Valve (R2) T Hydraulic Oil Tank



T1F3-03-03-009



Parking Brake Solenoid Valve (S2) Relief Valve (R2)



1 3



Port T (To Hydraulic Oil Tank) Valve Inner Passage B



From Pilot Pump Port S (From Accumulator)



2



Valve Inner Passage A



T3-9-7



T1F3-03-03-006



COMPONENT OPERATION / Transmission Control Valve (Blank)



T3-9-8



COMPONENT OPERATION / Others (Upperstructure) PILOT SHUT-OFF VALVE The pilot shut-off valve is a manual-operated switch valve. The spool in the pilot shut-off valve is rotated by moving the pilot control shut-off lever to turn on or off the pilot oil flow to the pilot valves.



• When Pilot Control Shut-Off Lever is in UNLOCK



Position The pilot shut-off valve is set in the ON position. The pressure oil from the pilot pump to flow into the pilot valves as the drain circuit is blocked. If the control lever is operated, the pilot valve works.



NOTE: The pressure oil is constantly supplied to the travel pilot valve irrespective of whether the pilot shut-off valve is ON or OFF.



• When Pilot Control Shut-Off Lever is in LOCK Position. The pilot shut-off valve is set in the OFF position. The pressure oil from the pilot pump does not flow into the pilot valves, but it is routed to the signal control valve. The pilot oil on the pilot valve side is routed to the hydraulic tank. The pilot valve does not work even if control lever is operated.



Section Z-Z



From Pilot Valve



A2



A1



To Signal Control Valve



T178-03-07-002



Z



Z



T1



T2



T3



A3



A4



T4



P



A5



T178-03-07-003



A1 - Left Pilot Valve



A4 - Plug



A2 - Right/Blade/Stabilizer Pilot Valve A3 - Positioning/Auxiliary Pilot Valve



A5 - Signal Control Valve (Port PI) P - Primary Pilot Pressure



T1 - Positioning/Auxiliary Pilot Valve T2 - Left Pilot Valve T3 - Right/Blade/Stabilizer Pilot Valve



T3-10-1



T4- Hydraulic Oil Tank



COMPONENT OPERATION / Others (Upperstructure) SOLENOID VALVE UNIT This machine is equipped with the 4-unit solenoid valve for valve control and the 3-unit solenoid valve for pump control, the 2-unit solenoid valve (optional) for auxiliary flow rate control, and the 2-unit solenoid valve (optional) for blade/stabilizer control. (Refer to the SYSTEM / Control System group for regulation of each solenoid valve.)



SC



SE



SI



SG



Solenoid Valve Unit The solenoid valve unit consists of four (SC, SE, SI, and SG) proportional solenoid valves and controls the control valve, the check valve (axle lock cylinder), the travel motor valve and brake valve in response to the signals from the MC (main controller). SC : Controls the arm regenerative valve in the control valve. SE : Controls the check valve (axle lock cylinder). SI : Controls the travel motor displacement angle control valve. SG : Controls the brake valve.



T1F3-03-10-017



Max. Pump 1 Flow Rate Shift Solenoid Valve



Max. Pump 2 Flow Rate Limit Solenoid Valve



Max. Pump 1 Flow Rate Limit Solenoid Valve



3-Unit Solenoid Valve (Pump Control) The 3-unit solenoid valve for pump control consists of the maximum pump 1 flow rate shift solenoid valve, the maximum pump 1 flow rate limit solenoid valve and the maximum pump 2 flow rate limit solenoid valve. Each solenoid valve is a proportional type solenoid valve and controls the pump flow rate in response to the signals from the MC. NOTE: Although the maximum pump 1 flow rate shift solenoid valve is the proportional type solenoid valve, it is used as the ON/OFF solenoid valve.



T1F3-03-10-016



T3-10-2



COMPONENT OPERATION / Others (Upperstructure) 2-Unit Solenoid Valve (Auxiliary Flow Rate Control) (Optional) The 2-unit auxiliary flow rate control solenoid valve consists of the auxiliary flow combiner solenoid valve and the auxiliary flow rate control solenoid valve. The auxiliary flow combiner solenoid valve is an ON/OFF type solenoid valve and shifts the control valve auxiliary flow combiner valve in response to the optional switch operation. The auxiliary flow rate control solenoid valve is a proportional type solenoid valve and shifts the auxiliary flow rate control valve in response to the signals from the MC.



Auxiliary Flow Combiner Valve



Auxiliary Flow Rate Control Solenoid Valve



T1GL-03-10-002



Blade/Stabilizer Solenoid Valve



2-Unit Solenoid Valve (Blade/Stabilizer Control) (Optional) The 2-unit solenoid for blade/stabilizer control is an ON/OFF type solenoid valve and opens the check valve (blade/stabilizer) when the signal arrives from the control switch.



T1F3-03-08-001



T3-10-3



COMPONENT OPERATION / Others (Upperstructure) Proportional Solenoid Valve Upon receiving an electric current signal from the MC, the proportional solenoid valve outputs hydraulic pressure proportional to the degree of the electric current. • When not energized (In neutral): 1. Spring (2) pushes spool (1) to the right, connecting the output port S to the tank port T.



T



S



P



1



• When energized: 1. Solenoid (3) pushes spool (1) to the left for a distance proportional to the electric current flowing through solenoid (3). 2. Pilot oil from port P flows into output port S, increasing the pressure at output port S. 3. The pressure at port S acts on the two banks of walls on spool (1). (See detail “a.”) Because of the pressure receiving area difference between the two walls, the pressure at port S acts as a force to push spool (1) to the right. 4. As the pressure at port S increases, the force to push spool (1) to the right also increases. When this force overcomes the force to push spool (1) to the left by solenoid (3), spool (1) moves back to the right side, closing the passage between output port S and port P. As a result, pressure increase at port S stops.



2



3



a



a T107-02-07-005



T3-10-4



COMPONENT OPERATION / Others (Upperstructure) ON/OFF Solenoid Valve The ON/OFF solenoid valve is used to switch the pilot pressure by switching the brake switch and each control switch.



• When not energized (In Neutral): Spool (1) is pushed to the right by spring (2). Output port S is connected to tank port T. • When energized: As solenoid (3) energized, spool (1) is pushed to the left. Pilot port P is connected to output port S, and the tank port T is blocked.



3 P



1



1 - Spool



2 - Spring



S



T



2



T105-02-11-010



3 - Solenoid



T3-10-5



COMPONENT OPERATION / Others (Upperstructure) TRAVEL SHOCKLESS VALVE The travel shockless valve is located between the travel pilot valve and the signal control valve, preventing the travel spool from quickly returning so that the occurrence of cavitation in the travel motor is reduced. In addition, the travel shockless valve is provided with two solenoid valves, one each in the forward and the reverse circuits to restrict travel operation. (See the SYSTEM / Control System group.)



• Shockless Operation: 1. The return oil from the control valve is routed to port B1 or B2 on the travel shockless valve via the signal control valve. 2. As the return oil closes check valve (3), the return oil is routed to orifice (4). When the return oil passes the orifice, the differential pressure is developed. 3. Then, the return oil flows back to the hydraulic oil tank after passing through spool (2) in the solenoid valve and the travel pilot valve. 4. Therefore, the travel spool in the control valve is slowly returned.



Travel Pilot Valve



1



1



2



A2



A1



T



Hydraulic Oil Tank



3



3



4



4 B2



B1



Travel Shockless Valve From Signal Control Valve



• Travel Operation Restriction:



2



1. When the solenoid valve is magnetized, spool (2) compresses spring (1) while moving downward. 2. Spool (2) completely blocks the pressure oil flow from port A1 or port A2. 3. Consequently, even if the travel pilot valve is operated, the travel system cannot be operated. The return oil from the signal control valve flows to port T (hydraulic oil tank) through around spool (2) at this time.



T1GL-03-10-006



Travel Pilot Valve



1



1



2



A2



A1



2



T



Hydraulic Oil Tank



3



3



4



4 B2



B1



Travel Shockless Valve From Signal Control Valve



T3-10-6



T1GL-03-10-007



COMPONENT OPERATION / Others (Upperstructure) a



a1



Port T (To Hydraulic Oil Tank) Check Valve



Check Valve



b



b



Port B1



Port B2



a



a1



T1F3-03-08-004



Shockless Operation Crosse Section b-b



Cross Section a-a, a1-a1



2 2 3



2 4



4



B2 From Signal Control Valve



B1



To Travel A Pilot Valve



T1F3-03-08-006



From Signal Control Valve



T1F3-03-08-005



3



Travel Operation Restriction Cross Section a-a, a1-a1



Cross Section b-b



2 2 2 Port T (To Hydraulic Oil Tank)



4



4



From A Travel Pilot Valve B2



1



T1F3-03-08-005



T3-10-7



From Signal Control Valve



B1 From Signal Control Valve



T1F3-03-08-006



COMPONENT OPERATION / Others (Upperstructure) PILOT RELIEF VALVE The pilot relief valve consists of the relief valve and the check valve. The relief valve maintains the pilot circuit pressure constant. The check valve blocks the return oil from the accumulator.



A



T1F3-03-08-008



Section A Check Valve



• Relief Operation: 1. The pressure oil from the pilot pump acts constantly on the pilot relief valve spool. At the same time, the pressure oil acts on the bottom of the spool through the hole in the spool. 2. When the oil pressure force overcomes the spring force, the spool is moved upward while compressing the spring. 3. Accordingly, the pressure oil is returned to the hydraulic oil tank.



From Pilot Pump



T1F3-03-08-003



Relief Valve



Spring



To Hydraulic Oil Tank



From Pilot Pump



Hole



T3-10-8



Spool



T1F3-03-08-002



COMPONENT OPERATION / Others (Upperstructure) ACCUMULATOR The accumulators are provided in the pilot circuits for the brake valve, the pilot relief valve, and the transmission control valve. The accumulator is charged with high pressure nitrogen gas. The oil pressure from the pilot pump compresses the nitrogen gas via the film. The compressed gaseous nitrogen maintains each circuit oil pressure constant.



Nitrogen Gas



Film



T1F3-03-08-007



From Pilot Pump



T3-10-9



COMPONENT OPERATION / Others (Upperstructure) ACCUMULATOR CHARGING VALVE The accumulator charging valve is located between the pilot pump and the brake valve circuit. The accumulator charging valve functions to give the pressure oil priority to flow to the brake circuit and simultaneously charges the accumulator in the brake circuit with the pressure oil. In addition, after charging the accumulator, the valve allows the pressure oil to flow to the pilot circuit. (Refer to the SYSTEM / Hydraulic System group.)



9



• Charging Pressure:



To Pilot Relief Valve



8



To Pressure Sensor



N



S1 S2



NOTE: Usually, the pressure oil from port P opens compensation plunger (8) so that the pressure oil flows to port N.



Pilot Pump



1. When the oil pressure in the brake circuit (accumulator) is reduced, the pressure oil from port P is routed into the sleeve through orifice (5). Then, the pressure oil flows to spool (1) through around check valve (6), holes on sleeve (10), and passage (3). 2. The pressure oil is routed onto the end face of compensator plunger (8) through around spool (1) and passage (9). 3. Then, compensator plunger (8) is moved downward, blocking the oil flow to port N. Thereby, the oil pressure in port P gradually increases. 4. When the oil pressure in port P overcomes spring (7) force, the pressure oil opens check valve (6) so that the pressure oil flows to port S2. 5. As mentioned above, the pressure oil flows to the brake circuit and simultaneously starts charging the accumulator.



To Brake Circuit (Accumulator)



P



10 1



7



T



6



5



4



Hydraulic Oil Pump



3



2 T1GL-03-10-003



S2 P



T1GL-03-10-003



12345-



T3-10-10



Spool Spring Passage Passage Orifice



678910 -



Check Valve Spring Compensator Plunger Passage Sleeve



COMPONENT OPERATION / Others (Upperstructure)



2



4



T



1



N



9



3



8



7



7



S2



S2



5 P Hole



1 - Spool 2 - Spring 3 - Passage



P



T1GL-03-10-008



10



6



6 4 - Passage 5 - Orifice



T1GL-03-10-004



67-



Check Valve Spring



T3-10-11



8 - Compensator Plunger 9 - Passage 10 - Sleeve



COMPONENT OPERATION / Others (Upperstructure) • Stopping to Charge (Holding) Pressure: 1. When the charged pressure in the accumulator reaches the saturation pressure (cutout pressure), the pressure in port P increases again. 2. The pressure oil acts on the poppet in the piston. When this pressure overcomes spring (2) force, the poppet and spool (1) are moved to the direction of arrow. 3. When the notch on spool (1) is connected to passage (9), the oil pressure in passage (9) [pushing compensator plunger (8) downward] flows to port T through the notch on spool (1). 4. Therefore, the pressure oil in passage (9) becomes equal to that in port T, allowing the oil pressure in port P to open compensator plunger (8) so that the pressure oil flows from port P to port N. 5. Accordingly, the oil pressure in port P is reduced to lower than port S2. Then, spool (1) is again moved to the direction of arrow by spring (2) force, blocking the oil flow from passage (9) to port T. 6. At the same time, check valve (6) is closed so that port P is disconnected from port S2. 7. Consequently, the oil pressure in the brake circuit (accumulator) is maintained.



9



To Pilot Relief Valve



8



To Pressure Sensor



N



S1 S2 To Brake Circuit (Accumulator)



P



Pilot Pump



1



7



T



6



5



4



Hydraulic Oil Tank



3



2 T1GL-03-10-003



N S2



T T1GL-03-10-005



12345-



T3-10-12



Spool Spring Passage Passage Orifice



6789-



Check Valve Spring Compensator Plunger Passage



COMPONENT OPERATION / Others (Upperstructure)



2



4



2 1



T



T N



9



N



1 Notch



9



Poppet



8



Piston



8



3 7 S2



S2



5 P Hole



123-



Spool Spring Passage



P



T1GL-03-10-009



6



T1GL-03-10-010



6 45-



Passage Orifice



67-



Check Valve Spring



T3-10-13



89-



Compensator Plunger Passage



COMPONENT OPERATION / Others (Upperstructure) HOSE-RUPTURE SAFETY VALVE The hose-rupture safety valves function to hold the front attachment in position if any hose for the front attachment is punctured accidentally. The hose-rupture safety valves are attached to the bottom side of the boom cylinder, the rod side of the arm cylinder, and the rod side of the positioning cylinder. NOTE: The following explanation will be made about the hose-rupture safety valve for the boom cylinder as an instance.



Chamber a Passage c



Passage b



• Hose-rupture safety valve operation when the



control lever is in neutral. 1. Because the pilot pressure Pi does not act on the spool, the spool remains in neutral. 2. The cylinder-holding pressure at the cylinder port B is applied to the poppet and to the spool through passage c. 3. The cylinder-holding pressure, after passing through passage c, is blocked by the spool. The pressure in the chamber a is applied to the spool through passage c, but not transmitted to passage a by blocking with the spool. 4. As a result, the cylinder pressure at cylinder port B is maintained unchanged. Therefore, even if any hose at the front attachment is punctured, the front attachment is held in position to avoid unintended lowering.



T3-10-14



Pilot Pressure Pi Port B Port A



Spool To the Spool in the Control Valve



Poppet



Passage a T178-03-07-006



COMPONENT OPERATION / Others (Upperstructure)



X



Section X-X



Passage a



Passage b



Spool Passage c Chamber a



Poppet



Port A



Port B



X



T178-03-07-008



T3-10-15



COMPONENT OPERATION / Others (Upperstructure) • Hose-rupture safety valve operation when the boom



lower control lever is operated 1. When moving the boom lower control lever at half stroke or less, the pilot pressure Pi acts on the spool, and makes the spool move to the orifice B position. 2. At this time, the spool blocks passage B, so that the poppet is pushed against the seat. 3. As a result, the pressurized oil from the port B flows through passages c and a in order to lower the boom. 4. When moving the boom lower control lever at half stroke or more, the pilot pressure Pi acts on the spool, and makes the spool shift to the orifice C position. 5. Then, passages b and a are connected through orifice C. At this time, an oil passage, from port B to orifice A to chamber a to passage b to orifice C to passage a to port A, is opened. 6. The oil from passage c is blocked by the spool, so that the oil does not flow into passage a. 7. The pressure in the chamber a lowers, and the poppet rises accordingly, so that the return oil from the cylinder port B flows into port A through the poppet to lower the boom.



The Boom Lower Control Lever: Half Stroke or less Relief Valve



Chamber a Passage c Passage b



Orifice A Poppet



Pressure Pi Port B



Spool



Port A To the Spool in the Control Seat Valve



Passage a



Orifice B T178-03-07-009



The Boom Lower Control Lever: Half Stroke or More Chamber a Passage c Passage b



Relief Valve



Passage A



Orifice C Pressure Pi



Port B



Spool Port A



T3-10-16



To the Spool Poppet in the Control Valve



Passage a T178-03-07-007



COMPONENT OPERATION / Others (Upperstructure)



Section X-X X



Relief Valve Passage a



Orifice B



Spool



Pressure Pi



Orifice C Passage c



Passage b Chamber a Spring Orifice A



From Port B Poppet Port A



Port B



X



T178-03-07-008



T3-10-17



COMPONENT OPERATION / Others (Upperstructure) EC MOTOR The EC motor is used to control engine speed. A worm gear is incorporated into the EC motor to prevent a loss of synchronism from occurring. The EC sensor is provided to detect the degrees of the EC motor rotation to calculate the governor lever position. (Refer to the Control System Group in SYSTEM Section.)



Output Gear



Output Shaft



Worm Gear



Motor



Sensor Gear



EC Sensor



Worm Wheel T157-02-05-018



T3-10-18



COMPONENT OPERATION / Others (Undercarriage) SWING BEARING This bearing is a single-row shear ball-type bearing, comprising outer race (1), inner race (3), balls (6), supports (5), and seals (2), (4). Outer race (1) is bolted to the upperstructure and inner race (3) is bolted to the undercarriage.



The internal gear of inner race (3) engages with the output shaft of the swing reduction gear.



1



2



5



3



4 6



T135-03-02-001



1 - Outer Race 2 - Seal



3 - Inner Race 4 - Seal



5 - Support



T3-11-1



6 - Ball



COMPONENT OPERATION / Others (Undercarriage) CENTER JOINT The pressure oil flows through the spindle to each port on the body. Then, the pressure oil is routed to the travel motors, the transmission, the front and rear wheel brakes, the check valve (blade/stabilizer), the steering cylinders, the 2-unit solenoid valve (blade/stabilizer), the stabilizer cylinders, and the blade cylinders. 9 15



Spindle



10



1



3 4



11



8 5



14 13



2



7



12



5



Body



6



9



3 Seal



14



8 4 1



6



2



10



7 Seal



12



11



13



T1F3-03-10-001



1 - Port 7: Travel Motor Displacement Angle Control Pilot Pressure 2 - Port 9: To Left Steering Cylinder



6-



Port 8: To Right Steering Cylinder



7-



Port 11: Transmission Hi Mode Shift Pilot Pressure 8 - Port 5: To Travel Forward



3 - Port 3: To Blade/Stabilizer Cylinder Rod (Raise) Side 4 - Port 6: To Axle Lock Cylinder



9-



5 - Port 1: To Blade/Stabilizer Cylinder Bottom (Lower) Side



10 - Port 10: Check Valve for Axle Lock Cylinder Control Pilot Pressure



Port 2: To Travel Reverse



T3-11-2



11 - Port 14: Transmission Low Mode Shift Pilot Pressure 12 - Port 12: To Rear Wheel Brake 13 - Port 13 To Front Wheel Brake 14 - Port 4: Check Valve for Blade/Stabilizer Cylinder Control Pilot Pressure 15 - Port D: To Hydraulic Oil Tank



COMPONENT OPERATION / Others (Undercarriage) SLIP RING The slip ring is installed on the upper part of the center joint. The slip ring is a joint which rotates 360°. When the upperstructure rotates, it transmits the current to the undercarriage while preventing the wiring from twisting. Also, it transmits the detected figures from sensors installed on the undercarriage to the upperstructure.



Center Joint



Slip Ling



Spindle



T1F3-03-10-015 T1F3-03-10-014



T3-11-3



COMPONENT OPERATION / Others (Undercarriage) (Blank)



T3-11-4



COMPONENT OPERATION / Others (Undercarriage) CYLINDER The axle lock cylinders, the stabilizer cylinders and the blade cylinders are mounted on the track frame. Each cylinder consists of the cylinder section and the check valve section.



Axle Lock Cylinder A



Blade/Stabilizer Cylinder



Check Valve



B



B A



B



B Check Valve T1F3-03-10-004



T1F3-03-10-005



Section B-B



Section A-A



Check Valve



T1F3-03-10-002



Check Valve



T3-11-5



T1F3-03-10-003



COMPONENT OPERATION / Others (Undercarriage) Check Valve (Axle Lock Cylinder) • When releasing the axle lock: NOTE: When the brake switch is turned OFF, the solenoid valve unit (SE) is activated. (Refer to the SYSTEM / Control System group.)



3. Consequently, the pressure oil in both right and left axle lock cylinders can move freely between them and to the hydraulic oil tank, allowing the axle lock cylinders to oscillate.



1. When the solenoid valve unit (SE) is activated, the pressure oil from the pilot pump is routed into port P of the check valve so that the pressure oil acts on the piston, causing the piston to move to the right. 2. The piston pushes the poppet and the check valve to the right, connecting port A (axle lock cylinder) to port T (hydraulic oil tank).



NOTE: The reaction loads from the travel road surface are absorbed by oscillation of both right and left axle lock cylinders. (Refer to the SYSTEM / Control System group.)



Check Valve T P



Axle Lock Cylinder



A



Solenoid Valve Unit



Pilot Pump



Solenoid Valve Unit (SE) Hydraulic Oil Tank



T1F3-03-10-008



Piston



Check Valve



Poppet



Check Valve



P



T Pilot Pump Hydraulic Oil Tank



A



Axle Lock Cylinder T1F3-03-10-006



T3-11-6



COMPONENT OPERATION / Others (Undercarriage) • When operating the axle lock: NOTE: When the brake switch is in the work brake, parking brake, or axle lock position, the solenoid valve unit (SE) is deactivated. (Refer to the SYSTEM / Control System group.) 1. The pressure oil from the pilot pump is blocked by the axle lock solenoid valve spool.



2. As long as the check valve is kept opened, the oil pressure in port A is equal to that in port T. Thereby, the poppet and the check valve in the check valve is moved to the left by spring force. 3. Therefore, port A (axle lock cylinder) on check valve is disconnected from port T (hydraulic oil tank). 4. Consequently, The pressure oil is enclosed in the axle lock cylinder so that the axle is locked.



Check Valve T P



Axle Lock Cylinder



A



Solenoid Valve Unit



Pilot Pump Solenoid Valve Unit (SE) Hydraulic Oil Tank T1F3-03-10-009



Piston



Check Valve



Poppet



P



Spring



Check Valve



T



A Axle Lock Cylinder



Hydraulic Oil Tank



T1F3-03-10-011



T3-11-7



COMPONENT OPERATION / Others (Undercarriage) Check Valve (Blade/Stabilizer Cylinder) • When operating the blade/stabilizer: NOTE: When the blade/stabilizer control switch is operated, the 2-unit solenoid valve (blade/stabilizer) is activated. (Refer to the SYSTEM / Control System group.)



2. The piston pushes the poppet and the check valve to the right, connecting port V to port C. 3. Then, the pressure oil from main pump 1 flows to either the rod or bottom side of blade/stabilizer cylinder via port V and port C on the check valve, causing the cylinder to extend or retract.



1. When the blade/stabilizer 2-unit solenoid valve is shifted, the pressure oil from the pilot pump is routed to port P on the check valve so that the piston is moved to the right.



Blade/Stabilizer Cylinder



2-Unit Solenoid Valve



C



P



Pilot Pump Hydraulic Oil Tank



Check Valve



V



Main Pump 1



T



T1F3-03-10-010



Blade/Stabilizer Cylinder



Hydraulic Oil Tank



C



Check Valve P



V Check Valve



Piston Pilot Pump



Main Pump 1



T3-11-8



Poppet T1F3-03-10-007



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Hitachi Construction Machinery Co. Ltd Attn: Publications, Marketing & Product Support Fax: 81-298-31-1162



Hitachi Ref. No.



SERVICE MANUAL REVISION REQUEST FORM NAME OF COMPANY:



MODEL: PUBLICATION NO.:



YOUR NAME: DATE: FAX:



(Located at the right top corner in the cover page)



PAGE NO.: (Located at the bottom center in the page. If two or more revisions are requested, use the comment column)



YOUR COMMENTS / SUGGESTIONS: Attach photo or sketch if required. If your need more space, please use another sheet.



REPLY:



(Copy this form for usage)



Technical Manual (Troubleshooting)



Vol No.: TTCBBE-00



INTRODUCTION TO THE READER • This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine. • Be sure to thoroughly read this manual for correct product information and service procedures.



• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.): Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-298-32-7173 FAX: 81-298-31-1162



ADDITIONAL REFERENCES • Please refer to the materials listed below in addition to this manual. • The Operator’s Manual • The Parts Catalog



• Operation Manual of the Engine • Parts Catalog of the Engine • Hitachi Training Material



MANUAL COMPOSITION • This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual. • Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.



IN-01



• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures. • Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/disassemble procedures.



INTRODUCTION PAGE NUMBER • Each page has a number, located on the center lower part of the page, and each number contains the following information: Example : T 1-3-5 Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual



W: Workshop Manual



SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.



•



CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.



• IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.



•



IN-02



NOTE: Indicates supplementary technical information or know-how.



INTRODUCTION UNITS USED • SI Units (International System of Units) are used in



Example : 24.5 MPa (250 kgf/cm2, 3560 psi)



this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units.



Quantity Length Volume



Weight Force Torque



To Convert From mm mm L L m3 kg N N N⋅m N⋅m



Into in ft US gal US qt yd3 lb kgf lbf kgf⋅m lbf⋅ft



A table for conversion from SI units to other system units is shown below for reference purposees.



Quantity



Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 1.0197 0.7375



Pressure Power Temperature Velocity Flow rate



IN-03



To Convert From MPa MPa kW kW °C km/h min-1 L/min mL/rev



Into kgf/cm2 psi PS HP °F mph rpm US gpm cc/rev



Multiply By 10.197 145.0 1.360 1.341 °C×1.8+32 0.6214 1.0 0.2642 1.0



INTRODUCTION (Blank)



IN-04



SAFETY RECOGNIZE SAFETY INFORMATION • This is the SAFETY ALERT SYMBOL. • When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. • Follow recommended precautions and safe operating practices.



001-E01A-0688 SA-688



UNDERSTAND SIGNAL WORDS • On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol. • DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. • WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. • CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. • Some safety signs don’t use any of the designated signal words above after the safety alert symbol are occasionally used on this machine. • CAUTION also calls attention to safety messages in this manual. • To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine.



•



NOTE indicates an additional explanation for an element of information. 002-E01C-1223



SA-1



SA-1223



SAFETY FOLLOW SAFETY INSTRUCTIONS • Carefully read and follow all safety signs on the machine and all safety messages in this manual.



• Safety signs should be installed, maintained and



• • •



•



replaced when necessary. • If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering). Learn how to operate the machine and its controls correctly and safely. Allow only trained, qualified, authorized personnel to operate the machine. Keep your machine in proper working condition. • Unauthorized modifications of the machine may impair its function and/or safety and affect machine life. The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine. 003-E01B-0003



SA-2



SA-003



SAFETY PREPARE FOR EMERGENCIES • Be prepared if a fire starts or if an accident occurs. • Keep a first aid kit and fire extinguisher on hand. • Thoroughly read and understand the label attached on the fire extinguisher to use it properly.



• To ensure that a fire-extinguisher can be always used when necessary, check and service the fire-extinguisher at the recommended intervals as specified in the fire-extinguisher manual. • Establish emergency procedure guidelines to cope with fires and accidents. • Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone.



SA-437



004-E01A-0437



WEAR PROTECTIVE CLOTHING • Wear close fitting clothing and safety equipment appropriate to the job. You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances. • Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine. • Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine. 005-E01A-0438



SA-3



SA-438



SAFETY PROTECT AGAINST NOISE • Prolonged exposure to loud noise can cause impairment or loss of hearing. • Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.



006-E01A-0434 SA-434



INSPECT MACHINE • Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury. • In the walk-around inspection be sure to cover all points described in the “PRE-START INSPECTION” chapter in the operator’s manual.



S007-E01A-0435 SA-435



SA-4



SAFETY GENERAL PRECAUTIONS FOR CAB • Before entering the cab, thoroughly remove all



• •



• • • •



dirt and/or oil from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal accident. Don’t leave parts and/or tools lying around the operator’s seat. Store them in their specified locations. Avoid storing transparent bottles in the cab. Don’t attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire. Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine. Keep all flammable objects and/or explosives away from the machine. After using the ashtray, always cover it to extinguish the match and/or tobacco. Don’t leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode. 524-E01A-0000



SA-5



SAFETY USE HANDHOLDS AND STEPS • Falling is one of the major causes of personal injury. • When you mounting and dismounting the machine, always face the machine and maintain a three-point contact with the steps and handrails. • Do not use any controls as hand-holds. • Never jump on or off the machine. Never mount or dismount a moving machine. • Be careful of slippery conditions on platforms, steps, and handrails when mounting and dismounting the machine. SA-439 008-E01B-0439



ADJUST THE OPERATOR'S SEAT • A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations. • The seat should be adjusted whenever changing the operator for the machine. • The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back. • If not, move the seat forward or backward, and check again. SA-378 009-E01A-0378



SA-6



SAFETY FASTEN YOUR SEAT BELT • If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death. • Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine. • Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident. • We recommend that the seat belt be replaced every three years regardless of its apparent condition.



SA-237



010-E01A-0237



MOVE AND OPERATE MACHINE SAFELY • Bystanders can be run over. • Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine. • Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move. • Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine. 011-E01A-0426



SA-7



SA-083



SAFETY OPERATE SEAT



ONLY



FROM



OPERATOR'S



• Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. • Start the engine only when seated in the operator's seat. • NEVER start the engine while standing on the track or on ground. • Do not start engine by shorting across starter terminals. • Before starting the engine, confirm that all control levers are in neutral. SA-084 012-E01B-0444



JUMP STARTING • Battery gas can explode, resulting in serious injury. • If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chapter in the operator’s manual. • The operator must be in the operator’s seat so that the machine will be under control when the engine starts. Jump starting is a two-person operation. • Never use a frozen battery. • Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine. S013-E01A-0032



SA-8



SA-032



SAFETY KEEP RIDERS OFF MACHINE • Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine. • Only the operator should be on the machine. Keep riders off. • Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner. 014-E01B-0379 SA-091



PROVIDE SIGNALS FOR FOBS INVOLVING MULTIPLE NUMBERS OF MACHINES • For jobs involving multiple numbers of machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.



018-E01A-0481 SA-481



CONFIRM DIRECTION OF MACHINE TO BE DRIVEN • Incorrect steering wheel shift lever operation may result in serious injury death. • Before driving the machine, confirm the position of the undercarriage in relation to the operator’s position. If the travel motors are located in front of the cab, the machine will move in reverse when travel pedals/levers are operated to the front. 017-E01A-0491 SA-092



SA-9



SAFETY DRIVE MACHINE SAFELY (WORK SITE) • Before driving the machine, always confirm that the steering wheel/shift lever direction corresponds to the direction you wish to drive. • Be sure to detour around any obstructions.



• Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death. • When driving up or down a slope, keep the bucket facing the direction of travel, approximately 0.5 to 1.0 m (A) above the ground. • If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.



SA-090



SA-288



• Driving across the face of a slope or steering on a slope may cause the machine to skid or overturn. If the direction must be changed, move the machine to level ground, then, change the direction to ensure sage operation.



019-E05B-0090



SA-10



SAFETY AVOID INJURY ACCI-DENTS



FROM



ROLLAWAY



• Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways: • Select level ground when possible to park machine. • Do not park the machine on a grade. • Lower the bucket and/or other work tools to the ground. • Place the shift lever in neutral, and put the brake switch in the P (parking brake) position. • Turn the auto-idle switch and the H/P mode switch off. • Run the engine at slow idle speed without load for 5 minutes to cool down the engine. • Stop the engine and remove the key from the key switch. • Pull the pilot control shut-off lever to LOCK position. • Block both tires and lower the bucket to the ground. Thrust the bucket teeth into the ground if you must park on a grade. • Position the machine to prevent rolling. • Park a reasonable distance from other machines. 020-E01A-0270



SA-11



SA-278



SAFETY AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS • If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: • Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR. • Keep the travel alarm in working condition (if equipped). ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE. • USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. Use hand signals, which conform to your local regulations, when work conditions require a signal person. • No machine motions shall be made unless signals are clearly understood by both signalman and operator. • Learn the meanings of all flags, signs, and markings used on the job and confirm who has the responsibility for signaling. • Keep windows, mirrors, and lights clean and in good condition. • Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting. • Read and understand all operating instructions in the operator’s manual. S021-E01A-0494



SA-12



SA-383



SA-384



SAFETY AVOID TIPPING DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE---SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT



• The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death.



SA-012



To avoid tipping:



• Be extra careful before operating on a grade. • Prepare machine operating area flat. • Keep the bucket low to the ground and close to the machine.



• Reduce operating speeds to avoid tipping or slipping.



• Avoid changing direction when traveling on grades.



• NEVER attempt to travel across a grade steeper than 5 degrees if crossing the grade is unavoidable. • Reduce swing speed as necessary when swinging loads. • Be careful when working on frozen ground. • Temperature increases will cause the ground to become soft and make ground travel unstable. S025-E01B-0495



SA-13



SA-562



SAFETY AVOID POWER LINES • Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines. • When operating near an electric line, NEVER move any part of the machine or load closer than 3 m (10 ft) plus twice the line insulator length. • Check and comply with any local regulations that may apply. • Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site.



SA-089



029-E01A-0381



OBJECT HANDLING • If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death. • When using the machine for craning operations, be sure to comply with all local regulations. • Do not use damaged chains or frayed cables, sables, slings, or ropes. • Before craning, position the upperstructure with the travel motors at the rear. • Move the load slowly and carefully. Never move it suddenly. • Keep all persons well away from the load. • Never move a load over a person's head. • Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground. • Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall. 032-E01A-0014



SA-14



SA-014



SAFETY PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body, serious injury may result. • Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. • Keep bystanders away from the working area before striking any object. 031-E01A-0432 SA-432



PARK MACHINE SAFELY To avoid accidents: • Park machine on a firm, level surface. • Lower bucket to the ground. • Place the shift lever in neutral, and put the brake switch in the P (parking brake) position. • Turn auto-idle switch and auto-acceleration switch off. • Run engine at slow idle speed without load for 5 minutes. • Turn key switch to OFF to stop engine. • Remove the key from the key switch. • Pull up the pilot shut-off lever further to release the catch, so that the left console can be moved upward (“CONSOLE UP” position). • Close windows, roof vent, and cab door. • Lock all access doors and compartments. 033-E07B-0093



SA-15



SA-093



SAFETY HANDLE FLUIDS SAFELY－AVOID FIRES • Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death. • Do not refuel the machine while smoking or when near open flame or sparks. • Always stop the engine before refueling the machine. • Fill the fuel tank outdoors.



• All fuels, most lubricants, and some coolants are flammable. • Store flammable fluids well away from fire hazards. • Do not incinerate or puncture pressurized containers. • Do not store oily rags; they can ignite and burn spontaneously. • Securely tighten the fuel and oil filler cap.



SA-018



034-E01A-0496



SA-019



SA-16



SAFETY SAFETY TRANSPORTING • The



danger of tipping is present when loading/unloading the machine onto/from a truck or trailer bed. • Be sure to observe local regulations when transporting the machine on public roads. • Provide an appropriate truck or trailer for transporting the machine. Take the following precautions when loading/unloading the machine: 1. Select firm level ground. 2. Be sure to use a loading dock or ramp. 3. Be sure to have a signal person when loading/unloading the machine. 4. Always turn the auto-idle switch, auto-acceleration switch and the H/P mode switch OFF when loading or unloading the machine, to avoid unexpected speed increase due to unintentional operation of a control lever. 5. Always select the slow travel with the fast/slow travel switches. 6. Avoid steering while driving up or down the ramp as it is extremely dangerous. If steering is unavoidable, first move back to the ground or flatbed, modify traveling direction, and begin to drive again. 7. Do not operate any levers besides the travel levers when driving up or down the ramp. 8. The top end of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it. 9. Prevent possible injury from machine tipping while the upperstructure is rotating. 10.Keep the arm tucked under and rotate the upperstructure slowly for best stability. 11.Turn the brake switch to the parking (P) position. Place blocks in front of and behind the tires to secure the machine. 12.Securely fasten chain or cables to the machine frame. Refer to "transporting" chapter in the operator’s manual for details. 035-E06A-0395



SA-17



Less than 15° SA-094



Less than 15° SA-095



SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents:



• Understand service procedures before doing work.



• Keep work area clean and dry. • Do not spray water or steam inside cab. • Never lubricate or service the machine while it is moving.



• Keep hands, feet and clothing away from power-driven parts.



• Before servicing the machine: 1) 2) 3) 4) 5) 6) 7) 8) 9) 10)



Park the machine on a level surface. Lower the bucket to the ground. Turn the auto-idle / acceleration selecltor off. Run the engine at slow idle speed without load for 5 minutes. Turn the key switch to OFF to stop engine. Relieve the pressure in the hydraulic system by moving the control levers several times. Remove the key from the switch. Attach a “Do Not Operate” tag on the control lever. Pull the pilot control shut-off lever to the LOCK position. Allow the engine to cool.



SA-18



SAFETY • If a maintenance procedure must be performed •



• •



• • •



• • • •



• •



with the engine running, do not leave machine unattended. If the machine must be raised, maintain a 90 to 110 angle between the boom and arm. Securely support any machine elements that must be raised for service work. Never work under a machine raised by the boom. Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter in the operator’s manual. Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris. When cleaning parts, always use nonflammable detergent oil. Never use highly frammable oil such as fuel oil and gasoline to clean parts or surfaces. Disconnect battery ground cable (-) before making adjustments to electrical systems or before welding on the machine. Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure that the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil. Sufficiently illuminate the work site. Use a maintence work light when working under or inside the machine. Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil antifreeze fluid, or window washer fluid may catch fire.



SA-028



SA-527



S500-E02B-0497



SA-037



SA-19



SAFETY WARN OTHERS OF SERVICE WORK • Unexpected machine movement can cause serious injury. • Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever. This tag is available from your authorized dealer.



SS2045102



SUPPORT MACHINE PROPERLY • Never attempt to work on the machine without securing the machine first. • Always lower the attachment 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 tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.



SA-527



519-E01A-0527



STAY CLEAR OF MOVING PARTS • Entanglement in moving parts can cause serious injury. • To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts. 502-E01A-0026



SA-026



SA-20



SAFETY PREVENT PARTS FROM FLYING • Travel reduction gears are under pressure. • As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury. GEAR OIL is hot. • Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure. 503-E03A-0344



SA-344



STORE ATTACHMENTS SAFELY • Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death. • Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas.



504-E01A-0034



SA-034



SUPPORT MAINTENANCE PROPERLY • Explosive separation of a tire and rim parts can cause serious injury or death. • Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Have it done by your authorized dealer or a qualified repair service. • Always maintain the correct tire pressure. DO NOT inflate tire above the recommended pressure. • When inflating tires, use a chip-on chuck and extension hose long enough to allow you to stand to one side and not in front of or over the tire assembly. Use a safety cage it available. • Inspect tires and wheels daily. Do not operate with low pressure, cuts bubbles, damaged rims, or missing lug bolts and nuts. • Never cut or weld on an inflated tire or rim assembly. Heat from welding could cause an increase in pressure and may result in tire explosion. 521-E02A-0249



SA-21



SA-249



SAFETY PREVENT BURNS Hot spraying fluids:



• After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. • To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap. • The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.



SA-039



Hot fluids and surfaces:



• Engine oil, gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well. • Wait for the oil and components to cool before starting any maintenance or inspection work. 505-E01B-0498



SA-225



REPLACE RUBBER HOSES PERIODICALLY • Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone. • Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator’s manual.) • Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death. S506-E01A-0019



SA-22



SA-019



SAFETY AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death. • Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. • Tighten all connections before applying pressure. • Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection. • If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.



SA-031



SA-292



507-E03A-0499



SA-044



SA-23



SAFETY PREVENT FIRES Check for Oil Leaks:



• Fuel, hydraulic oil and lubricant leaks can lead to fires. • Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts. • Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts. • Do not bend or strike high-pressure lines. • Never install bent or damaged lines, pipes, or hoses. Check for Shorts:



• Short circuits can cause fires. • Clean and tighten all electrical connections. • Check before starting work for loose, kinked, hardened or frayed electrical cables and wires.



• Check before starting work for missing or damaged terminal caps.



• DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.. Clean up Flammables:



• Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires. • Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately.



SA-24



SA-019



SAFETY Check Key Switch:



• If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting. • Always check key switch function before operating the machine every day: 1) Start the engine and run it at slow idle. 2) Turn the key switch to the OFF position to confirm that the engine stops. • If any abnormalities are found, be sure to repair them before operating the machine. Check Heat Shields:



• Damaged or missing heat shields may lead to fires. • Damaged or missing heat shields must be repaired or machine.



replaced



before



operating



the



S508-E02B-0019



SA-25



SAFETY EVACUATING IN CASE OF FIRE • If a fire breaks out, evacuate the machine in the following way: • Stop the engine by turning the key switch to the OFF position if there is time. • Use a fire extinguisher if there is time. • Exit the machine.



• In an emergency, if the cab door and/or the front



SA-393



window cannot be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab. Refer to the explanation page on “EMERGENCY EXIT” in Operator’s Manual. 518-E02B-0393



SS-1510



BEWARE OF EXHAUST FUMES • Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. • If you must operate in a building, be sure 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. 509-E01A-0016 SA-016



SA-26



SAFETY PRECAUTIONS GRINDING



FOR



WELDING



AND



• Welding may generate gas and/or small fires. • Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding. • Only qualified personnel should perform welding. Never allow an unqualified person to perform welding. • Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding. • After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.



SA-818



523-E01A-0818



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 temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc..



AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS • Do not weld or flame cut pipes or tubes that contain flammable fluids. them thoroughly with nonflammable solvent before welding or flame cutting them.



• Clean



510-E01B-0030



SA-27



SA-030



SAFETY REMOVE PAINT BEFORE WELDING OR HEATING • Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness. • Avoid potentially toxic fumes and dust. • Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly.



• Remove paint before welding or heating: 1) If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. 2) If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.



SA-029



511-E01A-0029



PREVENT BATTERY EXPLOSIONS • Battery gas can explode. • Keep sparks, lighted matches, and flame away from the top of battery.



• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. • Do not charge a frozen battery; it may explode. Warm the battery to 16 °C ( 60 °F ) first. • Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result. • Loose terminals may produce sparks. Securely tighten all terminals. • Battery electrolyte is poisonous. If the battery should explode battery electrolyte may be splashed into eyes, possibly resulting in blindness. • Be sure to wear eye protection when checking electrolyte specific gravity. 512-E01C-0032



SA-28



SA-032



SAFETY SERVICE AIR CONDITIONING SYSTEM SAFELY • If spilled onto skin, refrigerant may cause a cold contact burn. • Refer to the freon container for proper use when servicing the air conditioning system. • Use a recovery and recycling system to avoid venting freon into the atmosphere. • Never let the freon stream make contact with the skin. 513-E01A-0405



SA-405



HANDLE CHEMICAL PRODUCTS SAFELY • Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives. • A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. • Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment. S515-E01A-0309



SA-29



SA-309



SAFETY DISPOSE OF WASTE PROPERLY • Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. • Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. • Do not pour waste onto the ground, down a drain, or into any water source. • Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants. • Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center.



SA-226



S516-E01A-0226



BEFORE RETURNING THE MACHINE TO THE CUSTOMER • After maintenance or repair work is complete, confirm that: • The machine is functioning properly, especially the safety systems. • Worn or damaged parts have been repaired or replaced



S517-E01A-0435



SA-30



SA-435



SECTION AND GROUP CONTENTS



TECHNICAL MANUAL (Troubleshooting)



SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Excavator Test Group 5 Component Test Group 6 Adjustment



SECTION 5 TROUBLESHOOTING Group 1 General Group 2 Component Layout Group 3 Troubleshooting A Group 4 Troubleshooting B Group 5 Troubleshooting C Group 6 Electrical System Inspection Group 7 ICX TECHNICAL MANUAL (Operational Principle)



All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.



COPYRIGHT(C)2003 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved



SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION Group 1 Specifications Group 1 Pump Device Group 2 Component Layout Group 2 Swing Device Group 3 Component Specifications Group 3 Control Valve Group 4 Pilot Valve SECTION 2 SYSTEM Group 5 Travel Device Group 1 Control System Group 6 Signal Control Valve Group 2 Hydraulic System Group 7 Steering Valve Group 3 Electrical System Group 8 Brake Valve Group 9 Transmission Control Valve Group 10 Others (Upperstructure) Group 11 Others (Undercarriage)



WORKSHOP MANUAL SECTION 1 GENERAL INFORMATION SECTION 3 UNDERCARRIAGE Group 1 Precautions for DisassemGroup 1 Swing Bearing bling and Assembling Group 2 Travel Motor Group 2 Tightening Torque Group 3 Center Joint Group 3 Painting Group 4 Transmission Group 4 Bleeding Air from HydrauGroup 5 Axle lic Oil Tank Group 6 Axle Lock Cylinder Group 7 Check Valve SECTION 2 UPPERSTRUCTURE (Axle Lock Cylinder) Group 1 Cab Group 8 Propeller Shaft Group 2 Counterweight Group 3 Main Frame SECTION 4 FRONT ATTACHMENT Group 4 Pump Device Group 1 Front Attachment Group 5 Control Valve Group 2 Cylinder Group 6 Swing Device Group 3 Hose-Rupture Safety Valve Group 7 Pilot Valve Group 4 Check Valve Group 8 Pilot Shut-Off Valve (Blade/Stabilizer) Group 9 Signal Control Valve SECTION 5 ENGINE Group 10 Travel Shockless Valve Group 11 Solenoid Valve Group 12 Pilot Relief Valve Group 13 Steering Valve Group 14 Brake Valve Group 15 Accumulator Charging Valve Group 16 Transmission Control Valve



SECTION 4



OPERATIONAL PERFORMANCE TEST CONTENTS Group 1 Introduction



Group 4 Excavator Test



Operational Performance Tests....................T4-1-1



Travel Speed ................................................ T4-4-1



Preparation for Performance Tests...............T4-1-2



Service Brake Function Check .................... T4-4-2 Parking Brake Function Check .................... T4-4-3



Group 2 Standard



Swing Speed ................................................ T4-4-4 Swing Function Drift Check ......................... T4-4-5



Operational Performance Standard Table............................................T4-2-1



Swing Motor Leakage .................................. T4-4-6



Main Pump P-Q Diagram .............................T4-2-6



Maximum Swingable Slant Angle ................ T4-4-7



Injection Pump..............................................T4-2-8



Swing Bearing Play...................................... T4-4-8



Dr.ZX Monitor Indicating



Hydraulic Cylinder Cycle Time................... T4-4-10



Values .........................................................T4-2-9



Dig Function Drift Check............................ T4-4-12



Sensor Activating Range ............................T4-2-14



Control Lever Operating Force .................. T4-4-14 Control Lever Stroke .................................. T4-4-15



Group 3 Engine Test



Combined Boom Raise/Swing



Engine Speed ...............................................T4-3-1



Function Check ........................................ T4-4-16



Engine Compression Pressure ....................T4-3-4 Valve Clearance Adjustment ........................T4-3-6 Nozzle Check ...............................................T4-3-8 Injection Timing ..........................................T4-3-10 Lubricant Consumption ..............................T4-3-12



CBBT-4-1



Group 5 Component Test Primary Pilot Pressure..................................T4-5-1 Secondary Pilot Pressure.............................T4-5-4 Solenoid Valve Set Pressure........................T4-5-6 Main Pump Delivery Pressure......................T4-5-9 Main Relief Valve Set Pressure..................T4-5-10 Relief Pressure (When relieving Swing) ....T4-5-13 Relief Pressure (When relieving Travel) ....T4-5-14 Overload Relief Valve Set Pressure...........T4-5-15 Main Pump Flow Rate Measurement.........T4-5-18 Regulator Adjustment .................................T4-5-22 Swing Motor Drainage................................T4-5-25 Travel Motor Drainage................................T4-5-28 Steering Valve Relief Valve Set Pressure ..T4-5-31 Brake Pressure (Front and Rear)...............T4-5-32 Brake Accumulate Pressure.......................T4-5-34 Brake Warning Set Pressure (Decrease)...T4-5-36 Brake Warning Set Pressure (Increase) ....T4-5-38



Group 6 Adjustment Engine Speed Adjustment and Engine Learning......................................................T4-6-1 Governor Lever and Fuel Cut Lever Position .......................................................T4-6-4



CBBT-4-2



OPERATIONAL PERFORMANCE TEST / Introduction OPERATIONAL PERFORMANCE TESTS Use operational performance test procedure to quantitatively check all system and functions on the machine. Purpose of Performance Tests 1. To comprehensively evaluate each operational function by comparing the performance test data with the standard values. 2. According to the evaluation results, repair, adjust, or replace parts or components as necessary to restore the machine’s performance to the desired standard. 3. To economically operate the machine under optimal conditions.



The machine performance does not always deteriorate as the working hours increase. However, the machine performance is normally considered to reduce in proportion to the increase of the operation hours. Accordingly, restoring the machine performance by repair, adjustment, or replacement shall consider the number of the machine’s working hours. Definition of “Performance Standard” 1. Operation speed values and dimensions of the new machine. 2. Operational performance of new components adjusted to specifications. Allowable errors will be indicated as necessary.



Kinds of Tests 1. Base machine performance test is to check the operational performance of each system such as engine, travel, swing, and hydraulic cylinders. 2. Hydraulic component unit test is to check the operational performance of each component such as hydraulic pump, motor, and various kinds of valves. Performance Standards “Performance Standard” is shown in tables to evaluate the performance test data. Precautions for Evaluation of Test Data 1. To evaluate not only that the test data are correct, but also in what range the test data are. 2. Be sure to evaluate the test data based on the machine operation hours, kinds and state of work loads, and machine maintenance conditions.



T4-1-1



OPERATIONAL PERFORMANCE TEST / Introduction PREPARATION TESTS



FOR



PERFORMANCE



Observe the following rules in order to carry out performance tests accurately and safely. THE MACHINE 1. Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test. TEST AREA 1. Select a hard and flat surface. 2. Secure enough space to allow the machine to run straight more than 300 m (984 ft 3 in), and to make a full swing with the front attachment extended. 3. If required, rope off the test area and provide signboards to keep unauthorized personnel away. PRECAUTIONS 1. Before 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. 2. Operate the machine carefully and always give first priority to safety. 3. While 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. 4. Avoid 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. MAKE PRECISE MEASUREMENT 1. Accurately calibrate test instruments in advance to obtain correct data. 2. Carry out tests under the exact test conditions prescribed for each test item. 3. Repeat the same test and confirm that the test data obtained can be produced repeatedly. Use mean values of measurements if necessary.



T4-1-2



T105-06-01-003



T212-07-01-003



OPERATIONAL PERFORMANCE TEST / Standard OPERATIONAL PERFORMANCE STANDARD TABLE Engine Control Dial : Fast Idle Power Mode Switch : P Mode Auto-Idle/Acceleration Selector : OFF Work Mode Switch : Digging Mode Engine Speed Control Mode Selection Switch: Dial Mode Hydraulic Oil Temperature : 50±5 °C (122±9 °F)



The standard Performance values are listed in the table below. Refer to the Group T4-3 to T4-5 for performance test procedures. Values indicated in parentheses are reference values. The following switch positions shall be selected and the hydraulic oil temperature shall be maintained as indicated below as the preconditions of performance tests unless otherwise instructed in each performance test procedure: PERFORMANCE TEST DESIGNATION -1 ENGINE SPEED min Slow Idle Speed Fast Idle Speed (P mode) Fast Idle Speed (P mode Wirh ECO deactivated)



NOTE: 1 mm=0.03937 in



ZAXIS160W Performance Standard 950+150-100 1900±50 2000±50



Fast Idle Speed (P mode and Relief Operation)



1850±50



Fast Idle Speed (E mode)



1750±70



Fast Idle Speed (HP mode and Relief Operation)



2050±50



Slow Idle Speed(Pedal Mode)



950±100



Fast Idle Speed (Pedal Mode With Work Brake)



2200±50



Fast Idle Speed (Pedal Mode and Relief Operation)



2300±50



Auto-Idle Speed Auto-Acceleration Speed Warming Up Speed ENGINE COMPRESSION PRESSURE 2 (After engine warm-up) MPa (kgf/cm , psi) VALVE CLEARANCE (IN, EX) NOZZLE INJECTION PRESSURE 2



MPa (kgf/cm , psi)



INJECTION TIMING (Degrees before TDC)



deg.



1200±100 1600±100 1150±100 3.04 (31,440) 0.4 18.14 (185, 2640) 9°



T4-2-1



Remarks



Reference Page T4-3-1



Value indicated on Dr. ZX. ↑ ↑ Extend the arm cylinder to relieve the arm roll-in circuit.Value indicated on Dr. ZX. Value indicated on Dr. ZX. Extend the arm cylinder to relieve the arm roll-in circuit.Value indicated on Dr. ZX. Shift Lever: D or L. Brake Swithch: OFF or Axle Lock. Value indicated on Dr. ZX. Shift Lever: N. Brake Swithch: S. Value indicated on Dr. ZX. Shift Lever: D. Brake Swithch: OFF or Axle Lock. Machine jacked up. Keep brake pedal depressed for travel operation. Value indicated on Dr. ZX. Value indicated on Dr. ZX. ↑ ↑ After engine warm-up With the engine cold



T4-3-4 T4-3-7 T4-3-8 T4-3-10



OPERATIONAL PERFORMANCE TEST / Standard NOTE: 1 mm=0.03937 in ZAXIS160W Performance Standard



PERFORMANCE TEST DESIGNATION LUBRICANT CONSUMPTION (Rated output) TRAVEL SPEED



mL/h



48 or less



Remarks Hour meter: 1000 hours or less



Reference Page T4-3-12 T4-4-1



km/h(100 m)



Fast Speed



32.0+0.5-3.0



Slow Speed



8.2+0.5-1.0



Creeper



2.5±0.3



Engine speed control mode selection switch: Pedal Shift Lever: D Engine speed control mode selection switch: Pedal Shift Lever: L Engine speed control mode selection switch: Creeper Shift Lever: L



SERVICE BRAKE FUNCTION CHECK



T4-4-2 m



Braking distance at travel speed of 32 km/h Braking distance at travel speed of 20 km/h PARKING BRAKE FUNCTION CHECK mm/5 min



SWING SPEED sec/3 rev SWING FUNCTION DRIFT CHECK mm /90°



SWING MOTOR LEAKAGE mm/5 min MAXIMUM SWINGABLE SLANT ANGLE deg.



SWING BEARING PLAY HYDRAULIC CYLINDER CYCLE TIME



mm



13.6 or less 6.4 or less



13.5±1.0



Bucket empty



860 or less



Bucket empty



0 18.5° or possibly more 0.2 to 1.25



Bucket loaded Bucket loaded



T4-4-6 T4-4-7



Allowable limit: 2.0 to 3.05 0.60 m3 (PCSA heaped) bucket, bucket empty. Mono boom with 2.58 m arm. 2 piece boom with 2.50 m arm.



T4-4-8 T4-4-10



sec



Boom Raise (Mono Boom) Boom Raise (2 Piece Boom) Boom Lower (Mono Boom) Boom Lower (2 Piece Boom) Arm Roll-In Arm Roll-Out Bucket Roll-In Bucket Roll-Out Positioning Raise Positioning Lower Stabilizer Raise Stabilizer Lower Blade Raise Blade Lower



T4-4-3



0



3.2±0.3 3.3±0.3 3.1±0.3 2.7±0.3 3.5±0.3 2.8±0.3 3.7±0.3 2.1±0.3 6.4±0.5 3.4±0.3 2.0±0.3 2.0±0.3 1.1±0.5 1.6±0.5



T4-2-2



T4-4-4 T4-4-5



OPERATIONAL PERFORMANCE TEST / Standard NOTE: 1 mm=0.03937 in PERFORMANCE TEST DESIGNATION DIG FUNCTION DRIFT CHECK



ZAXIS160W Performance Standard



0.60 m3 (PCSA heaped) bucket, bucket empty. Mono boom with 2.58 m arm. 2 piece boom with 2.50 m arm.



mm/5 min



Boom Cylinder (Maximum Reach Position) Arm Cylinder (Maximum Reach Position) Bucket Cylinder (Maximum Reach Position) Positioning Cylinder (Maximum Reach Position) Front Sink Amount (Bucket Bottom) (Maximum Reach Position) CONTROL LEVER OPERATING FORCE



Remarks



15 or less



Bucket loaded



20 or less



Bucket loaded



20 or less



Bucket loaded



10 or less



Bucket loaded



150 or less



Bucket loaded



Reference Page T4-4-12



T4-4-14



N (kgf, lbf･ft)



Right Hand Lever: Forward/Backward Right Hand Lever: Right/Left Left Hand Lever: Forward/Backward Left Hand Lever: Right/Left Steering CONTROL LEVER STROKE mm Right Hand Lever: Forward/Backward Right Hand Lever: Right/Left Left Hand Lever: Forward/Backward Left Hand Lever: Right/Left Steering Wheel Turns (lock-to-lock)



15 (1.5, 10.8) or less 15 (1.5, 10.8) or less 15 (1.5, 10.8) or less 15 (1.5, 10.8) or less 20 (2.0, 14.5) or less T4-4-15 74±10 62±10 74±10 62±10 5.7±0.5



T4-2-3



OPERATIONAL PERFORMANCE TEST / Standard NOTE: 1 mm=0.03937 in PERFORMANCE TEST DESIGNATION COMBINED BOOM RAISE/SWING



ZAXIS160W Performance Standard



sec



3.9±0.3 (Bucket Teeth Height: H) mm PRIMARY PILOT PRESSURE 2 (Brake Pilot Pressure) MPa (kgf/cm , psi) Engine: Fast Idle



SECONDARY PILOT PRESSURE) (Engine: Fast Idle and Slow Idle) 2



MPa (kgf/cm , psi)



SOLENOID VALVE SET PRESSURE 2



MPa (kgf/cm , psi)



MAIN PUMP DELIVERY PRESSURE 2



MPa (kgf/cm , psi)



Remarks 0.60 m3 (PCSA heaped) bucket, bucket empty. 2 piece boom with 2.50 m arm. bucket empty



Reference Page T4-4-16



5300 or more T4-5-1 Accumulator pressure (when charged): 15 (153, 2180) or higher. 3.3 to 3.9 (34 to Value indicated on Dr. ZX 40, 480 to 567) (Lever: Full stroke) Travel, extra and blade/outriggers: 2.7 to 3.3 (28 to 34, 393 to 480) Value Indicated On Value Indicated On Dr. ZX Dr. ZX [SE (Brake switch: OFF): 3.7+1.0-0.5 (38+10-5, 538+145-73)] Value indicated on Dr. ZX 0.8±0.5 (8±5, 114±71) 3.9+1.0-0.5 +10 (40 -5, 567+145-73)



T4-5-4



T4-5-6



T4-5-9 T4-5-10



MAIN RELIEF VALVE SET PRESSURE 2



MPa (kgf/cm , psi)



Boom, Arm, and Bucket



RELIEF PRESSURE (When Relieving Swing)



MPa (kgf/cm , psi)



RELIEF PRESSURE (When Relieving Travel)



MPa (kgf/cm , psi)



2



2



2 RELIEF PRESSURE MPa (kgf/cm , psi) (When Relieving Stabilizer) (raise/lower)



2 RELIEF PRESSURE MPa (kgf/cm , psi) (When Relieving Blade) (raise/lower)



34.3+1.4-1.2 (350+14-12, 4980+204-174) 31.9+2.3-0 (325+25-0, 4620+356-0) 34.3+2.0-0.5 (350+20-5, 4980+284-71) 31.4±2.5 (320±25, 4565±356) 31.4±2.5 (320±25, 4565±356)



T4-2-4



Value indicated on Dr. ZX



Value indicated on Dr. ZX



T4-5-13



Value indicated on Dr. ZX Travel motor relief set pressure: 40 (408, 5815)



T4-5-14



Value indicated on Dr. ZX



Value indicated on Dr. ZX



OPERATIONAL PERFORMANCE TEST / Standard



ZAXIS160W PERFORMANCE TEST DESIGNATION Performance Standard OVERLOAD RELIEF VALVE SET PRES- (Reference values 2 SURE MPa (kgf/cm , psi) at 50 L/min) Boom (Raise/Lower), Arm Roll-In, and 37.3+1.0-0 Bucket Roll-In (380+10-0, 5400+142-0) Arm Roll-Out, Bucket Roll-Out, Position39.2+1.0-0 ing (Raise/Lower) (400+10-0, 5690+142-0) MAIN PUMP FLOW RATE TEST (L/min) SWING MOTOR DRAINAGE (L/min) With constant maximum speed 0.2 to 0.3 With the motor relieved (2 to 5) TRAVEL MOTOR DRAINAGE (L/min) With the jacked up machine Contact Hitachi for details. With the motor relieved Contact Hitachi for details. STEERING VALVE RELIEF VALVE 17.2+2.0-0 2 SET PRESSURE (175+20-0, MPa (kgf/cm , psi) 2490+284-0) BRAKE PRESSURE (F/R) MPa (kgf/cm2, psi) 7.0±1.0 Including working brake pressure (70±10, 995±142) BRAKE ACCUMLATE PRESSURE 15.0±1.0 2 MPa (kgf/cm , psi) (153±10, 2180±142) BRAKE WARNING SET PRESSURE 5.2±0.3 2 (DECREASE) MPa (kgf/cm , psi) (53±3, 754±43) BRAKE WARNING SET PRESSURE (IN5.2±0.3 2 CREASE) MPa (kgf/cm , psi) (53±3, 754±43) to 6.4±0.3 (65±3, 924±43)



T4-2-5



NOTE: 1 mm=0.03937 in Reference Remarks Page T4-5-15



Refer to T4-2-6 page.



T4-5-18 T4-5-25



T4-5-28 Contact Hitachi for details. Contact Hitachi for details. T4-5-31 Value indicated on Dr. ZX. T4-5-32 T4-5-34



T4-5-36 T4-5-38



OPERATIONAL PERFORMANCE TEST / Standard MAIN PUMP P-Q DIAGRAM • P-Q Control (Torque Control)



• Points on P-Q Line



(REFERENCE: Measured at Test Stand)



Delivery Pressure MPa (kgf/cm2, psi)



• Rated Pump Speed: 1850 min-1 (rpm) (This pump device is not equipped with a transmission so that the pump speed is equal to the engine speed. Therefore, measure the pump flow rate with the engine running at the rated pump speed.) • Hydraulic Oil Temperature: 50±5 °C (122±9 °F) • Output current value of torque control solenoid value: 540 mA



A



138±2.5 (36.4±0.6) B 7.8 (80, 1130) [137 (36)] C 14.7 (150, 2140) 125±5 (33.0±1.3) D 17.7 (181, 2570) 108±5 (28.5±1.3) E 22.6 (231, 3290) 77±5 (20.3±1.3) F 34.3 (350, 4990) [45 (11.9)] The value indicated in parentheses is only a reference value.



NOTE: Refer to T4-5-18.



L/min



A



Flow Rate L/min (gpm)



2.0 (20, 290)



B



C D E Flow Rate



F



Delivery Pressure



T4-2-6



MPa (kgf/cm2) T1F3-04-02-004



OPERATIONAL PERFORMANCE TEST / Standard • Pilot Characteristics



•



(REFERENCE: Measured at Test Stand)



• Rated Pump Speed: 1850 min-1 (rpm) (This pump device is not equipped with a transmission so that the pump speed is equal to the engine speed. Therefore, measure the pump flow rate with the engine running at the rated pump speed.) • Hydraulic Oil Temperature: 50±5 °C (122±9 °F)



Points on P-Q Line Pump Control pressure MPa (kgf/cm2, psi) 1.2±0.1 A (12.0±0.5, 147±15) 2.7±0.2 B (28±2, 393±29) 2.9±0.2 C (30±2, 422±29)



Flow Rate L/min (gpm) 31±3.0 (8.2±0.8) 137 ±3.0 (36.1±0.8) 146 ±3.0 (38.5±0.8)



NOTE: Refer to T4-5-20.



C



L/min



Main Pump1 B Main Pump2



Flow Rate A



Pump Control Pressure



T4-2-7



MPa (kgf/cm2) T1F3-04-02-003



OPERATIONAL PERFORMANCE TEST / Standard INJECTION PUMP Test Conditions: 1. Injection pump: PES4AD 101041-8950 2. Governor: EP/RSV 105411-2470 3. Nozzle and nozzle holder assembly: 105780-8140 (Bosch No. EF8511/9A) 4. Nozzle: 105780-0000 (Bosch No. DN12SD12T) 5. Nozzle holder: 105780-2080 (Bosch No. EF8511/9) 6. Nozzle opening pressure: 17.2 MPa (175 kgf/cm2, 2490 psi)



7. Test fuel: ISO 4113 or SAE J967d 8. Transfer pump pressure: 157 kPa (1.6 kgf/cm2, 33 psi) 9. Injection pipe: Inner Dia. 2 mm×Outer Dia. 6 mm-Length 600 mm (0.079×0.236-23.6 in) 10. Fuel temperature: 40+5 °C (104+9 °F) 11. Overflow valve opening pressure: 255 kPa (2.6 kgf/cm2, 37 psi)



Injection rate adjustment Maximum Variance Between Cylinders (%)



Fixed



Remarks



90±1.1



±2



Lever



Basic



8.8±1.4



±14



Rack



-



Lever



Average Injection Rate 3 (cm /1000 Stroke)



Adjusting Point



Pump Speed -1 (min )



A



1100



10.4



475



7.7±0.5



100



-



120±5



E



Rack Position (mm)



Rack limit



Governor adjustment



Rack Limit Idle-sub Spring Setting Above 14.0 Rack Position (mm)



Boost Compensator Stroke



Difference in Rack Posi-1 tion between 1100 min -1 and 550 min



Governor Spring Setting



Pump Speed



-1



min (rpm) T1F1-04-02-001



T4-2-8



OPERATIONAL PERFORMANCE TEST / Standard Dr. ZX MONITOR INDICATING VALUES Unless specified, test under the following conditions. Engine Control Dial : Fast Idle Power Mode Switch : P Mode Auto-Idle/Acceleration Selector : OFF Work Mode Switch : Digging Mode Engine Control Mode Selector Switch : Dial Mode Hydraulic Oil Temperature : 50±5 °C (122±9 °F)



Reference Value



Item PUMP 1 PRESSURE



0.8



Boom Raise∗



34.3



Arm Roll-In



Measured Value Second Third



Average



Remarks



(MPa)



Control Lever in Neutral∗ Boom Lower



First



∗



NOTE: Items marked ( ) are measurable with the built-in diagnosing system. ∗∗ Items marked ( ) are measurable with the built-in diagnosing system. However, it may be difficult to read the measured value while operating the machine.



∗



When relieving



-



∗



34.8



When relieving



34.8



When relieving



Bucket Roll-Out



35.0



When relieving



Bucket Roll-In*



35.5



When relieving



34.3



When relieving



∗



Arm Roll-Out



∗



Boom Raise + Arm Roll-In + Bucket Roll-In Combined ∗ Operation PUMP 2 PRESSURE (MPa) Control Lever in Neutral Boom Raise



∗



Boom Lower Arm Roll-In



∗



When relieving



34.3



∗



-



∗ ∗



Arm Roll-Out



∗



Bucket Roll-Out Bucket Roll-In



0.8



∗



Boom Raise + Arm Roll-In + Bucket Roll-In Combined ∗ Operation



35.0



When relieving



35.0



When relieving



1.0



When relieving



0.8



When relieving



35.0



When relieving



T4-2-9



OPERATIONAL PERFORMANCE TEST / Standard Reference Value



Item PUMP 1 PUMP CONTROL PRESSURE (MPa) Control Lever in Neutral∗ Boom Raise∗ Boom Lower Arm Roll-In



∗



Bucket Roll-Out Bucket Roll-In



∗



Boom Raise + Arm Roll-In + Bucket Roll-In Combined ∗ Operation PUMP 2 PUMP CONTROL PRESSURE (MPa) ∗ Control Lever in Neutral



Arm Roll-In



∗



When relieving



3.69



When relieving



3.72



When relieving



3.77



When relieving



3.77



When relieving



3.64



When relieving



1.14 When relieving



3.69



∗



-



∗ ∗



Arm Roll-Out



∗



Bucket Roll-Out Bucket Roll-In



Remarks



-



∗



Arm Roll-Out



Boom Lower



Average



1.16 3.69



∗



∗



Boom Raise



First



Measured Value Second Third



∗



Boom Raise + Arm Roll-In + Bucket Roll-In Combined ∗ Operation



3.69



When relieving



3.72



When relieving



0.98



When relieving



0.98



When relieving



3.67



When relieving



T4-2-10



OPERATIONAL PERFORMANCE TEST / Standard Reference Value



Item TARGET ENGINE SPEED



Fast Idle (With ECO deactivated) ∗ Fast Idle (When operating a control lever)∗



1850



Fast Idle (HP Mode) (When operating a control lever)∗



2050



∗



1600



∗∗



1450



∗



1050



∗



800



∗



Slow Idle (Pedal Mode) Shift Lever: L or D ∗ Fast Idle (Pedal Mode) Shift Lever: N ∗ Fast Idle (Pedal Mode) Shift Lever: D



ACTUAL ENGINE SPEED Fast Idle



800



Axle Lock.



2050



Break Switch: S. Jack-up traveling. Axle Lock.



2300 -1



(min )



∗



1950



Fast Idle (With ECO deactivated) ∗ Fast Idle ∗ (When operating a control lever)



2050



Fast Idle (HP Mode) (When operating a control lever)∗



2070



Fast Idle (E Mode)



∗



Auto-Accel



1880



1690



∗



Slow Idle



When relieving arm roll-in circuit When relieving arm roll-in circuit



1810



∗∗



Auto-Idle



When relieving arm roll-in circuit When relieving arm roll-in circuit



1850



Auto-Accel Slow Idle



Remarks



-1



1750



Auto-Idle



Average



(min )



Fast Idle∗



Fast Idle (E Mode)



First



Measured Value Second Third



1250



∗ ∗



Slow Idle (Pedal Mode) Shift Lever: L or D ∗ Fast Idle (Pedal Mode) Shift Lever: N ∗ Fast Idle (Pedal Mode) Shift Lever: D



1030 1010



Axle Lock.



2240



Break Switch: S. Jack-up traveling. Axle Lock.



2290



T4-2-11



OPERATIONAL PERFORMANCE TEST / Standard Reference Value



Item EC ANGLE Minimum



Maximum



3.02 (Volt)



∗



0.62



∗



Maximum



TRAVEL MOTOR SPEED



4.35 Jack-up traveling. Pedal Mode. AxleLock.



(min-1)



Drive



3040



Low



3360



VEHICLE SPEED



Traveling. Pedal Mode.



Drive



-



Low



-



BOOM RAISE PILOT ∗ CONTROL PRESSURE ARM ROLL-IN PILOT ∗ CONTROL PRESSURE SWING CONTROL PILOT ∗ PRESSURE



Remarks



2.51



∗



Minimum



Average



(Volt)



∗



DIAL ANGLE



First



Measured Value Second Third



(MPa) (MPa) (MPa)



3.88



When relieving



3.88



When relieving



-



FORWARD TRAVEL CONTROL PILOT PRESSURE (MPa)



2.90



REAR TRAVEL CONTROL PILOT PRESSURE (MPa)



2.92



FRONT ATTACHMENT ∗ CONTROL PRESSURE PUMP FLOW CHANGEOVER PROPORTIONAL VALVE OUTPUT (MPa)



Jack-up traveling. Pedal Mode. Shift Lever L or D. Axle Lock. Jack-up traveling. Pedal Mode. Shift Lever L or D. Axle Lock. “ON-OFF” is displayed Jack-up traveling. Pedal Mode. Shift Lever D. Axle Lock.



0 (When stop traveling: 3.91)



T4-2-12



OPERATIONAL PERFORMANCE TEST / Standard Reference Value



Item



First



Measured Value Second Third



Average



Remarks



ARM REGENERATIVE PROPORTIONAL VALVE OUTPUT (MPa)



Lever in Neutral Swing, Arm Roll-In, and Boom Raise Combined Operation TRAVEL MOTOR TILT PROPORTIONAL VALVE OUTPUT (MPa) Drive or Low Creeper WORKING BREAK PROPORTIONAL VALVE OUTPUT (MPa) EC MOTOR POSITION



(Step)



1.55 Jack-up traveling. Axle Lock. Pedal Mode.



0



Creeper Mode.



2.93 3.34 (Brake Off: 0)



Brake Switch: S.



When relieving arm roll-in circuit



268



TRAVEL DRAIN PRESSURE (MPa)



Low



0.32



Drive



0.29



Jack-up traveling. Axle Lock. Jack-up traveling. Axle Lock.



ENGINE SPEED DEVIATION -1



(min )



Fast Idle



200



Fast Idle (With ECO deactivated) Fast Idle (When operating a control lever) Fast Idle (HP Mode) (When operating a control lever) Fast Idle (E Mode)



200



Auto-Accel



240



Auto-Idle



200



Slow Idle



230



Slow Idle (Pedal Mode) Shift Lever: L or D Fast Idle (Pedal Mode) Shift Lever: N Fast Idle (Pedal Mode) Shift Lever: D PUMP TORQUE PROPORTIONAL VALVE OUTPUT (MPa) PUMP2 PROPORTIONAL VALVE OUTPUT (MPa) PUMP1 PROPORTIONAL VALVE OUTPUT (MPa)



210



30



When relieving arm roll-in circuit



20



When relieving arm roll-in circuit



210



Jack-up traveling. Axle Lock. Break Switch: S.



190



Jack-up traveling. Axle Lock.



10 0.84



Lever in neutral



3.93



Lever in neutral



3.93



Lever in neutral



T4-2-13



OPERATIONAL PERFORMANCE TEST / Standard SENSOR ACTIVATING RANGE 1. Checking Method • Hydraulic Oil Temperature: 50 ± 5 °C • Unless specified: Engine Control Dial Fast Idle



Power Mode Switch P



Work Mode Switch Digging



Auto-Idle /Auto-Accelerati -on Selector OFF



• Monitor each sensor using Dr. ZX. 2.



Sensor Activating Range Sensor Engine Control Dial



EC Sensor



Pressure Sensor (Boom Raise, Arm Roll-in, Swing) Pressure Sensor (Travel) Pump Control Pressure Sensor Travel Drain Pressure Sensor N Sensor



Operation Minimum Speed Maximum Speed Minimum Speed Maximum Speed (Power Mode Switch: P) Maximum Speed (Power Mode Switch: HP) Control Lever: Neutral Pilot Control Shut-Off Lever: LOCK Control Lever: Full Stroke Pilot Control Shut-Off Lever: UNLOCK Pedal: Neutral Pilot Control Shut-Off Lever: LOCK Pedal: Full Stroke Pilot Control Shut-Off Lever: UNLOCK Control Lever: Neutral Control Lever: Full Stroke



20°C (Between Ground to Signal)



T4-2-14



Specification 0.3 to 1.0 V 4.0 to 4.7 V 2.5 to 2.7 V 3.0 to 3.4 V Maximum Speed (Mode Switch: OFF) +0.2 V or more 0 to 0.1 MPa (0 to 1.0 kgf/cm2) 3.3 to 3.9 MPa (34 to 40 kgf/cm2) 0 to 0.1 MPa (0 to 1.0 kgf/cm2) 2.7 to 3.3 MPa (28 to 34 kgf/cm2) 0.7 to 1.3 MPa (7 to 13 kgf/cm2) 2.9 to 3.9 MPa (30 to 40 kgf/cm2) 0 to 0.3 MPa (0 to 3 kgf/cm2) 810 ± 240 Ω



OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE SPEED Summary 1. Measure the engine speed using the built-in diagnosing system or Dr. ZX. If the built-in diagnosing system or Dr. ZX is not available, use an engine speed meter or a pulse counter. (Refer to the TROUBLESHOOTING / General group.) 2. Measure the engine speeds in each mode. NOTE: Measure the engine speed before performing all other tests to check that the engine speed meets specification. Because, if the engine speed is not adjusted correctly, all other performance data will be unreliable.



2 1



T107-06-02-002



3



Preparation: 1. Select the monitor function of the built-in diagnosing system (In case of Dr. ZX, connect it first). When using an engine speed meter, install speed pickup (2) to injection pipe (1). When using a pulse counter, disconnect the N-sensor connector. 2. Warm up the machine until the engine coolant temperature reaches 50 °C (122 °F) or more, and hydraulic oil is 50±5 °C (122±9 °F). IMPORTANT: Never attempt to the readjust stopper (3). T1F3-04-02-001



T4-3-1



OPERATIONAL PERFORMANCE TEST / Engine Test Measurement: 1. Check engine speeds for auto-warm up (when starting the engine), auto-idle, slow idle, fast idle (when normal), fast idle (when the ECO is deactivated), fast idle (in the E mode), fast idle (in the HP mode) and, slow idle (in the pedal mode), fast idle (in the pedal mode with work brake) and fast idle in the pedal mode and relief operation. 2. Select the switch positions and the test conditions corresponding to the engine speed to be measured as shown in the table below. 3. When using the pulse counter, read the pulse counter. Calculate the engine speed using the following formula: Engine Speed (min-1) = Pulse Numbers (Hz) × 60 / 32



Evaluation: Refer to T4-2 Operational Performance Standard. Remedy: Refer to T5-4 Troubleshooting B. NOTE: ECO stands for the auto engine speed reduction system by 100 min-1.



Engine Speed Control Mode Selection Switch：Dial Mode Engine Power Auto-Idle/ AutoControl Mode Acceleration Dial Switch Selector Slow Idle



Min. Speed



P



OFF



Max. Speed



P



OFF



Max. Speed



P



OFF



Max. Speed



P



OFF



Max. Speed



E



OFF



Max. Speed



HP



OFF



Auto-Idle



Max. Speed



P



Auto-Idle



Auto-Acceleration



Max. Speed



P



Auto-Acceleration



Warming Up



Min. Speed



P



OFF



Fast Idle (P model) Fast Idle (P model With ECO deactivated) Fast Idle (P model relief operation) Fast Idle (E mode) Fast Idle (HP mode)



T4-3-2



Work Mode Switch Digging Mode Digging Mode



Test Conditions



Check in the Dr. ZX special Digging functions with ECO deactiMode vated. Check the engine speed while Digging relieving the arm roll-in circuit. Mode Digging Mode Digging Check the engine speed while Mode relieving the arm roll-in circuit. Check engine speed 4 seconds Digging after returning all control levers Mode to neutral. Check reduced engine speed Digging within 3 seconds after returning Mode all control levers to neutral. Digging Check only when oil temperaMode ture is lower than 0 °C (32 °F).



OPERATIONAL PERFORMANCE TEST / Engine Test Engine Speed Control Mode Selection Switch：Pedal Mode Power Auto-Idle/ AutoTravel Pedal Mode Acceleration Switch Selector Slow Idle (Pedal Mode)



Don’t Touch



P



OFF



Fast Idle (Pedal Mod With Work Brake)



Full Stroke



P



OFF



Fast Idle (Pedal Mode and Relief Operation)



Full Stroke



P



OFF



Work Mode Switch



Test Conditions



Shift Lever: D or L. Brake Digging Switch: OFF or Axle Lock. Mode Engine Control Dial: Minimum. Shift Lever: N Digging Brake Switch: S Mode Shift Lever: D. Brake Switch: OFF or Axle Lock. Digging Machine Jacked up. Mode Keep Brake Pedal Depressed for Travel Operation.



Jacking Up: Raise the undercarriage with the stabilizer and blade provided at the front and rear of the undercarriage. CAUTION: Securely support the raised track using wooden blocks. When the machine is equipped with the stabilizer or blade at only the rear of the undercarriage, lower the front attachment, and raise the front wheels as shown at right. T1F3-04-02-002



Monitor Panel



Switch Panel Engine Control Dial



Engine Speed Control Mode Selection Switch



Work Mode Switch Power Mode Switch Auto-Idle/Acceleration Selector



MCBB-01-012 MCBB-01-014



T4-3-3



OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE COMPRESSION PRESSURE Summary: 1. Measure compression pressure in the cylinders to check for a decline in engine power. 2. Check exhaust gas color. Keep track of engine oil consumption. 3. Check for abnormalities in the intake system, including the air filter. Preparation: 1. Confirm that valve clearances are correct. 2. Confirm that the batteries are charged properly. 3. Run the engine until the coolant temperature gauge reaches the operating range. 4. Stop the engine. Remove glow plugs from each cylinder. NOTE: Unless the fuel delivery pipes are disconnected, fuel will ignite in the cylinders so that pressure in the cylinders will increase. T105-06-02-001



5. Install an adaptor (Isuzu 5-85317-001-0) and compression gauge in place of the glow plug in one cylinder. (Be sure to sufficiently tighten the adaptor and compression gauge to prevent air leakage.) Measurement: 1. Turn the starter to crank the engine. Record the compression pressure of each cylinder. 2. Repeat measurement three times for each cylinder and calculate the mean values. Evaluation: Refer to T4-2 Operational Performance Standard. Remedy: Refer to engine shop manual.



T4-3-4



OPERATIONAL PERFORMANCE TEST / Engine Test (Blank)



T4-3-5



OPERATIONAL PERFORMANCE TEST / Engine Test VALVE CLEARANCE ADJUSTMENT Summary: 1. Perform the measurement when the engine is cold. 2. Before starting work, clean the head cover mounting area to avoid contamination in the engine. Preparation: 1. Locate the top dead center (TDC) in the compression stroke. Align the TDC mark on the crank pulley with the pointer located on the timing gear case as illustrated. Piston No.1 (or piston No.4) is now positioned at the TDC in its compression stroke. NOTE: When rotating the crank pulley, remove the fan guard. Then, rotate the fan while holding the fan belt. If it is difficult to rotate, remove all glow plugs to release the compression pressure. 2. Remove the head cover. 3. Move push rods for the intake and exhaust valves on the No.1 cylinder up and down by hand. If any clearances on the both ends of the push rods are found, piston No.1 is positioned at TDC in the compression stroke. (If the exhaust valve of cylinder No.1 is pushed down, piston No.4 is positioned at TDC in the compression stroke. Start measurement from the cylinder (No.1 or No.4) positioned at TDC in the compression stroke.



T4-3-6



Top Mark



TDC Mark Timing Gear Case Crank Pulley



T157-05-02-002



OPERATIONAL PERFORMANCE TEST / Engine Test Measurement: 1. Insert a thickness gauge into the clearance between the rocker arm and the valve stem end to measure the valve clearance. NOTE: The cylinders are aligned from No.1 to No.4 in that order, as viewed from the fan side. 2. When the measurement is started from No.1 cylinder, perform the same measurement to all valves indicated with the mark “○” in the table below. (When the measurement is started from No.4 cylinder, perform the measurement in the valves shown with mark “×”.) Cylinder No. Valve locations When the measurement is started from No.1 cylinder When the measurement is started from No.4 cylinder



No.1 I E



No.2 I E



×



T107-02-12-005



No.3 I E



No.4 I E



×



×



3. Rotate the crankshaft 360°. Align the TDC mark with the pointer. Then, continue measurement of other valves in the same way. Evaluation: Refer to T4-2 Operational Performance Standard. Adjustment: If the measurement results are out of specification, adjust the valve clearance in the same order of measurement. 1. Loosen the adjusting screw lock nuts for the rocker arms. Insert the thickness gauge set at 0.4 mm, adjust the adjusting screws. 2. After adjusting, retighten the lock nuts to the specification. Recheck the valve clearance after the lock nuts are tightened. : 25.5±4.9 N⋅m (2.6±0.5 kgf⋅m, 18.8±3.6 lbf⋅ft)



T4-3-7



×



OPERATIONAL PERFORMANCE TEST / Engine Test NOZZLE CHECK Summary: 1. Check the injection pressure and the spray pattern with a nozzle tester. 2. Before starting work, clean the nozzle holder mounting area to avoid contamination in the engine. Preparation: 1. Remove the nozzle holders. Remove all nozzle holders and fuel injection pipings from the engine. 2. Attach a nozzle holder to the nozzle tester. Measurement: CAUTION: Never touch spray directly. The fuel spray from the nozzle may penetrate the skin, resulting in serious injury. If fuel penetrates into the blood stream, it may cause blood toxication. 1. Injection pressure After attaching the nozzle holder to the nozzle tester, strongly make several strokes of the tester to inject fuel. Then, while operating the tester at approx. 60 time strokes a minute, measure the fuel injection pressure. If adjustment is required, loosen the lock nuts and adjust the adjusting screws. Turn clockwise to increase the pressure, and counterclockwise to decrease the pressure. 2. Spray pattern For this test, turn the pressure tester knob to bypass the pressure gauge. Attach the nozzle holder to the nozzle tester. Strongly make several strokes of the tester and check the fuel spray pattern. 3. Oil tight condition Keep the pressure slightly below the injection pressure. Check for fuel leak from around the nozzle tip. NOTE: Use clean diesel oil.



T4-3-8



T107-06-02-006



OPERATIONAL PERFORMANCE TEST / Engine Test Evaluation: 1. Standard Injection Pressure: Refer to T4-2 Operational Performance Standard. 2. Spray Pattern • Large-size spray should not be visible to the naked eye. • No stray sideways sprays should be seen. • During initial injection stage, spray size should be fine and injected intermittently. • There should be no drips found. • Injection spray angle must be normal. 3. Oil Tight Condition No fuel leaks.



Normal



T102-02-11-005



Abnormal



Adjustment: 1. To adjust the injection pressure, loosen the lock nuts. Adjust the adjusting screw. Turn clockwise to increase the pressure, and counterclockwise to decrease the pressure. 2. After adjusting, retighten the lock nuts.



T102-02-11-006



T107-06-02-007



T4-3-9



OPERATIONAL PERFORMANCE TEST / Engine Test INJECTION TIMING Timing Mark



Inspection: 1. Position No.1 piston to the top dead center. Turn the crank pulley in the direction of rotation (clockwise as seen from the front of the engine) to set a “TDC” mark on the crank pulley under the “Top mark”, located on the timing gear case. NOTE: When rotating the crank pulley, remove the fan guard. Then, rotate the fan while holding the fan belt. If it is difficult to rotate, remove all glow plugs to release the compression pressure. 2. Remove the timing check hole cover on the front section of the fuel injection pump. When the mark on the injection pump is set under the projection of the gear case, No.1 piston is positioned at the top dead center. If the mark is not set under the projection, keep turning to adjust. NOTE: The alignment mark on the injection pump cannot be directly seen through the check hole. Use a mirror for checking. 3. Remove the injection piping from No.1 cylinder. 4. Remove the delivery valve holder for No.1 cylinder from the injection pump to pull the delivery valve and the spring out. Reinstall the delivery valve holder. : 39 to 44 N⋅m (4 to 4.5 kgf⋅m, 28.9 to 32.6 lbf⋅ft)



Top Mark



TDC Mark Timing Gear Case Crank Pulley



T157-05-02-002



Gear Case Projection



Check Hole



Injection Pump Alignment Mark T107-02-12-007



Gear Case Projection



Injection Pump Alignment Mark



T4-3-10



T107-02-12-008



OPERATIONAL PERFORMANCE TEST / Engine Test 5. Turn the crank pulley at approx. 30 degrees counterclockwise. 6. While supplying fuel with the feed pump, turn the crank pulley slowly clockwise just until fuel cannot be seen from the top of the delivery valve hole. This is the position where the injection starts. 7. Check the “TDC” mark, located on the crank pulley for what degrees the “TDC” mark indicates. Adjustment: 1. Turn the crank pulley so that the “TDC” mark comes just above the correct timing position on the timing gear case. 2. Loosen the mounting nuts of the injection pump. 3. When advancing timing, tilt the injection pump outward against the cylinder block. When delaying timing, tilt the injection pump inward against the cylinder block.



T4-3-11



T107-02-12-009



OPERATIONAL PERFORMANCE TEST / Engine Test LUBRICANT CONSUMPTION Measuring Method 1. Place the machine on level firm ground, and leave it for at least one hour to let the lubricant lower to the oil pan. At this time, confirm that the machine is level, using a leveler. 2. Record the read-out A (unit: hour) of the hour meter. 3. Replenish the lubricant up to the high-level gauge. 4. Operate the machine for at least 100 hours or until the oil level lowers to the low-level gauge. IMPORTANT: Make sure to keep the machine-leaving time in Step 1 above. 5. Place the machine on level firm ground, and leave it for at least one hour to let the lubricant lower to the oil pan. At this time, confirm that the machine is level, using a leveler. 6. Record the read-out B (unit: hour) of the hour meter. 7. Replenish the lubricant up to the high-level gauge while measuring the oil-replenishing volume C. NOTE: For measuring, use a high-precision measuring cylinder or the like. 8. Determine lubricant consumption from the following equation: Oil replenishing volume (C) [mL] / Operating hours (B-A) [hr] Evaluation: Refer to T4-2 Operational Performance Standard.



T4-3-12



OPERATIONAL PERFORMANCE TEST / Excavator Test TRAVEL SPEED Summary: 1. Measure the time required for the machine to travel a 100 m (328 ft) test track.



Evaluation: Refer to the Performance Standard Table in Group T4-2.



Preparation:



Remedy: Refer to the Troubleshooting B in Group T5-4.



CAUTION: Be sure to place the swing lock lever to the LOCK position before traveling. 1. Adjust the air pressure in all tires equally. Air Pressure: 640 kPa (6.5 kgf/cm2, 93 psi) 2. Prepare a 100 m long straight test track on level firm ground with a 200 m long approach runway. 3. Position front attachment for travel as instructed in Operator’s Manual. 4. Maintain hydraulic oil temperature at 50±5 °C (122±9 °F).



End 100 m (328 ft) Start Acceleration Zone 200 m (656 ft)



Measurement:



T1F3-04-04-003



CAUTION: Measurement in reverse travel operation is dangerous. Perform measurement in forward travel operation. 1. Measure the fast, slow and creep speeds of the machine. 2. Select the following switch positions: Engine Speed Control Shift Lever Mode Selection Switch Fast Speed D Pedal Low Speed L Pedal Creep L Creep



Travel Pedal Full Stroke Full Stroke Full Stroke



3. Start traveling the machine in the acceleration zone with the Forward/Reverse travel pedal moved to the Forward position and full stroke. 4. Measure the travel speed in each travel speed. 5. Repeat steps 3. to 5. Three times in each direction and calculate the average values. 6. Convert the measured value to “km/h” unit using the formula below: Where: Measured Value = S (sec) Converted Value = A (km/h) A=



100×3600 S×1000



T4-4-1



Power Mode Work Mode Auto-Idle/ AccelSwitch Switch eration Selector P Digging OFF P Digging OFF P Digging OFF



OPERATIONAL PERFORMANCE TEST / Excavator Test SERVICE BRAKE FUNCTION CHECK Summary: 1. Determine the collective capacity of the hydraulic pressure circuit, master cylinder and service brake. 2. The braking capacity test is the maintenance item. Be sure to perform the capacity test. Preparation: CAUTION: Be sure to place the swing lock lever to the LOCK position before traveling. 1. Adjust the air pressure in all tires equally. Air Pressure: 640 kPa (6.5 kgf/cm2, 93 psi) 2. Prepare a dry and solid test track 200 m (656 ft) in length, and mark the brake starting point. 3. Position front attachment for travel as instructed in Operator’s Manual. 4. Maintain hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement:



Stop Distance



Stop Position



Brake Starting Position T1F3-04-04-004



CAUTION: Measurement in reverse travel operation is dangerous. Perform measurement in forward travel operation. 1. Measure fast speed of the machine. 2. Select the following switch positions: Engine Speed Control Power Mode Work Mode Auto-Idle/ AccelShift Lever Travel Pedal Mode Selection Switch Switch Switch eration Selector D Pedal Full Stroke P Digging OFF 3. Start traveling the machine in the acceleration zone with Forward/Reverse travel pedal moved to the Forward position and full stroke, then travel in 32 km/h (19.9 mph) or 20 km/h (12.4 mph). 4. Depress the brake at the brake starting point to stop the machine completely. 5. Measure the distance between the brake starting point and the ground contacting point of the front tire. 6. Repeat steps 3. to 5. three times in each direction and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4.



T4-4-2



OPERATIONAL PERFORMANCE TEST / Excavator Test PARKING BRAKE FUNCTION CHECK Summary: 1. Measure the parking brake function on the specified slope. 2. The braking capacity test is the maintenance item. Be sure to perform the capacity test. Preparation: 1. Prepare a flat and solid test slope of 11.31°. 2. Position front attachment for travel as instructed in Operator’s Manual. 3. Maintain hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Climb up the slope, then move the brake switch to the parking position. 2. Stop the engine. 3. After the machine stops, mark white lines on the tire and the slope. 4. Wait for 5 minutes, then measure the distance between the white lines on the tire and the slope. Evaluation: Refer to the Performance Standard Table in Group T4-2.



T4-4-3



T1F3-04-04-005



OPERATIONAL PERFORMANCE TEST / Excavator Test SWING SPEED Summary: 1. Measure the time required to swing three complete turns. Preparation: 1. Check the lubrication of the swing gear and swing bearing. 2. Place the machine on flat, solid ground with ample space for swinging. Do not conduct this test on a slope. 3. With 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. 4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). NOTE: In case a sufficient space for the measurement is difficult to find, carry out the measurement with the boom fully raised and the arm fully rolled-in. CAUTION: Prevent personal injury. Always make sure that the area is clear and that co-workers are out of the swing area before starting the measurement. Measurement: 1. Select the following switch positions: Auto-Idle/ Engine Con- Power Mode Work Mode Acceleration Brake Switch trol Dial Switch Switch Selector Fast Idle P Digging OFF S (Working) 2. Operate swing control lever fully. 3. Measure the time required to swing 3 turns in one direction. 4. Operate swing control lever fully in the opposite direction and measure the time required for 3 turns. 5. Repeat steps 2. to 4. three times and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4.



T4-4-4



The same height as the boom foot pin. T1F3-04-04-006



OPERATIONAL PERFORMANCE TEST / Excavator Test SWING FUNCTION DRIFT CHECK Summary: 1. Measure the swing drift on the bearing outer circumference when stopping after a 90° full-speed swing. Preparation: 1. Check the lubrication of the swing gear and swing bearing. 2. Place the machine on flat, solid ground with ample space for swinging. Do not conduct this test on a slope. 3. With 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. 4. Make two chalk marks: one on the swing bearing and one directly below it on the chassis frame. 5. Swing the upperstructure 90°. 6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



Two Check Marks



T202-07-03-005



Start the test from the position where the upperstructure is rotated 90°.



CAUTION: Prevent personal injury. Always make sure that the area is clear and that co-workers are out of the swing area before starting the measurement. Measurement: 1. Select the following switch positions:



T1F3-04-04-007



Auto-Idle/ Engine Con- Power Mode Work Mode Brake Acceleration trol Dial Switch Switch Switch Selector Fast Idle P Digging OFF S (Working) 2. Operate the swing control lever fully and return it to the neutral position when the mark on the upperstructure aligns with that on the chassis frame after swinging 90°. 3. Measure the distance between the two marks. 4. Align the marks again, swing 90°, then test in the opposite direction. 5. Repeat steps 2. to 4. three times each and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2.



Measure Difference Between Marks



Marking on Track Frame Marking on Swing Bearing T105-06-03-010



Remedy: Refer to the Troubleshooting B in Group T5-4.



T4-4-5



OPERATIONAL PERFORMANCE TEST / Excavator Test SWING MOTOR LEAKAGE Summary: 1. Check for upperstructure drift while suspending a load on a slope. Preparation: 1. Check the lubrication of the swing gear and swing bearing. 2. Park the machine on a smooth slope with a gradient of 26.8 %(15°) 3. Load bucket fully. In lieu of loading the bucket, weight (W) of the following specification can be used. W=900 kg (1980 lb) 4. With the arm rolled out, and bucket rolled in, position the arm top pin height to be level with the boom foot pin. 5. Swing the upperstructure to position it 90° to the slope. Make aligning marks on the swing bearing periphery and chassis frame using tape, as illustrated. 6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



T212-07-03-001



Measurement: 1. Select the following switch position: Auto-Idle/ Brake Engine Con- Power Mode Work Mode Acceleration Switch trol Dial Switch Switch Selector Slow Idle P Digging OFF S (Working) 2. Maintain the engine at slow idle. After five minutes, measure the difference between the marks along the swing bearing periphery and the chassis frame. 3. Perform the measurement in both right and left swing directions. 4. Perform the measurement three times in each direction and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4.



Measure Difference Between Marks



Marking on the Chassis Frame Marking on the Swing Bearing T105-06-03-010



T4-4-6



OPERATIONAL PERFORMANCE TEST / Excavator Test MAXIMUM SWINGABLE SLANT ANGLE CAUTION: Do not turn the brake switch OFF during swing, since the machine can cause tipping. Summary: 1. With the upperstructure swung 90° to the slope, check the maximum slant angle on which the upperstructure can swing to the uphill side. Preparation: 1. Check that the swing gear and bearing are well lubricated. 2. Load bucket fully, In lieu of loading the bucket, weight (W) of the following specification used. W=900 kg (1980 lb) 3. With 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. 4. Climb a slope and swing the upperstructure 90° to the slope. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). T212-07-03-001



Measurement: 1. Select the following switch positions: Auto-Idle/ Engine Con- Power Mode Work Mode Acceleration Brake Switch trol Dial Switch Switch Selector Fast Idle P Digging OFF S (Working) 2. Operate the swing lever to full stroke to swing the upperstructure to the uphill side. 3. If the machine can swing, measure the cab floor slant angle. 4. Increase the slope angle and repeat steps 2. and 3. Check both clockwise and counterclockwise. 5. Perform the measurement three times. Evaluation: Refer to the Performance Standard Table in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4.



T4-4-7



OPERATIONAL PERFORMANCE TEST / Excavator Test SWING BEARING PLAY Summary: 1. Measure the swing bearing play using a dial gauge to check the wear of bearing races and balls. Preparation: 1. Check swing bearing mounting bolts for looseness. 2. Check the lubrication of the swing bearing. Confirm that bearing rotation is smooth and without noise. 3. Install a dial gauge on the chassis frame as shown, using a magnetic base. 4. Position the front attachment to the front of the machine. 5. Position the dial gauge so that its needle point comes into contact with the bottom face of the bearing outer race. 6. Bucket should be empty. Measurement: 1. With 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). 2. Lower the bucket to the ground and use it to raise the front tires 0.5 m (20 in). Record the dial gauge reading (h2). 3. Calculate bearing play (H) from this data (h1 and h2) as follows: H = h2 − h1



Dial Gauge



Magnetic Base



T202-07-03-008



Round Frame Chassis



Magnetic Base



Dial Gauge



T105-06-03-015



Measurement (h2)



Measurement (h1)



The same height as the boom foot pin height.



T1F3-04-04-008 T212-07-05-003



Evaluation: Refer to the Performance Standard Table in Group T4-2.



T4-4-8



OPERATIONAL PERFORMANCE TEST / Excavator Test (Blank)



T4-4-9



OPERATIONAL PERFORMANCE TEST / Excavator Test HYDRAULIC CYLINDER CYCLE TIME Summary: 1. Measure the cycle time of the boom, arm, bucket, positioning (if equipped), blade (optional) and stabilizer (optional) cylinders. 2. The bucket should be empty. Preparation: 1. Be sure to measure at the position as follows. • To measure the cycle time of the boom cylinders: With the arm rolled out and the empty bucket rolled in, lower the bucket to the ground, as shown. • To measure the cycle time of the arm cylinder: With the empty bucket rolled in, position the arm so that it is vertical to the ground. Lower the boom until the bucket is 0.5 m (20 in) above the ground. • To measure the cycle time of the bucket cylinder: The empty bucket should be positioned at mid-stroke between roll-in and roll-out, so that the sideplate edges are vertical to the ground. • To measure the cycle time of the positioning cylinder: With the boom raise, arm rolled out and the empty bucket rolled in, as shown. • To measure the cycle time of the blade cylinder: Lower the bucket to the ground and use it to lift the machine to allow the blade cylinder to move fully upwards and downwards. • To measure the cycle time of the stabilizer cylinder: Lower the bucket to the ground and use it to lift the machine to allow the stabilizer cylinder to move fully upwards and downwards. 2. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



Boom Cylinder:



T1F3-04-04-009



Arm Cylinder:



0.5 m T1F3-04-04-010



Bucket Cylinder:



T105-06-03-018



Positioning Cylinder:



T1F3-04-04-002



T4-4-10



OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Select the following switch positions: Auto-Idle/ Engine Con- Power Mode Work Mode Acceleration trol Dial Switch Switch Selector Fast Idle P Digging OFF 2. To measure cylinder cycle times: (Cylinder full stroke includes cylinder cushioning zone.) • Boom cylinders: Measure the time it takes to raise the boom, and the time it takes to lower the boom. To do so, position the boom at one stroke end, then move the control lever to the other stroke end as quickly as possible. • Arm cylinder: Measure the time it takes to roll in the arm, and the time it takes to roll out the arm. To do so, position the arm at one stroke end, then move the control lever to the other stroke end as quickly as possible. • Bucket cylinder: 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. • Positioning cylinder: Measure the time it takes to raise the positioning, and the time it takes to lower the positioning. To do so, position the positioning at one stroke end, then move the control pedal to the other stroke end as quickly as possible. • Blade Cylinder: Measure the time it takes to raise the blade, and the time it takes to lower the blade. To do so, position the blade at one stroke end, then move the control lever to the other stroke end as quickly as possible. • Stabilizer Cylinder: Measure the time it takes to raise the stabilizer, and the time it takes to lower the stabilizer. To do so, position the stabilizer at one stroke end, then move the control lever to the other stroke end as quickly as possible. Move stabilizer cylinders, if provided at front and/or rear on both sides, one by one to measure each cycle time. 3. Repeat each measurement three times and calculate the average values.



Evaluation: Refer to the Performance Standard Table in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4.



T4-4-11



OPERATIONAL PERFORMANCE TEST / Excavator Test DIG FUNCTION DRIFT CHECK • Maximum Reach Position



Retracted Distance



Summary: Measure dig function drift, which can be caused by oil leakage in the control valve and boom, arm, bucket and positioning(If equipped) cylinders, with the loaded bucket. NOTE: When testing the dig function drift just after cylinder replacement, slowly operate each cylinder for ten minutes to its stroke end to purge air. Preparation: 1. Load bucket fully. In lieu of loading the bucket, weight (W) of the following specification can be used. W=900 kg (1980 lb) 2. Position the arm cylinder with the rod 50 mm (2 in) extended from the fully retracted position. 3. Position the bucket cylinder with the rod 50 mm (2 in) retracted from the fully extended position. 4. Position the positioning cylinder with the rod 50 mm (2 in) retracted from the fully extended position. 5. With the arm rolled out and the bucket rolled in, hold the bucket so that the height of the bucket pin is the same as the boom foot pin. 6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



Extended Distance



Retracted Distance



The arm top pin and the boom foot pin are at the same Drifting height. Amount T1F3-04-04-011



2-piece Boom



Retracted Distance



T1F3-04-04-001



Arm Cylinder Extension



Measurement: 1. Stop the engine. 2. Five minutes after the engine has been stopped, measure the change in the position of the bottom of the bucket and positioning, as well as the boom, arm and bucket cylinders. 3. Repeat step 2. three times and calculate the average values.



Mark



T110-06-03-001



Evalution: Refer to the Operational Performance Standard in Group T4-2.



Boom, Bucket and Positioning Cylinder Retraction Mark Mark



Remedy: Refer to the Troubleshooting B in Group T5-4.



T110-06-03-002



T4-4-12



OPERATIONAL PERFORMANCE TEST / Excavator Test (Blank)



T4-4-13



OPERATIONAL PERFORMANCE TEST / Excavator Test CONTROL LEVER OPERATING FORCE Summary: 1. Check the operation of each control lever and the steering wheel, and measure their operating force. 2. Measure the maximum operating force of the control lever for the front attachment and the steering wheel. 3. Measure the force at the center of the control lever grip. Preparation: Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). CAUTION: Prevent personal injury. Always make sure that the area is clear and that co-workers are out of the swing area before starting the measurement. Measurement: 1. Measure the force at steering wheel and each control lever. 2. Select the following switch positions: Auto-Idle/ Engine Con- Power Mode Work Mode Acceleration trol Dial Switch Switch Selector Fast Idle P Digging OFF 3. Operate each boom (raise), arm and bucket lever to the fully and measure the maximum operating force for each with each actuator relieved. 4. Operate boom (lower) lever and measure the maximum operating force with the boom (lower) relieved by jacking up the machine in a safe area. 5. Operate swing lever and measure the maximum operating force with swing relieved after securing the front attachment to prevent swinging. 6. To measure the steering wheel, attach the spring scale on the knob and measure the maximum operating force when moving the steering wheel. 7. Repeat steps 3. to 6. three times and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2.



T4-4-14



T107-06-03-003



Knob



MCBB-01-022



OPERATIONAL PERFORMANCE TEST / Excavator Test CONTROL LEVER STROKE Summary: 1. Measure each lever stroke at the lever top using a ruler. 2. Measure the lever stroke at the grip center of each control lever. 3. In case lever stroke play is present in the neutral position, add half (1/2) the play present to both side lever strokes. Preparation: Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Stop the engine. 2. Measure each lever stroke at the lever top from neutral to the stroke end using a ruler. 3. For steering, measure the rotation frequency necessary for the right to left stroke end or vice versa. 4. Repeat step 2. to 3. three times and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2.



T4-4-15



Stroke



Stroke



Neutral



T1F3-04-04-012



OPERATIONAL PERFORMANCE TEST / Excavator Test COMBINED BOOM RAISE / SWING FUNCTION CHECK Summary: 1. Check boom raise and swing movement and speeds while operating both functions simultaneously. 2. Make sure that the cylinders don’t hesitate while operating the cylinder with the engine running at fast idle. Preparation: 1. With the arm fully rolled out and bucket fully rolled in, lower the bucket to the ground. The bucket must be empty. 2. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



T212-07-03-005



CAUTION: Prevent personal injury. Always make sure that the area is clear and that co-workers are out of the swing area before starting the measurement. Measurement: 1. Select the following switch positions: T212-07-03-006



Auto-Idle/ Engine Con- Power Mode Work Mode Acceleration trol Dial Switch Switch Selector Fast Idle P Digging OFF 2. Raise the boom and swing simultaneously, both at full stroke. 3. When the upperstructure rotates 90°, release the control levers to stop both functions. Measure the time required to swing 90° and the height (H) of the bucket teeth. (The bucket must be empty.) 4. Repeat steps 2. to 3. three times and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4.



T4-4-16



H



90°



T212-07-03-007



OPERATIONAL PERFORMANCE TEST / Component Test PRIMARY PILOT PRESSURE (Including Brake Circuit) CAUTION: If air is mixed in the brake system, the brake function is reduced, possibly resulting in serious hazard. Be sure to bleed air from the brake system after disconnecting and reconnecting the pipe lines. Refer to the Troubleshooting B in Group T5-4. IMPORTANT: Primary pilot pressure circuit shuts off a circuit connecting to pilot relief valve if pressure in the accumulator is insufficient, and delivers primary pilot pressure to accumulator circuit. At this time, primary pilot pressure reaches 15 MPa (153 kgf/cm2, 2180 psi) or high, so use a pressure gauge capable of measuring 15 MPa (153 kgf/cm2, 2180 psi) or higher.



Pilot Filter



MCBB-07-026



Preparation: 1. Properly shut down the engine. 2. Press the air release valve on top of the hydraulic oil tank to release any remaining pressure. 3. Disconnect the hose end from the pilot filter inlet or outlet port Install tee 3/4-16UNF(ST 6477), fitting (ST 6069), pressure gauge (ST 6314) and coupling (ST 6332). : 22 mm, 24 mm 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Select the following switch positions: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Fast Idle



P



Digging



OFF



2. Measure the pilot pressure in each specified setting above. 3. Repeat the measurement three times and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2.



T4-5-1



T1F3-04-05-001



OPERATIONAL PERFORMANCE TEST / Component Test Primary Pilot Pressure Adjustment Procedure Adjustment: Adjust the relief valve set-pressure as necessary.



Pilot Relief Valve



1. Remove plug (1) from the relief valve. : 36 mm 2. Remove shims (2) from the relief valve. 3. Install the estimated number of shims (2). 4. Tighten plug (1). : 58.8±5.9 N⋅m (6±0.6 kgf⋅m, 43±4 lbf⋅ft) 5. Check the set-relief pressure. NOTE: Standard Change in Pressure Set the thickness of shims at less than 1.5 mm. Shim Thickness



W1F3-02-05-001



1



Change in Relief Pressure



(mm)



kPa



(kgf/cm2)



(psi)



0.2



61.8



(0.63)



(9)



0.4



124.6



(1.27)



(18)



0.8



249.2



(2.54)



(36)



2



T1F3-03-08-002



T4-5-2



OPERATIONAL PERFORMANCE TEST / Component Test (Blank)



T4-5-3



OPERATIONAL PERFORMANCE TEST / Component Test SECONDARY PILOT PRESSURE Preparation: 1. Properly shut down the engine. 2. Press the air release valve on top of the hydraulic oil tank to release any remaining pressure. 3. Measure pressure at the location between the pilot valve and the signal control valve: Disconnect the pilot circuit hose to be measured from the signal control valve. Connect hose (9/16-18UNF approx. 400 mm long) to the signal control valve. Install tee (4351843), adapter (ST 6460) fitting (ST 6069), coupling (ST 6332) and pressure gauge (ST 6315) between the hoses. : 17 mm, 19 mm



Signal Control Valve



NOTE: When disconnecting the pilot lines from the signal control valve, use tool (SNAP-ON GAN850812B: size 19.05 mm) to easily disconnect the lines. 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



T4-5-4



T1F3-04-05-008



OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Select the following switch positions: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Fast Idle P Digging OFF 2. Measure the pilot pressure in each specified setting above with the corresponding control lever operated full stroke. 3. Repeat the measurement three times and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4.



T4-5-5



OPERATIONAL PERFORMANCE TEST / Component Test SOLENOID VALVE SET PRESSURE Solenoid Valve Unit Measure solenoid valve set pressure with both the Dr.ZX and the pressure gauge. Preparation: 1. Properly shut down the engine. 2. Press the air release valve on top of the hydraulic oil tank to release any remaining pressure. 3. Disconnect line (1) from the solenoid valve to be measured. Install hose (Parts Number: 4216453), tee (ST 6451), adapter (ST 6461), and pressure gauge (ST 6942) to the disconnected end at the solenoid valve side, as illustrated. : 17 mm, 19 mm, 22 mm Connect Dr.ZX to the machine for solenoid valve set pressure monitoring. 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



SC



SE



SI



SG



T1F3-03-10-017



Solenoid Valve Pressure Gauge



1



Hose



T4-5-6



Tee



Adapter



T157-05-04-002



OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Select the following switch positions: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Fast Idle P Digging OFF Slow Idle P Digging OFF 2. Operate as instructed below for each measuring solenoid valve: Solenoid Valve SC: Perform a combined operation of boom raise and arm roll-in. Solenoid Valve SE: Set the brake switch to OFF position. (ON-OFF Valve) Solenoid Valve SI: Set the engine speed control mode selection switch to Creeper. Solenoid Valve SG: Set the brake switch to S (Working). 3. Read the values on both Dr.ZX and the pressure gauge. The solenoid valve SE cannot be measured with Dr.ZX. 4. Repeat the measurement three times and calculate the average values. Evaluation: Refer to the performance Standard Table in Group T4-2.



T4-5-7



OPERATIONAL PERFORMANCE TEST / Component Test Solenoid Valve Set Pressure Adjustment Procedure



7



IMPORTANT: Do not loosen the adjusting screw excessively. The O-ring on the threads may come off the sealing surface, causing oil to leak. Be sure not to loosen more than 2 turns. 1. Loosen lock nut (7). Turn adjusting screw (8) to adjust the set pressure of the solenoid valve. 2. Retighten lock nut (7). : 10 mm : 3 mm : 5 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft) 3. Check the set pressure of the solenoid valve. NOTE: Standard Change in Pressure (Reference) Screw Turns 1/4 1/2 3/4 1 kPa 78 156 234 312 Change in Pres- (kgf/cm2) (0.8) (1.6) (2.4) (3.2) sure (psi) (11) (23) (34) (46)



8



T107-06-04-020



The distance between the lock nut end and screw end should be 2.0 mm (0.079 in) or less.



8 7 T107-06-05-001



7



Pressure Increase



8



Pressure Decrease



W107-02-05-129



T4-5-8



OPERATIONAL PERFORMANCE TEST / Component Test MAIN PUMP DELIVERY PRESSURE The main pump delivery pressure can also be measured with Dr.ZX. Preparation: 1. Properly shut down the engine. 2. Press the air release valve on top of the hydraulic oil tank to release any remaining pressure. 3. Remove the plug from the main pump delivery port. Install adapter G1/4(ST 6067), hose (ST 6943) and pressure gauge (ST 6941) on the port. : 19 mm Or connect Dr.ZX to the machine for main pump delivery pressure monitoring. 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Select the following switch positions: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Fast Idle



P



Digging



OFF



2. Measure the pressure with the control levers in neutral. 3. Repeat the measurement three times and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4.



T4-5-9



Pump2: Delivery Port a2



Pump1: Delivery Port a1 T1F3-01-02-008



OPERATIONAL PERFORMANCE TEST / Component Test MAIN RELIEF VALVE SET PRESSURE The main relief pressure can also be measured with Dr.ZX. Summary: Measure the main relief valve setting pressure at the main pump delivery port. Preparation: 1. Properly shut down the engine. 2. Press the air release valve on top of the hydraulic oil tank to release any remaining pressure. 3. Remove the plug from the main pump delivery port. Install adapter G1/4 (ST 6067), hose (ST 6943) and pressure gauge (ST 6941) on the port. : 19 mm Or connect Dr.ZX to monitor the main pump delivery pressure. 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



T4-5-10



Pump2: Delivery Port a2



Pump1: Delivery Port a1 T1F3-01-02-008



OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Select the following switch positions: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Fast Idle P Digging OFF 2. Relieve each actuator to measure main relief pressures. First, slowly operate bucket, arm, and boom control levers to the stroke end to relieve each function at a time. 3. As for the swing function, place the swing lock lever to the Lock position so the upperstructure is immovable. Slowly operate the swing lever to relieve the swing function. 4. For travel operation, set the engine speed control model selection switch to the pedal mode. Slowly depress travel pedal for forward travel, while depressing positively the brake pedal not to allow the machine to move. Evaluation: Refer to the Performance Standard Table in Group T4-2. NOTE: If the measure pressures for all functions are lower than the specified range, the probable cause is a decrease of the main relief valve setting pressure. If the relief pressure of a particular function is lower, the probable cause is other than main relief valve.



T4-5-11



OPERATIONAL PERFORMANCE TEST / Component Test Main Relief Pressure Setting Adjustment Procedure Adjustment: 1. Loosen lock nut (1). : 17 mm : 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)



Main Relief Valve



2. Turn adjusting screw (2) to adjust the main relief set pressure referring to the table below. 3. Retighten lock nut (1). 4. Recheck the set pressures. NOTE: Standard Change in Pressure (Reference) Plug Turns 1/4 Change in MPa 2.79 Relief (kgf/cm2) (28.5) Pressure (psi) (405)



1/2 5.59 (57) (811)



3/4 8.36 (85.2) (1212)



1 11.2 (114) (1620)



T176-03-03-035



1



2



T176-03-03-010



Adjusting Screw



Pressure Increase



Pressure Decrease



T105-06-05-002



T4-5-12



OPERATIONAL PERFORMANCE TEST / Component Test RELIEF Swing)



PRESSURE



(When



relieving



Adjust pressure by changing the number of shims (2). 1. Remove the swing relief valve. : 41 mm



Swing Relief Valve



2. Remove plug (5), sleeve (4), and piston (3). : 30 mm 3. Adjust the set-pressure by installing shims (2) between piston (3) and spring seat (1). 4. After adjusting, install piston (3), sleeve (4), and plug (5). : 118 N⋅m (12 kgf⋅m, 88 lbf⋅ft) NOTE: Replace seals (A, B, and C) with new ones. A: JIS B 2401 G30 1B B: AS568-023 (Aero-Space Standard) C: AS568-125 (Aero-Space Standard)



T178-03-02-001



1



5. Install the swing relief valve. : 176 N⋅m (18 kgf⋅m, 130 lbf⋅ft)



2



3



4



5



6. Check the set-pressure. NOTE: Standard Change in Pressure (Reference) Shim Thickness



Change in Relief Pressure



(mm)



kPa



(kgf/cm2)



(psi)



0.1



610



6.3



(60)



A



T4-5-13



B



C



T178-03-02-005



OPERATIONAL PERFORMANCE TEST / Component Test RELIEF Travel)



PRESSURE



(When



relieving



Adjustment Loosen lock nut (2) to adjust adjusting screw (1). 1. Loosen lock nut (2). : 19 mm 2. Turn adjusting screw (1) to adjust. : 6 mm 3. Tighten lock nut (2). : 20±2 N⋅m (2±0.2kgf⋅m, 14.5±1.5 lbf⋅ft) Travel Relief Valve



NOTE: Standard Change in Pressure (Reference) Adjusting Screw Turns Change in Pressure



W1F3-03-02-001



1



MPa



15



(kgf/cm2)



153



(psi)



2180



1



NOTE: Relief valve at travel motor works when brake is applied. Main relief valve at control valve works during normal travel.



2 T1F3-03-05-035



2



Pressure Increase



1



Pressure Decrease W107-02-05-129



T4-5-14



OPERATIONAL PERFORMANCE TEST / Component Test OVERLOAD PRESSURE



RELIEF



VALVE



SET



Summary: 1. The circuit pressure must be increased by applying an external force while blocking the return circuit from the control valve. This measuring method is hazardous and the results obtained with this method are unreliable. 2. The oil flow rate used to set the overload relief pressure is far less than that used to set the main relief pressure. Therefore, measuring the overload pressure in the main circuit by increasing the main relief set-pressure more than the overload valve set-pressure is not a proper method. In addition, in case a main relief valve designed to leak a small quantity of oil before reliving is used, its pre-leaking start pressure must be increased more than the overload relief valve set-pressure. However, the pre-leaking start pressure is not always increased more than the overload relief valve set-pressure as the adjustable upper limit of the main relief valve set-pressure is provided. Accordingly, the overload relief valve assembly should be removed from the machine and checked on a specified test stand at a correct oil flow rate. Some overload relief valves come in contact with the control valve body to block the oil passage. When this type of overload relief valve is checked, the control valve body must be precisely finished as the test unit. Provide one control valve other than that on the machine as a test kit.



3. If the overload relief valve performance must be checked on the machine, however, measure the main relief pressure while releasing each front function respective to the measuring overload relief valve. And, assume that the overload relief valve is functioning correctly if the obtained main relief pressure is within the specified value range. Measure the main pressure of the front functions as follows: Preparation: 1. Properly shut down the engine. 2. Press the air release valve on top of the hydraulic oil tank to release any remaining pressure. 3. Remove the plug from the main pump delivery port. Install adapter G1/4 (ST 6067), hose (ST 6943) and pressure gauge (ST 6941) on the port. : 19 mm 4. Connect Dr.ZX to the machine for main pump delivery pressure monitoring. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



Pump2: Delivery Port a2



Pump1: Delivery Port a1 T1F3-01-02-008



T4-5-15



OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Select the following switch positions: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Fast Idle P Digging OFF 2. Slowly operate bucket, arm, and boom control levers to the stroke ends to relieve each function one at a time. 3. Read the pressures on the pressure gauge while releasing the front functions. 4. Perform the measurement for the bucket, arm, and boom, in that order. 5. Repeat the measurement three times and calculate the average value for each front function. Evaluation: 1. Performances of the overload relief valves are normal if the measured main relief pressures are within the specified value range. Refer to the Performance Standard Table in Group T4-2.



T4-5-16



OPERATIONAL PERFORMANCE TEST / Component Test Overload Relief Valve Set Pressure Adjusting Procedure NOTE: In principle, adjust the overload relief valve set pressure on a test stand.



1



2



Adjustment: 1. Loosen lock nut (1). : 17 mm : 31.5 N⋅m (3.2 kgf⋅m, 23.2 lbf⋅ft) 2. Turn adjustiing screw (2) to adjust the overload relief pressure setting referring to the table below.



T176-03-03-012



3. Retighten lock nut (1). 4. Recheck the set pressures.



Adjusting Screw



NOTE: Standard Change in Pressure (Reference) Plug Turns 1/4 1/2 3/4 1 Change in MPa 2.79 5.59 8.36 11.2 Relief (kgf/cm2) (28.5) (57) (85.2) (114) Pressure (psi) (405) (811) (1212) (1620)



Pressure Increase



Pressure Decreas e



T105-06-05-002



T4-5-17



OPERATIONAL PERFORMANCE TEST / Component Test MAIN PUMP FLOW RATE MEASUREMENT • P-Q Control (Torque Control) Summary: Main pump performance is checked by measuring the pump flow rate with a hydraulic tester installed at the main pump delivery port (one side) to be measured. Use Dr. ZX and a pressure gauge at the same time. IMPORTANT: This measurement procedure is a simple method. The measured data will be lower by approx. 5 % than the accurately measured value. To measure accurately, disconnect the return circuit from the control valve and connect it to the hydraulic oil tank. Preparation: 1. Stop the engine. Push the air bleed valve to bleed air. Connect a vacuum pump to the oil filler port. NOTE: Operate the vacuum pump while connecting the pump flow rate test line. 2. Disconnect the delivery hose from the main pump (one side) to be measured. Connect pipe (1) to the pump delivery port using the split flanges and bolts which were used to connect the disconnected delivery hose. : 41 mm : 8 mm 3. Connect pipe (1) to hydraulic tester (4) using test hose (2) and adapter (3). Connect adapter (5), test hose (6) and flange (7) to hydraulic tester (4). : 41 mm



5. Install a pressure gauge to the main pump to be measured. (Refer to T4-5-10 Main Relief Pressure Check.) ： 19 mm 6. Disconnect the vacuum pump. Loosen plug (10) on the top of the pump casing to bleed air from the main pump casing until oil only comes out of the plug clearance. 7. Fully open the loading valve of the hydraulic tester. 8. Start the engine. Check the pressure gauge connection for any oil leaks. Install Dr. ZX and select the monitor function. Measurement: 1. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). 2. Measure the maximum flow rate. 3. Select each switch position as follows: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Fast Idle



P



Digging



OFF



4. Adjust the main relief valve set-pressure in the control valve to each pressure point specified along the main pump P-Q curve. (Refer to T4-2-6) Slowly close the loading valve of the hydraulic tester while relieving the pressure in the arm roll-in circuit. Measure the flow rates and engine speeds at the pressure points specified in the P-Q curve. 5. Repeat each measurement three times and calculate the average values.



4. Connect the delivery hose to flange (7) with split flanges (8) and bolts (9). : 8 mm



T4-5-18



OPERATIONAL PERFORMANCE TEST / Component Test Evaluation: 1. Convert the measured flow rates to those at the specified pump speed using the following formulas:



2. Standard Flow Rate Refer to T4-2 Operational Performance Standard. NOTE: When actually measuring, install pipe (1) only to the pump to be measured.



Qc = (Ns × Q) ⁄ Ne Qc : Q: Ns : Ne :



Converted Flow Rate Measured Flow Rate Specified Pump Speed:1850 min-1 Measured Engine Speed: Dr.ZX



1



2



3



5



4



6



7



8



9



Delivery Hose (To Control Valve)



T1F3-04-05-010



10



MCBB-07-055



1 - Pipe (ST 6192) 2 - Test Hose (ST 6145) 3 - Adapter G1 × UNF1-7/8 (ST 6146)



4 - Hydraulic Tester (ST 6299) 5 - Adapter G1 × UNF1-7/8 (ST 6146) 6 - Test Hose (ST 6145)



7 - Flange (ST 6121) 8 - Split Flange (4506459)



T4-5-19



9 - Bolt (J781030) (4 Used) 10 - Plug



OPERATIONAL PERFORMANCE TEST / Component Test • Pilot Characteristics CAUTION: If air is mixed in the brake system, the brake function is reduced, possibly resulting in serious hazard. Be sure to bleed air from the brake system after disconnecting and reconnecting the pipe lines. Refer to the Troubleshooting B in Group T5-4. Summary: Main pump performance is checked by measuring the pump flow rate with a hydraulic tester installed at the main pump delivery port (one side) to be measured. Use Dr. ZX and a pressure gauge at the same time. IMPORTANT: This measurement procedure is a simple method. The measured data will be lower by approx. 5 % than the accurately measured value. To measure accurately, disconnect the return circuit from the control valve and connect it to the hydraulic oil tank. Preparation: 1. Referring to steps 1 to 5 on page T4-5-18, connect a hydraulic tester to the main pump to be measured. 2. Disconnect the hose from regulator port Pi of the pump to be measured. Connect plug (4174545) (9/16 UNF) to the disconnected hose. : 19 mm 3. Install adapters (14) (3 used) to reducing valve (15). Disconnect the hose (PE) from P3 port of the 3-unit solenoid valve, and install tee (11), adapter (12) and hose (13). Connect the other end of hose (13) to regulator port P1 on reducing valve (15). : 19 mm 4. Install tee (16) to port P2 on reducing valve (15). Connect pressure gauge (17) and hose (13) to tee (16). Connect hose (13) to the regulator. : 19 mm 5. Connect hose (13) and adapter (14) to port T on reducing valve (15). Remove plug L from the return pipe. Connect hose (13) to the plug L port. : 19 mm 6. Remove all the connectors from the 3-unit solenoid valve for pump control.



7. Disconnect the vacuum pump. Loosen plug (10) on the top of the pump casing. Bleed air from the pump casing until oil only comes out of the plug. 8. Fully open the loading valve of the hydraulic tester. 9. Start the engine. Check the line connections for any oil leaks. Measurement: 1. The pump flow rate in response to the external command pilot pressure is measured. 2. Select each switch position as follows: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Fast Idle P Digging OFF 3. Adjust the reducing valve set-pressure to each pressure point specified along the main pump P-Q curve. (Pilot Characteristics) (Refer to T4-2-7) Measure the flow rates and engine speeds at the pressure points specified in the P-Q curve. 4. Repeat each measurement three times and calculate the average values. Evaluation: 1. Convert the measured flow rates to those at the specified pump speed using the following formulas: Qc = (Ns × Q) / Ne Qc : Q: Ns : Ne :



Converted Flow Rate Measured Flow Rate Specified Pump Speed (1850 min-1) Measured Engine Speed: Dr.ZX



2. Standard Flow Rate Refer to T4-2 Operational Performance Standard.



T4-5-20



OPERATIONAL PERFORMANCE TEST / Component Test 1



2



3



5



4



6



7



8



9



Delivery Hose (To Control Valve) Hose (PE)



T1F3-04-05-010



Pi port (opposite faces)



Pi port



T1F3-03-01-002



10 T1F3-01-02-010



3-Unit Solenoid Valve Reducing Valve Port Position



Reducing Valve



Return Pipe



T L



P2



P1



14



17



To 3-Unit Solenoid Valve P3 Prt



13 14



To Regulator Port Pi



13



16



14



14



15



13



12



11 T1F3-04-05-009



1 - Pipe (ST 6192)



6 - Test Hose (ST 6145)



2 - Test Hose (ST 6145)



7 - Flange (ST 6121)



3 - Adapter G1 × UNF1-7/8 (ST 6146) 4 - Hydraulic Tester (ST 6299)



8 - Split Flange (4506459)



5 - Adapter G1 × UNF1-7/8 (ST 6146)



11 - Tee 7/16-20UNF x 7/16-20UNF x G1/4 (ST6456) 12 - Adapter 9/16 UNF x G1/4 (A852123) 13 - Hose 9/16 UNF (4304905)



9 - Bolt (J781030) (4 Used)



14 - Adapter 9/16 UNF x G3/8 (A852133)



10 - Plug



T4-5-21



15 - Reducing Valve (4325439)



16 - Tee 9/16 UNF x G1/4 (ST 6450) 17 - Pressure Gauge (ST 6931)



OPERATIONAL PERFORMANCE TEST / Component Test REGULATOR ADJUSTMENT • Minimum and Maximum Flow Rate Adjustment This regulator can adjust minimum and maximum flow rates with adjusting screws (1) and (2) at each main pump body. 3



4



2



4



3



1



1



Main Pump1 1 - Adjusting Screw (For Minimum Flow Adjustment)



2-



Adjustment Item 1. Minimum Flow Rate



Adjusting Screw (For Maximum Flow Adjustment)



Main Pump2 3-



Lock Nut (For Minimum Flow Adjustment)



4-



T1F3-03-01-003



Lock Nut (For Maximum Flow Adjustment)



Adjustment Procedure Remarks Loosen lock nut (3) and turn 1) Other control characteristics remain adjusting screw (1). unchanged. Notice that the required Rotating adjusting screw (1) 1/4 power is increased at maximum a turn clockwise increases the delivery pressure if tightened minimum pump flow rate by 3.0 excessively. L/min. (183 in3/min). 2) Securely retighten lock nut (3) after : 24 mm Nut (3) the adjustment. : 130 N･m (13.3 kgf･m)



Q



Pi



2. Maximum Flow Rate



Loosen lock nut (4) and turn 1) Other control characteristics remain adjusting screw (2). unchanged, except that only Rotating adjusting screw (2) 1/4 maximum oil rate varies. a turn clockwise decreases the 2) Securely retighten lock nut (4) after maximum pump flow rate by 3.0 the adjustment. L/min. (183 in3/min). : 24 mm Nut (4) : 130 N･m (13.3 kgf･m)



Q



Pi



T4-5-22



OPERATIONAL PERFORMANCE TEST / Component Test • Torque Adjustment (P-Q Control) For torque adjustment, similarly adjust both the adjusting screws (5) and (6) at the main pumps 1 and 2. Pressure change due to adjustment is that when both the pumps are pressurized at the same time.



9



8 5 6



10 7



T1F3-03-01-008



Adjustment Item 1. Outer Spring Adjustment Q



P1+P2



Pd



2. Inner Spring Adjustment Q



P1+P2



Pd



Adjustment Procedure Remarks Loosen lock nut (7) and turn 1) When adjusting screw (5) is turned, inner spring (8) set-force adjusting screw (5). varies. Therefore, when adjusting screw (5) is turned clockwise, turn Rotating adjusting screw (5) 1/4 adjusting screw (6) 1.69 times a turn clockwise: turns of adjusting screw (5) • Compensating: + 1.75Mpa counterclockwise to keep inner (17.8 kgf/cm2) spring (8) set-force unchanged. • Torque: + 36.5 N･m (3.63 kgf･ 2) Securely retighten lock nut (7) and m) nut (10) after the adjustment. : 36 mm : Nut (7) : 160 N･m (16.3 kgf･m)



Loosen lock nut (10) and turn 1) Securely retighten lock nut (10) after the adjustment. adjusting screw (6). Rotating adjusting screw (6) 1/4 a turn clockwise: • Pump flow rate: + 7.1 L/min. (433 in3/min). • Torque: + 38.1 N･m (3.88 kgf･ m) : 13 mm : Nut (10) : 16 N･m (1.63 kgf･m)



T4-5-23



OPERATIONAL PERFORMANCE TEST / Component Test • Pilot Pressure Characteristics



11 12



T1F3-03-01-007



Adjustment Item Pilot Pressure Characteristics



Adjustment Procedure Remarks Loosen lock nut (11) and turn 1) Securely retighten lock nut (11) after the adjustment. adjusting screw (12). Rotating adjusting screw (12) 1/4 a turn clockwise: • Pump flow rate: + 12.6 L/min. (769 in3/min). • Flow rate control starting pressure: + 177 kPa (1.8 kgf/cm2) : 13 mm : Nut (11) : 16 N･m (1.63 kgf･m)



Q



Pi



T4-5-24



OPERATIONAL PERFORMANCE TEST / Component Test SWING MOTOR DRAINAGE Summary: To check swing motor performance, measure the amount of oil draining from the swing motor while swinging the upperstructure. NOTE: The amount of drain oil from the swing motor will change depending on hydraulic oil temperature.



1



CAUTION: Prevent personal injury. Always make sure that the area is clear and that co-workers are out of the swing area before starting the measurement. Also, take care not to fall off the machine while the measurement. Preparation: 1. Maintain hydraulic oil temperature at 50±5 °C (122±9 °F). Rotate the swing motor to warm the inside of the motor. 2. Properly shut down the engine. Press air release valve (1) on the top of the hydraulic oil tank to release any remaining pressure. 3. Disconnect swing motor drain hose (2) at the hydraulic oil tank end. Install plug (ST 6213) to the disconnected end on the hydraulic oil tank. : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)



MCBB-07-025



2



T178-04-04-005



T4-5-25



OPERATIONAL PERFORMANCE TEST / Component Test Preconditions for Measurement: 1. Select the following switch positions: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Fast Idle P Digging OFF Measurement: 1. Amount of Oil Drained While Swinging the Upperstructure (1) Fully retract the arm cylinder. Fully extend the bucket cylinder. Raise the boom so that the arm tip pin height is the same as the boom foot pin height. Be sure that the bucket is empty. (2) Start the engine. Operate and hold the swing lever full stroke. Start draining oil measurement after the swing speed reaches a constant maximum speed. The measuring time should be more than 45 seconds. (3) Repeat the measurement at least three times in both clockwise and counterclockwise directions, and calculate the average values. 2. Amount of Oil Drained While Relieving Swing Motor Circuit (1) Lower the swing lock pin to the Lock position so that the upperstructure does not move. (2) Thrust the bucket teeth into the ground as illustrated so that the upperstructure does not rotate when the swing lever is operated full stroke. (3) Start the engine. Operate and hold the swing lever full stroke. Start drain oil measurement when drain oil starts coming out of the drain hose end. The measuring time should be more than 45 seconds. (4) Repeat the measurement at least three times in both clockwise and counterclockwise directions, and calculate the average values.



The same height as boom foot pin height



T212-07-04-001



Swing Lock Pin



M216-05-004



T212-07-04-002



T4-5-26



OPERATIONAL PERFORMANCE TEST / Component Test Evaluation: Refer to the Operational Performance Standard Table in Group T4-2. ∗ Conversion of the amount of drain oil measured into the per-minute value First measure the amount of drain oil using a calibrated container. Then, convert the measured drain oil into the per-minute value using the formula below: △Q = 60 × q / t Where: △Q : Amount of drain oil per minute (L/min) t : Time measured (seconds) q : Total amount of drain oil (L)



T107-06-05-008



T4-5-27



OPERATIONAL PERFORMANCE TEST / Component Test TRAVEL MOTOR DRAINAGE Summary: To check travel motor performance, measure the amount of oil draining from the travel motor while rotating the travel motor with the measuring jacked up. Be sure to secure the safety of the personnel during the measurement, and pay good attention to the safety of the surroundings.



1



NOTE: The amount of drain oil from the travel motor will change depending on hydraulic oil temperature. Preparation: 1. Main hydraulic oil temperature at 50±5 °C (122±9 °F). Rotate the travel motor to warm the inside of the motor. 2. Properly shut down the engine. Press the air release valve (1) on top of the hydraulic oil tank to release any remaining pressure.



MCBB-07-025



2



3. Disconnect the travel motor drain hose (2) at the travel motor end. Install plug (3/4-16UNF) (4174546) to the disconnected end. Connect the drain hose (3/4-16UNF) to the travel motor. : 22 mm, 27 mm Preconditions for Measurement: 1. Select the following switch positions: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Full P Digging OFF Shift Lever D



Brake Switch A (Ale Lock)



T1F3-04-05-007



T4-5-28



OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Amount of Oil Drained While Rotating Travel Motor 1-1. Start the engine. CAUTION: Securely support the raised track using wooden blocks. When working around moving parts is unavoidable, pay special attention to ensure that hands, feet, and clothing do not become entangled. 1-2. Raise the undercarriage with the stabilizer and blade provided at the front and rear of the undercarriage. When the machine is equipped with the stabilizer or blade at only the rear of the undercarriage, lower the front attachment, and raise the front wheels as shown at right. 1-3. Rotate the travel motor with the travel pedal operated full stroke. Receive the drain oil from the test hose and measure the time at the same time. The measuring time should be more than 45 seconds. 1-4. Repeat the measurement at least three times in forward and reverse directions, and calculate the average values. 2. Amount of Oil Drained While Relieving Travel Motor 2-1. Start the engine. 2-2. With the service brake depressed, depress the travel pedal gradually to relieve the travel motor. 2-3. Start drain oil measurement when drain oil starts coming out of the drain hose end while relieving travel motor. The measuring time should be more than 45 seconds. 2-4. Repeat the measurement at least three times in both directions, and calculate the average values.



T4-5-29



T1F3-04-02-002



OPERATIONAL PERFORMANCE TEST / Component Test Evaluation: Refer to the Performance Standard Table in Group T4-2. ∗ Conversion of the amount of drain oil measured into the per-minute value First measure the amount of drain oil using a calibrated container. Then, convert the measured drain oil into the per-minute value using the formula below: ∆Q = 60 × q / t Where: ∆Q : Amount of drain oil per minute (L/min) t : Time measured (seconds) q : Total amount of drain oil (L)



T4-5-30



OPERATIONAL PERFORMANCE TEST / Component Test STEERING VALVE RELIEF VALVE SET PRESSURE Measure steering valve relief valve set pressure with both the Dr.ZX and the pressure gauge. Summary: The steering circuit has the steering valve relief valve. When the steering valve relief valve is malfunctioning, the steering wheel may become heavier.



1



Preparation: 1. Properly shut down the engine. 2. Press the air release valve (1) on top of the hydraulic oil tank to release any remaining pressure. 3. Disconnect the hose end from the steering pilot filter inlet or outlet port. Install tee 3/4-16UNF(ST 6477), fitting (ST 6069) and pressure gauge assembly (ST 6933). : 22 mm, 24 mm



MCBB-07-025



Connect Dr.ZX to the machine for pump3 delivery pressure monitoring. 4. Start the engine. Check the pressure gauge connection for any oil leakage. 5. Maintain hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Select the following switch positions: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Fast Idle P Digging OFF 2. Turn the steering wheel to the right or left stroke end to measure the steering pressure using the pressure gauge. 3. Repeat the measurement three times, and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2. Remedy: The steering valve relief valve cannot be adjusted. If it does not fulfill the standard, replace as a unit.



T4-5-31



T1F3-04-05-006



Steering Pilot Filter



OPERATIONAL PERFORMANCE TEST / Component Test BRAKE PRESSURE (Front and Rear) CAUTION: If air is mixed in the brake system, the brake function is reduced, possibly resulting in serious hazard. Be sure to bleed air from the brake system after disconnecting and reconnecting the pipe lines. Refer to the Troubleshooting B in Group T5-4. Summary: Brake pressure is measured on the output side of the brake valve. Measure the pressure when the brake pedal is depressed, and that when the working brake is applied. Preparation: CAUTION: Attaching the measuring devices is carried out under the machine. To avoid unintended travel or operation of the machine, the machine must be parked on the level firm ground with the bucket penetrated into the ground as shown. 1. Properly shut down the engine. 2. Press air release valve on the top of the hydraulic oil tank to release any remaining pressure. 3. Press and release the brake at least 50 strokes to reduce the accumulated pressure left in the brake circuit. 4. Attach the measuring devices to the front and rear wheel brake circuits. 4-1. Front wheel brake circuit pressure: Disconnect the front wheel brake hose (1). Connect tee 9/16-18UNF (ST 6485), fitting (ST 6069) and pressure gauge assembly (ST 6932) in the disconnected hose. : 19 mm, 22 mm 4-2. Rear wheel brake circuit pressure: Disconnect the rear wheel brake hose (2). Connect tee 9/16-18UNF (ST 6485), fitting (ST 6069) and pressure gauge assembly (ST 6932) in the disconnected hose. Rear Axle : 19 mm, 22 mm



SA-1140



Front Axle



T1F3-04-05-003



1



5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



T1F3-04-05-004



2



T4-5-32



OPERATIONAL PERFORMANCE TEST / Component Test Preconditions for Measurement: Select the following switch positions: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Fast Idle P Digging OFF



Shift Lever



Brake Switch



N



OFF



Measurement: 1. Measure the pressure when fully depressing the brake pedal to the floor. 2. Measure the pressure when setting the brake switch to S (working), without depressing the brake pedal. 3. Repeat the measurement three times, and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4. Normally, the front and rear wheel brake pressures become equal. If not, malfunction of the brake valve and dirt caught in the valve are suspected.



T4-5-33



OPERATIONAL PERFORMANCE TEST / Component Test BRAKE ACCUMLATE PRESSURE CAUTION: If air is mixed in the brake system, the brake function is reduced, possibly resulting in serious hazard. Be sure to bleed air from the brake system after disconnecting and reconnecting the pipe lines. Refer to the Troubleshooting B in Group T5-4. Summary: The accumulated brake pressure is measured at output port of the accumulator. The accumulated brake pressure varies according to operation of the brake. Record the maximum value. Preparation: CAUTION: Attaching the measuring devices is carried out under the machine. To avoid unintended travel or operation of the machine, the machine must be parked on the level firm ground with the bucket penetrated into the ground as shown. 1. Properly shut down the engine. 2. Press air release valve on the top of the hydraulic oil tank to release any remaining pressure. 3. Press and release the brake at least 50 strokes to reduce the accumulated pressure left in the brake circuit. 4. Remove the cover from the bottom of the cab. Disconnect the brake hose (1). Connect tee 9/16-18UNF (ST 6485), fitting (ST 6069) and pressure gauge assembly (ST 6932) in the disconnected hose. : 19 mm, 22 mm



SA-1140



5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



T1F3-04-05-005



1



T4-5-34



OPERATIONAL PERFORMANCE TEST / Component Test Preconditions for Measurement: Select the following switch positions: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Fast Idle P Digging OFF



Shift Lever



Brake Switch



N



OFF



Measurement: 1. Measure maximum pressure when depressing the brake pedal slowly. 2. Repeat the measurement three times, and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4.



T4-5-35



OPERATIONAL PERFORMANCE TEST / Component Test BRAKE WARNING (DECREASE)



SET



PRESSURE



CAUTION: If air is mixed in the brake system, the brake function is reduced, possibly resulting in serious hazard. Be sure to bleed air from the brake system after disconnecting and reconnecting the pipe lines. Refer to the Troubleshooting B in Group T5-4. Summary: When the warning buzzer sounds by reducing the accumulated brake pressure, the pressure is measured at the output port of the accumulator. Preparation: CAUTION: Attaching the measuring devices is carried out under the machine. To avoid unintended travel or operation of the machine, the machine must be parked on the level firm ground with the bucket penetrated into the ground as shown.



SA-1140



1. Properly shut down the engine. 2. Press air release valve on the top of the hydraulic oil tank to release any remaining pressure. 3. Press and release the brake at least 50 strokes to reduce the accumulated pressure left in the brake circuit. 4. Remove the cover from the bottom of the cab. Disconnect the brake hose (1). Connect tee 9/16-18UNF (ST 6485), fitting (ST 6069) and pressure gauge assembly (ST 6932) in the disconnected hose. : 19 mm, 22 mm 5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



T4-5-36



T1F3-04-05-005



1



OPERATIONAL PERFORMANCE TEST / Component Test Preconditions for Measurement: Select the following switch positions: Shift Lever Brake Switch N P (Parking) Measurement: 1. Properly shut down the engine. Turn key switch to ON position. 2. Measure the pressure when warning buzzer sounds by slowly depressing the brake pedal several times. 3. Repeat the measurement three times, and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4.



T4-5-37



OPERATIONAL PERFORMANCE TEST / Component Test BRAKE WARNING (INCREASE)



SET



PRESSURE



CAUTION: If air is mixed in the brake system, the brake function is reduced, possibly resulting in serious hazard. Be sure to bleed air from the brake system after disconnecting and reconnecting the pipe lines. Refer to the Troubleshooting B in Group T5-4. Summary: When sounding of the warning buzzer stops by increasing the accumulated brake pressure, the pressure is measured at the output port of the accumulator. Preparation: CAUTION: Attaching the measuring devices is carried out under the machine. To avoid unintended travel or operation of the machine, the machine must be parked on the level firm ground with the bucket penetrated into the ground as shown.



SA-1140



1. Properly shut down the engine. 2. Press air release valve on the top of the hydraulic oil tank to release any remaining pressure. 3. Press and release the brake at least 50 strokes to reduce the accumulated pressure left in the brake circuit. 4. Remove the cover from the bottom of the cab. Disconnect the brake hose (1). Connect tee 9/16-18UNF (ST 6485), fitting (ST 6069) and pressure gauge assembly (ST 6932) in the disconnected hose. : 19 mm, 22 mm 5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



T4-5-38



T1F3-04-05-005



1



OPERATIONAL PERFORMANCE TEST / Component Test Preconditions for Measurement: Select the following switch positions: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Digging Minimum P Mode OFF Mode



Shift Lever



Brake Switch



N



P (Parking)



Measurement: 1. Properly shut down the engine. Turn key switch to ON position. 2. Depress the brake pedal several times to make the warning buzzer sound. 3. Start the engine. Measure the pressure when sounding of the warning buzzer stops. Notice that it is difficult to read the gauge because the pressure increases rapidly. 4. Repeat the measurement three times, and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4.



T4-5-39



OPERATIONAL PERFORMANCE TEST / Component Test (Blank)



T4-5-40



OPERATIONAL PERFORMANCE TEST / Adjustment ENGINE SPEED ADJUSTMENT ENGINE LEARNING



AND



After removing and/or replacing the components as described below for repair and/or inspection, or if error in engine speed is found, readjust engine speed and perform engine learning.



• Removal of the engine, engine control cable, or EC motor



• Replacement of MC Adjustment of Engine Speed: 1. Turn the key switch to the START position to start the engine. NOTE: Turn the air conditioner OFF. 2. Rotate the engine control dial to the minimum speed position. (The output voltage from the EC sensor is 2.5 V.) 3. Deactivate the auto warming up and ECO control systems by Dr. ZX. 4. When Dr. ZX is not available, keep the engine running for about 15 minutes to warm coolant temperature to more than 30 °C (86 F°) until the auto warming up control system is deactivated. Holding Bolt



5. Loosen the bolt holding the control lever to the EC motor output shaft. 6. While monitoring the actual engine speed with Dr. ZX or the engine speed meter, adjust the control lever so that the minimum speed (slow idle) matches the specification. Specification: Refer to T4-2 OPERATIONAL PER FORMANCE TEST. 7. Tighten the lever holding bolt to secure the control lever to the motor output shaft. : 13 N⋅m (1.3 kgf⋅m, 9.4 lbf⋅ft) NOTE: Don’t lubricate the motor output shaft. 8. Perform engine learning.



T4-6-1



Control Lever



T157-07-04-015



OPERATIONAL PERFORMANCE TEST / Adjustment Engine Learning: 1. Turn the key switch OFF NOTE: In case the engine doesn’t stop when the key switch is turned OFF, pull the handle located under the seat to stop the engine.



Learning Switch



Dr.ZX Connector to MC



2. Disconnect Dr. ZX. Wait for 5 seconds. 3. Turn the learning switch ON. 4. Turn the key switch ON. Wait for 5 seconds. 5. Turn the key switch OFF. Wait for 5 seconds. 6. Turn the learning switch OFF. 7. Check the engine speed.



T178-01-02-006



Learning Switch is Turned to Stamp E Learning Switch



Stamp



T1CC-05-01-001



T4-6-2



OPERATIONAL PERFORMANCE TEST / Adjustment (Blank)



T4-6-3



OPERATIONAL PERFORMANCE TEST / Adjustment GOVERNOR LEVER LEVER POSITION



AND



FUEL



CUT



• Check the fuel cut lever position during cranking. If the position is normal, the engine unit and/or fuel system may have trouble.



• Governor Lever and Fuel Cut Lever 1



2



3



4



T1F3-05-04-002



1 - Governor Cable (From EC Motor) 2 - Governor Lever 3 - Fuel Cut-Off Cable (Fuel Cut-Off Handle) 4 - Fuel Cut Lever



T4-6-4



OPERATIONAL PERFORMANCE TEST / Adjustment • Governor Lever Position A - Key Switch OFF (Engine Stop Position) B - Key Switch ON (Engine Start Position) B STOP



FULL



A



T1F3-05-04-002



STOP



FULL



• Fuel Cut Lever Position A - Fuel Cut-Off Handle Pulled Position B - Fuel Cut-Off Handle Returned Position



B



A



T1F3-05-04-002



T4-6-5



OPERATIONAL PERFORMANCE TEST / Adjustment (Blank)



T4-6-6



MEMO ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... 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MEMO ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... 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SECTION 5



TROUBLESHOOTING CONTENTS Group 1 General



Components in Control Valve ..................T5-2-12



Introduction ............................................... T5-1-1



Signal Control Valve



Diagnosing Procedure .............................. T5-1-2 Built-In Diagnosing System Operation ...... T5-1-6 Built-In Diagnosing Function



Port Location .......................................T5-2-26



Group 3 Troubleshooting A



Display List............................................ T5-1-7



Troubleshooting A Procedure ....................T5-3-1



Dr. ZX Operation ....................................... T5-1-8



Fault Code List ..........................................T5-3-2



Dr. ZX Fault Code List (MC).................... T5-1-10



Fault Code 01, 02, 03................................T5-3-3



Dr. ZX Monitoring Item List ..................... T5-1-12



Fault Code 04............................................T5-3-3



Dr. ZX Special Function .......................... T5-1-14



Fault Code 06............................................T5-3-4



Dr. ZX Service Mode............................... T5-1-15



Fault Code 07............................................T5-3-5



Adjustment Data List............................... T5-1-25



Fault Code 10, 11 ......................................T5-3-6 Fault Code 12, 13......................................T5-3-7



Group 2 Component Layout



Fault Code 14, 15, 16, 18, 23, 24 ..............T5-3-8



Main Component Layout ........................... T5-2-1



Fault Code 19..........................................T5-3-10



Electrical Component Layout .................... T5-2-4



Fault Code 20.......................................... T5-3-11



(Overview)



Fault Code 22..........................................T5-3-12



Electrical System (Relays) ........................ T5-2-5 Electrical System ...................................... T5-2-7 (Monitors and Switches) Electrical System (Column Box)................ T5-2-8 Pump Device ............................................ T5-2-9 Swing Device ............................................ T5-2-9 Signal Control Valve.................................. T5-2-9 Control Valve .......................................... T5-2-10 Auxiliary control Valve............................. T5-2-10 4-Unit Solenoid Valve Unit ...................... T5-2-10 3-Unit Solenoid Valve Unit ...................... T5-2-10 Travel Shockless Valve / Accumulator Chrging Valve ................... T5-2-11 Transmission Control Valve .................... T5-2-11 Travel Device .......................................... T5-2-11 Filter ....................................................... T5-2-11



CBBT-5-1



Group 4 Troubleshooting B



Malfunction of Overload Alarm



Troubleshooting B Procedure ................... T5-4-1 Relationship between Machine Trouble



Indicator (Optional)................................T5-5-20 Malfunction of Auto-Acceleration



Symptoms and Related Parts.................. T5-4-2 Correlation between Trouble



Indicator ................................................T5-5-24 Malfunction of Auto-Idle Indicator ............T5-5-26



Symptoms and Part Failures ................. T5-4-26



Malfunction of Digging Mode Indicator



Engine System Troubleshooting ............. T5-4-40



or Attachment Mode Indicator................T5-5-27



All Actuator System Troubleshooting ...... T5-4-66



Malfunction of LCD..................................T5-5-28



Front Attachment System



Malfunction of Hour Meter .......................T5-5-29



Troubleshooting .................................... T5-4-72



Malfunction of Blade/Stabilizer



Swing System Troubleshooting ............... T5-4-80



Indicator ................................................T5-5-30



Travel System Troubleshooting............... T5-4-82



Malfunction of Buzzer..............................T5-5-34



Brake System Troubleshooting ............... T5-4-92



Malfunction of Turn Signal Indicator ........T5-5-36



Steering System Troubleshooting ........... T5-4-97



Malfunction of Travel Motor Indicator ......T5-5-37



Other System Troubleshooting................ T5-4-98



Malfunction of Work Light Indicator .........T5-5-38



Exchange Inspection............................. T5-4-114



Malfunction of Shift Lever Indicator .........T5-5-40



Bleeding Air from Transmission............. T5-4-116



Malfunction of Work Brake Indicator........T5-5-42



Bleeding Air from Brake (Axle) .............. T5-4-117



Malfunction of Parking Brake Indicator ....T5-5-44



Emergency Boom Lowering Procedure



Malfunction of Axle Lock Indicator ...........T5-5-46



(without Hose-Rupture Safety Valve) .. T5-4-118 Emergency Boom Lowering Procedure



Malfunction of Clearance Light Indicator ................................................T5-5-48



(with Hose-Rupture Safety Valve) ....... T5-4-119



Malfunction of Hazard Light Indicator ......T5-5-49 Malfunction of High-Beam Indicator ........T5-5-50



Group 5 Troubleshooting C Troubleshooting C Procedure ................... T5-5-1



Malfunction of Buzzer in Column Box......T5-5-52



Malfunction of Coolant



Malfunction of Brake Oil Pressure



Temperature Gauge ................................ T5-5-2



Gauge ...................................................T5-5-54



Malfunction of Fuel Gauge ........................ T5-5-4



Malfunction of Speed Meter.....................T5-5-56



Malfunction of Indicator Light



Malfunction of Brake Oil Pressure



Check System ......................................... T5-5-6



Indicator ................................................T5-5-58



Malfunction of Preheat Indicator ............... T5-5-7 Malfunction of Overheat Indicator ............. T5-5-8 Malfunction of Air Filter Restriction Indicator ................................................ T5-5-10 Malfunction of Fuel Level Indicator ......... T5-5-12 Malfunction of Alternator Indicator .......... T5-5-14 Malfunction of Engine Oil Pressure Indicator ................................................ T5-5-16 Malfunction of Hydraulic Oil Filter Indicator (Optional) ............................... T5-5-18



CBBT-5-2



Group 6 Electrical System Inspection Precautions for Inspection and Maintenance ........................................... T5-6-1 Instructions for Disconnecting Connectors ............................................. T5-6-3 Fuse Inspection ........................................ T5-6-4 Fusible Link Inspection ............................. T5-6-6 Battery Voltage Check .............................. T5-6-7 How to Troubleshoot Alternator Malfunctions............................................ T5-6-8 Continuity Check..................................... T5-6-10 Voltage and Current Measurement ......... T5-6-13 Check by False Signal ............................ T5-6-17 Test Harness........................................... T5-6-18



Group 7 ICX Outline ...................................................... T5-7-1 ICX Fault Code List................................... T5-7-8 Satellite Terminal Fault Code List.............. T5-7-8 Fault Code 1 to 6 ...................................... T5-7-9 Fault Code 7 to 10 .................................... T5-7-9 Some Parts of Data in Daily Report, Frequency Distribution, Cumulative Operation Hours are not Recorded ....... T5-7-10



CBBT-5-3



(Blank)



CBBT-5-4



TROUBLESHOOTING / General INTRODUCTION Refer to the inspection and troubleshooting procedures after any machine trouble has occurred. The inspection and troubleshooting procedures are presented in an orderly fashion in this section to quickly find the cause of the machine trouble and solution. The troubleshooting section in this manual consists of 7 groups; General, Component Layout, Troubleshooting A (base machine diagnosis using fault codes), Troubleshooting B (base machine diagnosis starting with inspection of abnormal operational status), Troubleshooting C (monitor diagnosis), Electrical System Inspection, and ICX.



• Troubleshooting B (base machine diagnosis starting with inspection of abnormal operational status) Refer to these procedures when no fault codes are displayed after diagnosing the machine with Dr. ZX (or the built-in diagnosing system). Trace the cause of trouble based on the inspected result of the abnormal symptom. Example: Even if the engine control dial is operated, engine speed remains unchanged.



• Troubleshooting C (monitor diagnosis)



• General



Refer to these procedures when gauges and/or indicators are malfunctioning.



• Component Layout



Example: Malfunction of fuel gauge



• Troubleshooting A (base machine diagnosis using fault codes) Refer to these procedures if any fault codes are displayed when the main controller (MC) is diagnosed with Dr. ZX (or the built-in diagnosing system). (MC self-diagnosing function retains a record of the electrical signal system malfunction in the form of fault codes.) Example: Fault Code 06: Abnormal EC Sensor



• Electrical System Inspection Refer to this group when required to obtain precautions and/or information for the electrical system inspection. Example: Fuse Inspection



• ICX Refer to these procedures after any fault code is displayed after diagnosing ICX (Information Controller) with Dr. ZX. (The controller self-diagnosing function retains a record of the electrical signal system malfunction in the form of fault codes.) Example: ICX Fault Code 7: MC Communication Time Out



T5-1-1



TROUBLESHOOTING / General DIAGNOSING PROCEDURE These six basic steps are essential for efficient troubleshooting: 1. Study the System Study the machine’s technical manuals. Know the system and how it works, and what the construction, functions and specifications of the system components are.



2. Ask the operator Before inspecting, get malfunctions from your operator.



T107-07-01-001



the star



full story of witness … the



(a) How is the machine being used? (Find out if the machine is being operated correctly) (b) When was the trouble noticed, and what types of work the machine doing at that time? (c) What are the details of the trouble? Is the trouble getting worse, or did it appear suddenly for the first time? (d) Did the machine have any other troubles previously? If so, which parts were repaired before? T107-07-01-002



T5-1-2



TROUBLESHOOTING / General 3. Inspect the machine Before starting the troubleshooting procedure, check the machine’s daily maintenance points, as shown in the operator's manual. Also, check the electrical system, including the batteries, as troubles in the electrical system such as low battery voltage, loose connections and blown fuses will result in malfunction of the controllers, causing total operational failure of the machine. If troubleshooting is started without checking for blown fuses, a wrong diagnosis may result, wasting time. Be sure to check for blown fuses before troubleshooting. Even if a fuse looks normal by visual inspection, a fine crack is difficult to find. Always use a tester when checking the fuses. 4. Operate the machine yourself Try to identify the trouble by operating the machine yourself. If the trouble cannot be confirmed, stop the engine and obtain further details of the malfunction from the operator. Also, check for any incomplete connections of the wire harnesses.



T5-1-3



T107-07-01-003



TROUBLESHOOTING / General 5. Perform troubleshooting CAUTION: Never attempt to disconnect harnesses or hydraulic lines while the engine is running. The machine may malfunction or pressurized oil may spout, possibly resulting in personal injury. Be sure to stop the engine before disconnecting harnesses or hydraulic lines. Perform diagnosis by connecting Dr. ZX to the machine or by operating the built-in diagnosing system. In case any fault code has been displayed by diagnosis using Dr. ZX (or the built-in diagnosing system), delete the fault code once and retry self-diagnosis again. If the fault code is displayed again, check the cause of the trouble by referring to Troubleshooting A in this section. After the machine trouble has been corrected, the fault code (displayed by the built-in diagnosing function) will be deleted. Therefore, in case problems, which are not easily re-predicable are encountered, use Dr. ZX to display the fault code. In case no fault codes are displayed, check all related parts/component operating condition using the monitor function of Dr. ZX (or the built-in diagnosing system) while referring to troubleshooting B in this section. ※ Note that the fault codes displayed do not necessarily indicate machine trouble. The controller stores even temporary electrical malfunctions, such as a drop in battery output voltage or disconnections of the switches, sensors, etc., for inspections. For this reason, the “RETRIAL” is required to erase the accumulated fault codes from the controller memory and to confirm if any fault codes are indicated after the “RETRIAL”. 6. Trace possible causes Before reaching a conclusion, check the most likely causes again. Try to identify the actual cause of the trouble. Based on your conclusion, make a plan for appropriate repairs to avoid consequent malfunctions.



T5-1-4



T107-07-01-005



T107-07-01-006



T107-07-01-007



TROUBLESHOOTING / General (Blank)



T5-1-5



TROUBLESHOOTING / General BUILT-IN DIAGNOSING SYSTEM OPERATION IMPORTANT: This system is to be operated by the HITACHI Dealer Only. Don’t explain this system function to the customer. In the service mode, the monitor LCD displays the diagnosing items, fault codes and monitored results (not all of them) without using Dr. ZX. Built-In Diagnosing System Activation 1. While pressing the monitor SET switch, turn the key switch ON. Built-In Diagnosing System Operation 1. Each time the display selection switch is pressed, the displayed item will be changed as shown on next page. NOTE: The fault code is indicated in the display order 8. All fault codes (Dr. ZX fault code list) can be indicated. In case more than one fault code is indicated, they will be displayed with an interval of 1 second in order. After the machine malfunction has been repaired, the fault codes are automatically deleted. Accordingly, if any trouble, which is not reproducible, is encountered, it is recommended to use Dr. ZX. • The built-in diagnosing system displays only the item No. on the left and the monitored result on the right. The item description is not displayed.



Display Selection Switch SET Switch



LCD



MCBB-01-012



T5-1-6



TROUBLESHOOTING / General BUILT-IN DIAGNOSING FUNCTION DISPLAY LIST Display Order 1 2 3 4 5 6 7 8 9 10



Description Hour Meter Trip 1 Trip 2 Engine Actual Speed



Monitored Result h h h n



L1 L2 0 1



21 22 23



Att. Control Pressure Work Mode



E F



12 13 14 15 16 17 18 19 20



-1



°C



Pump 1 Delivery Pressure Pump 2 Delivery Pressure Pump 1 Pump (Flow) Control Pressure Pump 2 Pump (Flow) Control Pressure Engine Target Speed EC Angle Dial Angle Boom Raise Pilot Pressure Arm Roll-In Pilot Pressure Swing Control Pilot Pressure Travel Control Pilot Pressure Front Att. Operation



11



min



Hydraulic Oil Temperature



Fault Code* ML Switch**



Unit



E E



－ － － 0: Switch OFF 1: Switch ON MPa



2



Remarks Standard Mode Standard Mode (Subtraction) Standard Mode (Subtraction) User Mode (Required to set in the Dr. ZX service mode) User Mode (Required to set in the Dr. ZX service mode) Display Purpose Only Display Purpose Only Possible to display Possible to display Possible to display



3



MPa



Possible to display



4



MPa



Possible to display



5



MPa



Possible to display



6 7 8 9



min V V MPa



-1



Possible to display Possible to display Possible to display Possible to display



A



MPa



Possible to display



b



MPa



Possible to display



c



MPa



Possible to display



d



0: Not Operating 1: Operating MPa 0: Digging 1: Breaker 2: Secondary Crusher (Demolisher) 3: Crusher 4: Vibro-Hammer



Possible to display



NOTE: *: Refer to T5-1-10 for the Fault Codes. **: ML specification is only available in Japanese domestic market.



T5-1-7



Possible to display Possible to display



TROUBLESHOOTING / General Dr. ZX OPERATION Dr. ZX is a troubleshooting tool to diagnose the electronic control system including the MC (main Controller) and ICX (Information Controller). When Dr. ZX is connected to either the MC or the ICX, it displays whether the controllers and sensors operate normally in the form of fault codes (Self-Diagnosing Result Display Function). In addition, Dr. ZX can display the inputs from sensors and switches to the MC and/or the outputs to actuators such as solenoid valves from the MC in real time while operating the machine (Monitor Display Function).



Rear Console



Fuse Box



Dr. ZX Connector (MC)



NOTE: This group describes how to operate Dr. ZX connected to the MC. Refer to Group 7 “ICX” for operation of Dr. ZX connected to the ICX. Dr. ZX Connector (ICX) T1F3-01-02-012



Palm （Dr. ZX）



Hot Sync Cable



Battery Box Cable



T178-05-01-167



T5-1-8



TROUBLESHOOTING / General Operation 1. Connect palm (Dr. ZX) to the diagnosis connectors (MC and ICX) located in the cab, using Hot Sync cable and battery box cable. 2. Turn the key switch ON, or start the engine. 3. When the palm power is turned ON, palm displays the following screens in order. 3-1. Title Screen Select the Dr. ZX icon 3-2. Select Kind Screen + Select the EPVC-Mid 3-3. Menu Screen Select the Start. 3-4. Model Name Screen (Example) Model: ZX160W 3-5. Function Selection Screen + Self-Diagnostic Results +



Monitor Display



+



Special Function



Start



Title Screen



Cannot Communicate · Check harness · Check fuse



OK ?



4. Select Self-Diagnostic Results. Then, continue to operate palm by following instructions to be displayed at the screen bottom hereafter.



OK



Self-Diagnosing Result Display Function



Self-diagnostic Result by controller is displayed



Retry B



Self-diagnostic Result is displayed



T5-1-9



Menu Screen



Model Name Confirmation



NOTE: Special functions allow the ECO and WU deactivation. (Refer to T5-1-14)



NOTE: Refer to the Dr. ZX Operation Manual for the detailed operation of Dr. ZX.



Select Kind Screen



Select function



Record



NOT OK



Replace software



Monitor



Special Function



Enter model code and serial No.



Select data to be monitored



Monitored data is displayed



TROUBLESHOOTING / General FAULT CODE LIST (MC) Fault code 01 02 03 04



Problem Abnormal EEPROM Abnormal RAM Abnormal A/D Conversion Abnormal Sensor Voltage



06



Abnormal EC Sensor



07



Abnormal Engine Control Dial Angle



10 11



Abnormal Pump 1 Delivery Pressure Abnormal Pump 2 Delivery Pressure



12 13



Abnormal Pump 1 Pump Control Pressure Abnormal Pump 2 Pump Control Pressure



14 15 16 18 19



Abnormal Swing Pilot Pressure Sensor Abnormal Boom Raise Pilot Pressure Sensor Abnormal Arm Roll-In Pilot Pressure Sensor Abnormal Travel Pilot Pressure Sensor Abnormal Hydraulic Oil Temperature



20



Abnormal Travel Motor Drain Pressure Sensor



22



Abnormal Travel Motor



23 24



Abnormal Travel Forward Pilot Pressure Sensor Abnormal Travel Reverse Pilot Pressure Sensor



*26



Travel Motor Over-rev.



NOTE: In case the travel motor runs at an excessive speed, fault code 26 is displayed. Using Dr. ZX service mode, check the excessive speed rotation numbers (the excessive speed running is not caused by the faulty travel motor). Select the retry when deleting the fault code.



T5-1-10



Cause



•



Faulty MC



• • • • • • • • • • • • • • • • • •



Faulty MC Faulty Harness Faulty Sensor Faulty MC Faulty Harness Faulty EC Sensor Faulty MC Faulty Harness Faulty Engine Control Dial Faulty MC Faulty Harness Faulty Pump Delivery Pressure Sensor Faulty MC Faulty Harness Faulty Pump Control Pressure Sensor Faulty MC Faulty Harness Faulty Pilot Pressure Sensor



• • • • • • • • • • • • •



Faulty MC Faulty Harness Faulty Hydraulic Oil Temperature Sensor Faulty MC Faulty Harness Faulty Travel Motor Drain Pressure Sensor Faulty MC Faulty Harness Faulty Travel Motor Drain Pressure Sensor Faulty MC Faulty Harness Faulty Travel Pilot Pressure Sensor Travel Motor Over-rev.



TROUBLESHOOTING / General (Blank)



T5-1-11



TROUBLESHOOTING / General Dr. ZX MONITORING ITEM LIST Dr. ZX displays the input signals from the switches and sensors to the MC and the control signals to the actuators from the MC. Item Pump 1 Delivery Pressure Pump 1 Pump Flow Control Pressure Pump 2 Delivery Pressure Pump 2 Pump Flow Control Pressure Pump 2 Max. Displacement Engine Target Speed Engine Actual Speed Travel Motor Speed Vehicle Speed EC Angle Dial Angle Boom Raise Pilot Pressure Arm Roll-In Pilot Pressure Swing Control Pilot Pressure Forward Travel Control Pilot Pressure Rear Travel Control Pilot Pressure Front Att. Operation Hydraulic Oil Temperature E/P/HP Mode Switch Auto-Idle/Auto-Accel Switch Creeper Mode Switch Neutral Switch Key Switch Mission Switch Pedal EC Switch Working/Parking Switch



Data Input signals from pump 1 delivery pressure sensor Input signals from pump 1 control pressure sensor



MPa MPa



Input signals from pump 2 delivery pressure sensor Input signals from pump 2 control pressure sensor



MPa MPa



Control signal to pump 2 flow rate control solenoid valve Target speed when loaded. Approx. 150 min-1 differs from speed when unloaded. Input signal from N sensor (engine speed sensor) Input signal from N sensor (travel speed sensor) Input signal from N sensor (travel speed sensor) Input signal from EC sensor Input signal from engine control dial Input signal from pressure sensor (boom raise) Input signal from pressure sensor (arm roll-in) Input signal from pressure sensor (swing) Input signal from pressure sensor (travel forward)



cm3 min-1 min-1 min-1 km/h V V MPa MPa MPa MPa



Input signal from pressure sensor (travel reverse)



MPa



Input signal from pressure sensor (front att.)



Unit



Fr (ON: Outline Type Font) Input signal from oil temperature sensor °C Power mode switch selection status E, P, HP (ON: Outline Type Font) Auto-Idle/Auto-Acceleration selector selection status AI, AA (ON: Outline Type Font) Engine speed control mode selection switch selection Trpr (ON: Outline status Type Font) Shift lever selection status N (ON: Outline Type Font) Key switch selection status Ky (ON: Outline Type Font) Shift lever selection status High, Low (ON: Outline Type Font) Engine speed control mode selection switch selection PEC (ON: Outline status Type Font) Brake switch selection status Wk, Pk (ON: Outline Type Font)



T5-1-12



TROUBLESHOOTING / General Item Working Mode ATT. Mode



Engine Learning Control



Pump Torque P/S Valve Pump Flow Changeover P/S Valve Output Travel Motor Tilt P/S Valve Output Working Brake P/S Valve Output Parking Brake Relay Fw/Bk Cut Relay EC Motor Position Pump 3 Delivery Pressure Travel Drain Pressure Pump 1 Max. Displacement Engine Speed Differential Pump 2 P/S Valve Output Pump 1 P/S Valve Output Arm Regenerative P/S Valve Output



Data Work mode switch selection status



Unit STD, ATT (ON: Outline Type Font) Work mode switch selection status BU, CS, CL, HB (ON: Outline Type Font) Done, Undone, Aborted (ON: Outline Type Font) Control signal to torque control solenoid valve MPa Control signal to max. pump 1 flow rate shift so- MPa lenoid valve Control signal to solenoid valve SI MPa Control signal to solenoid valve SG MPa Signal to buzzer of parking brake alarm ON, OFF (ON: Outline Type Font) Signal to travel forward/reverse Pi cut solenoid FW, BK (ON: Outvalve line Type Font) Step Input signal from steering pump delivery pressure MPa sensor Input signal from travel motor drain pressure MPa sensor Control signal to pump 1 flow rate control sole- cm3 noid valve Calculated Value min-1 (Target Engine Speed - Actual Engine Speed) Control signal to pump 2 flow rate control sole- MPa noid valve Control signal to pump 1 flow rate control sole- MPa noid valve Control signal to solenoid valve SC MPa



Optional Item Boom Cylinder Bottom Pressure Arm Roll-Out Pilot Pressure ATT. Control Pilot Pressure ATT. P/S Valve Output Tr/Sw/OverLoad Alarm



Data Input signal from pressure sensor (boom raise) Input signal from pressure sensor (arm roll-out) Input signal from pressure sensor (auxiliary) Control signal to auxiliary flow rate control solenoid valve Signal to each alarm



T5-1-13



Unit MPa MPa MPa MPa Tr, Sw, Load (ON: Outline Type Font)



TROUBLESHOOTING / General Dr. ZX SPECIAL FUNCTION NOTE: The following explanation exemplifies the transition diagrams for ZAXIS160W. Start the service software in the operation mode



Select a special function



If the following screen appears, you are in the operation mode. Select Special Function.



Select the function you want to execute.



Fig. A



Fig. B



T178-05-01-168



T178-05-01-013



Select ESC to return to Fig. A.



Special function Select Execute to execute the function.



ECO control deactivation



WU deactivation



Execute



Execute



T178-05-01-030



Select ESC to return to Fig. B.



T178-05-01-031



Select ESC to return to Fig. B.



T5-1-14



T178-05-01-032



Select ESC to return to Fig. B.



T178-05-01-033



Select ESC to return to Fig. B.



TROUBLESHOOTING / General Dr. ZX SERVICE MODE Engine Learning Switch



Dr. ZX Connector (MC)



Dr. ZX has three modes, learning value display, parameter change, and monitor display information setting. Learning Value Display Displays the values set by learning function. Parameter Change Engine speed, pump delivery flow rate, and solenoid valve output pressure can be adjusted. Monitor Display Information Setting Items to be displayed on the monitor LCD can be added.



• Accessing Service Mode 1. After turning the key switch OFF, wait for more than 10 seconds. 2. Connect Dr. ZX to the connector to MC on the base machine. 3. Turn the engine learning switch to the learning position (the stamped mark E side). 4. Turn the key switch ON. Don’t start the engine at this time. 5. Turn Dr. ZX switch ON.



Dr. ZX Connector (ICX) T1F3-01-02-012



The learning switch is turned to the stamped mark E Learning Switch



Stamped Mark E



T1CC-05-01-001



T5-1-15



TROUBLESHOOTING / General Item Learning Data Display EC Motor Stop Position EC Motor Maximum Speed Position Parameter Change Li Speed Adjustment WU Speed Adjustment AI Speed Adjustment E Speed Adjustment P Speed Adjustment Breaker Engine Speed Adjustment Secondary Crusher (Demolisher) Engine Speed Adjustment Crusher Engine Speed Adjustment Vibro-Hammer Speed Adjustment Travel Li Speed Adjustment Hyd. Breaker P1 Max. Swash Angle Adjustment Secondary Crusher (Demolisher) P1 Max. Swash Angle Adjustment Crusher P1 Max. Swash Angle Adjustment Vibro P1 Max. Swash Angle Adjustment Hyd. Breaker P2 Max. Swash Angle Adjustment Secondary Crusher (Demolisher) P2 Max. Swash Angle Adjustment Crusher P2 Max. Swash Angle Adjustment Vibro P2 Max. Swash Angle Adjustment



Data Display of the engine stop value in engine learning Display of max. engine speed valve in engine learning Adjustment of minimum engine speed Adjustment of warming up engine speed Adjustment of auto-idle engine speed Adjustment of E-mode engine speed Adjustment of P-mode engine speed Adjustment of breaker operation engine speed Adjustment of secondary crusher (demolisher) operation engine speed Adjustment of crusher operation engine speed Adjustment of vibratory hammer operation engine speed Adjustment of traveling engine speed Adjustment of lowest pump 1 max. flow rate in breaker operation Adjustment of lowest pump 1 max. flow rate in secondary crusher operation Adjustment of lowest pump 1 max. flow rate in crusher operation Adjustment of lowest pump 1 max. flow rate in vibratory hammer operation Adjustment of lowest pump 2 max. flow rate in breaker operation Adjustment of lowest pump 2 max. flow rate in secondary crusher operation Adjustment of lowest pump 2 max. flow rate in crusher operation Adjustment of lowest pump 2 max. flow rate in vibratory hammer operation Adjustment of pump P-Q curve Adjustment of optional solenoid valve Setting of time required for engine speed increase Setting of engine speed in crane mode



Pump PQ Base Torque Correction ATT P/S Valve Adjustment ATT. Speed Increase Down Waiting Time *Max. ML Crane Speed Adjustment Min. Boom CYL. Bottom Pressure Over Balance Travel Motor Over-rev. Counter Display of the travel motor excessive speed rotation NOTE: *: ML specification is only available in Japanese domestic market.



T5-1-16



TROUBLESHOOTING / General (Blank)



T5-1-17



TROUBLESHOOTING / General Displaying Engine Learning Data and Angle Sensor Correction Valve NOTE: The following explanation exemplifies the transition diagrams for ZAXIS200. Start the service software in the service mode Select Start from the EPVC_Mid software menu.



Fig. A



T178-05-01-006



The service software will start in the service mode Press Correct displayed model correct.



Fig. B



if the name is



T178-05-01-012



Confirm that you are in the service mode, and select Rechecked.



Fig.C



Select the function you want to execute



Learning data items will be displayed



The menu will be displayed. Select Learning Data Display from the menu.



Select the item you want to execute.



Fig. E



Fig. F



T178-05-01-036



Select ESC to return to Fig. D.



T178-05-01-034



Select ESC to return to Fig. A.



Select ESC to return to Fig. A.



T178-05-01-037



Select ESC to return to Fig. F.



T5-1-18



Select Special Function.



Fig. D



T178-05-01-035



Select ESC to return to Fig. A.



TROUBLESHOOTING / General



EC Motor stop position



T178-05-01-038



Select ESC to return to Fig. F.



EC Motor Maximum engine speed position



T178-05-01-039



Select ESC to return to Fig. F.



T5-1-19



Boom angle sensor correction value



T178-05-01-040



Select ESC to return to Fig. F.



Arm angle sensor correction value



T178-05-01-041



Select ESC to return to Fig. F.



TROUBLESHOOTING / General Changing Parameters In The Controller NOTE: The following explanation exemplifies the transition diagrams for ZAXIS200. Start the service mode on the condition that the engine learning switch is turned on. To change the parameter, it is necessary to enter the password. To change the password, refer to the “Changing the password” section. Start the service software in the service mode Select Start from the EPVC_Mid software menu.



Fig. A



T178-05-01-006



The service software will start in the service mode Press Correct if the displayed model name is correct.



Fig. B



Confirm that you are in the service mode, and select Rechecked.



Fig. C



T178-05-01-012



Enter the password



The menu will be displayed. Select Parameter Change from the menu.



Enter the password to change the parameter.



T178-05-01-042



Select ESC to return to Fig. D.



Fig. F



Fig. D



Select ESC to return to Fig. A.



Execute the parameter change



Fig. E



T178-05-01-034



Select ESC to return to Fig. A.



Select Special Function.



T178-05-01-043



Select ESC to return to Fig. E.



T178-05-01-035



Select ESC to return to Fig. A



Select a parameter change item Select the item you want to change. The up- and down-arrow buttons can be used to scroll through the item list.



Fig. G



T5-1-20



T178-05-01-044



Select ESC to return to Fig. E.



TROUBLESHOOTING / General



Enter the new value



Confirm the new value



Parameter adjustment result



Enter the new value in the Adjustment space, and press Execution.



The new value will be displayed in the Adjustment space. Select Execute to change to this value.



The adjusted value will be displayed.



T178-05-01-045



Select ESC to return to Fig. G.



T178-05-01-047



T178-05-01-046



Select ESC to return to Fig. G.



Select ESC to return to Fig. G.



T5-1-21



TROUBLESHOOTING / General Changing The User Mode Display on The Monitor Panel NOTE: The following explanation exemplifies the transition diagrams for ZAXIS200. Start the service mode on the condition that the engine learning switch is turned on. Start the service software in the service mode Select Start from the EPVC_Mid software menu.



Fig. A



T178-05-01-006



The service software will start in the service mode Press Correct if the displayed model name is correct.



Fig. B



T178-05-01-012



Confirm that you are in the service mode, and select Rechecked.



Fig. C



Select ESC to return to Fig. A.



T178-05-01-034



Select Special Function.



Fig. D



T178-05-01-035



Select ESC to return to Fig. A.



Select ESC to return to Fig. A.



Execute the monitor display change



Select a display change item



The menu will be displayed. Select Monitor Display from the menu.



Select the monitor display change item you want to execute.



Select Disp or No Disp.



Fig. F



Fig. G



Fig. E



T178-05-01-042



Select ESC to return to Fig. D.



T178-05-01-048



Select ESC to return to Fig. E.



T5-1-22



Select Display or No Display



T178-05-01-049



Select ESC to return to Fig. F.



TROUBLESHOOTING / General



Confirm Disp/No Disp



Confirm the result



Confirm that the Monitor space shows Disp or No Disp. If it is correctly displayed, select Execute.



It has been changed as shown on-screen. Select ESC.



Fig. H



Fig. I



T178-05-01-050



Select ESC to return to Fig.F.



T178-05-01-051



Select ESC to return to Fig. F.



T5-1-23



TROUBLESHOOTING / General • Operational Performance Check After Adjustment (Check that pump flow rate and engine speed have been changed.) IMPORTANT: After adjusting the engine speed and flow rate to the attachment, turn the engine learning switch to neutral. If the engine is started with the engine learning switch in the engine learning position, the MC will not control the engine, pumps, and valves so that change in the pump flow rate and the engine speed cannot be checked. 1. 2. 3. 4.



Turn the key switch OFF. Wait approx. 10 seconds. Turn the engine learning switch to neutral. Disconnect the Dr. ZX. connector (When monitoring with Dr. ZX, pass this step.) 5. Turn the key switch ON. 6. Start the engine. 7. Check operational performances of the machine.



T5-1-24



TROUBLESHOOTING / General ADJUSTMENT DATA LIST Adjustment Data Li Speed WU Speed AI Speed E Speed P Speed Breaker Speed Secondary Crusher (Demolisher) Speed Crusher Speed Vibro-Hammer Speed Travel Li Speed Hyd. Breaker P1 Max. Swash Angle Secondary (Demolisher) P1 Max. Crusher Swash Angle Crusher P1 Max. Swash Angle Vibro P1 Max. Swash Angle Hyd. Breaker P2 Max. Swash Angle Secondary Crusher (Demolisher) P2 Max. Swash Angle Crusher P2 Max. Swash Angle Vibro P2 Max. Swash Angle Pump PQ Base Torque ATT. P/S Valve ATT. Speed Increase Down Wait Time *Max. ML Crane Speed Min. Boom CYL. Bottom Pressure Over Balance Travel Motor Over-rev. Counter



Min. Adjustment Value 10 min-1 10 min-1 10 min-1 10 min-1 10 min-1 10 min-1



0 to 120 -120 to 120 -120 to 120 -120 to 120 -120 to 120 -500 to 200



Standard Adjustment 0 min-1 0 min-1 0 min-1 0 min-1 0 min-1 0 min-1



10 min-1



-500 to 200



200 min-1



10 min-1 10 min-1 10 min-1



-500 to 200 -500 to 200 -120 to 120



200 min-1 0 min-1 0 min-1



0.6 cm3/rev



37.2 to 80.4



80.4 cm3/rev



0.6 cm3/rev



37.2 to 80.4



80.4 cm3/rev



0.6 cm3/rev



37.2 to 80.4



80.4 cm3/rev



0.6 cm3/rev



37.2 to 80.4



80.4 cm3/rev



0.6 cm3/rev



37.2 to 80.4



80.4 cm3/rev



0.6 cm3/rev



37.2 to 80.4



80.4 cm3/rev



0.6 cm3/rev



37.2 to 80.4



80.4 cm3/rev



0.6 cm3/rev 2.45 N⋅m 0.03 MPa



37.2 to 80.4 -78.4 to 0 -0.89 to 0.89



80.4 cm3/rev 0 N⋅m 0 MPa



12.5 ms



0 to 3000



3000 ms



-500 to 300



0 min-1



0.1 MPa



-9.81 to 9.81



0 MPa



1 digit



0 to 255



0 digit



10 min



-1



Adjustable Range



NOTE: *: ML specification is only available in Japanese domestic market. NOTE: 1 MPa=10.197 kgf/cm2 1 kgf/cm2=0.098 MPa



T5-1-25



Remarks



TROUBLESHOOTING / General (Blank)



T5-1-26



TROUBLESHOOTING / Component Layout MAIN COMPONENT LAYOUT Upperstructure 2



3



4



5



6



7



8



9



10



12



11



1



13 14 15 16 17 29 18 19



28 27



20 26 25



24 23



22



1 - Pilot Valve (Left)



9 - Center Joint



16 - Accumulator (Pilot Circuit)



2 - Positioning/Auxiliary Pilot Valve 3 - Steering Valve 4 - Brake Valve



10 - Signal Control Valve



17 - 4-Unit Solenoid Valve Unit



11 - Swing Device 12 - Control Valve



18 - 3-Unit Solenoid Valve Unit 19 - Pilot Filter



13 - Accumulator (Transmission Circuit) 14 - Transmission Control Valve



20 - Steering Filter 21 - Pump Device



15 - Pilot Relief Valve



22 - Engine



5 - Travel Pilot Valve 6 - Pilot Valve (Right) 7 - Blade/Stabilizer Pilot Valve 8 - Auxiliary Control Valve



T5-2-1



21



T1F3-01-02-001



23 - Shuttle Valve (Swing Parking Brake Release Circuit) 24 - Accumulator Charging Valve 25 - Travel Shockless Valve 26 - Shuttle Valve (Blade/Stabilizer Circuit) 27 - Blade/Stabilizer Signal Shift Valve 28 - Accumulator (Brake Circuit) 29 - Pilot Shut-Off Valve



TROUBLESHOOTING / Component Layout Undercarriage



2



1



3



4



5



8 7



6 T1F3-01-02-002



1 - Blade Cylinder 2 - Rear Axle



3-



2-Unit Solenoid Valve (Blade/Stabilizer) 4 - Axle Lock Cylinder



5-



Front Axle



7-



Transmission



6-



Stabilizer Cylinder



8-



Travel Motor



T5-2-2



TROUBLESHOOTING / Component Layout Front Attachment 2-Piece Boom



Monoblock Boom 1



2



2



3 4 7



7 4



1 5



6



6



T1F3-01-02-004



T1F3-01-02-003



1 - Bucket Cylinder



3-



Positioning Cylinder



2 - Arm Cylinder



4-



Boom Cylinder



5-



Hose-Rupture Safety Valve (Positioning) 6 - Hose-Rupture Safety Valve (Boom)



NOTE: Hose-rupture safety valves (5), (6), (7) are optional.



T5-2-3



7-



Hose-Rupture Safety Valve (Arm)



TROUBLESHOOTING / Component Layout ELECTRICAL COMPONENT LAYOUT (Overview)



1



2



Refer to the Transmission Control Valve. (T5-2-11)



Refer to the Signal Control Valve. (T5-2-9)



Refer to the Swing Device. (T5-2-9)



3



Refer to the Control Valve. (T5-2-10)



4



15



5



14



Refer to the Pump Device. (T5-2-9)



13



6 Refer to the Travel Shockless Valve and Accumulator Charging Valve. (T5-2-11)



Refer to the Filter. (T5-2-11)



12



7 T1F3-01-02-011



11



10



9



8



1 - Service Brake Pressure Switch 2 - Fuel Sensor



5 - EC Motor/EC Sensor 6 - 3-Unit Solenoid Valve Unit



9 - Coolant Temperature Sensor 10 - Battery Relay



3 - 4-Unit Solenoid Valve Unit 4 - Hydraulic Oil Temperature Sensor



7 - Engine Oil Pressure Switch 8 - Overheat Switch



11 - Glow Plug Relay 12 - Battery



T5-2-4



13 - Air Cleaner Restriction Switch 14 - Brake Remaining Pressure Switch 15 - Slip Ring



TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM (RELAYS)



1



2



5



4



3



6



7



8 9



Relay Position (T5-2-6)



10



T1F3-01-02-012



1 - QOS Controller 2 - Transistor Unit 2



45-



Transistor Unit 1 Fuse Box



78-



3 - Flasher Relay



6-



Dr. ZX Connector to MC



T5-2-5



Learning Switch ICX (Information Controller)



9 - MC (Main Controller) 10 - Dr. ZX Connector to ICX



TROUBLESHOOTING / Component Layout Relay Position



A



1 2



T1F3-01-02-012



3



View A



4 5 6 7 8 9



30 29 28 27 26



10 11 12



25 24 23



13 14 15



22 21



16



20 T1F3-01-02-013



19 18



17



1 - Head Lamp Relay (Left-Lower) (R29) 2 - Parking Brake Relay 3 (R30) 3 - Parking Brake Relay 2 (R11) 4 - Work Light Relay (R4)



9-



Head Lamp Relay (Right-Lower) (R13) 10 - Wiper Relay A (R6)



5 - High Beam Relay (R14) 6 - Wiper Relay B-1 (R7)



13 - Right Clearance Light Relay (R12) 14 - Horn Relay (R5)



7 - Starter Relay (R10)



15 - Wiper Relay B-2 (R8)



8 - Work Light Relay (R3)



16 - Load Damp Relay (R1)



11 - Wiper Relay B-3 (R9) 12 - Washer Relay (R2)



17 - Left Turn Signal Relay (R15) 18 - Work Brake Indicator Relay (R18) 19 - Neutral Signal Relay (R21) 20 - Right Turn Signal Relay (R16) 21 - Travel Forward Pi Cut Relay (R24) 22 - Axle Lock Relay (R19) 23 - Travel Motor Alarm Relay (R22)



T5-2-6



24 - Stop Lamp Relay (R17) 25 - Travel Reverse Pi Cut Relay (R25) 26 - Parking Brake Alarm Relay (R23) 27 - Transmission Changeover Relay (R20) 28 - Auto-Acceleration Cancel Relay (R26) 29 - Parking Brake Relay 1 (R27) 30 - Left Clearance Light Relay (R28)



TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM (Monitors and Switches)



1 2 19



18 3



17 16



4



15



MCBB-01-022



5



14 6 7 13



20



8



12 11



21



10 MCBB-01-012



22



9



23



24



25



26 M216-01-021



MCBB-01-014



1 - Coolant Temperature Gauge 2 - Fuel Gauge



8-



3 - Display Selection Switch



10 -



4 - Set Switch



11 -



5 - Work Mode Switch



12 -



6 - Fuel Level Indicator



13 - Air Filter Restriction Indicator 14 - Overheat Indicator



7 - Alternator Indicator



9-



Blade/Stabilizer Operation Indicator Overload Alarm Indicator (Optional) Hydraulic Oil Filter Restriction Indicator Engine Oil Pressure Indicator Preheat Indicator



15 - Digging Mode Indicator



22 - Work Light Switch



16 - Attachment Mode Indicator 17 - Liquid Crystal Display (LCD) 18 - Auto-Idle Indicator



23 - Power Mode Switch



19 - Auto-Acceleration Indicator 20 - Engine Control Dial 21 - Engine Speed Control Mode Selection Switch



T5-2-7



24 - Auto-Idle/Acceleration Selector 25 - Brake Switch 26 - Shift Lever



TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM (Column Box) 8 1, 2, 3, 4



9



10



12



11



5



6



13



12 MCBB-01-004



14



15



16



17



18



19



20



7 MCBB-01-005



22



21 MCBB-01-006



1 - Turn Signal Switch 2 - Light Switch 3 - Dimmer Switch



789-



4 - Passing Switch 5 - Hazard Light Switch



Horn Switch Turn Signal Indicator Abnormal Travel Motor Indicator 10 - Work Light Indicator 11 - Travel Mode Indicator



6 - Wiper Switch



12 - Auxiliary 2



13 - Auxiliary 1 14 - Brake Oil Pressure Gauge 15 - Speed Meter



18 - Clearance Light Indicator 19 - Parking Brake Indicator 20 - Work Brake Indicator



16 - Hazard Light Indicator 17 - High-Beam Indicator



21 - Axle Lock Indicator 22 - Brake Oil Pressure Indicator



T5-2-8



8



TROUBLESHOOTING / Component Layout PUMP DEVICE 2



1



6



5



T1F3-01-02-008



4



10



3



SWING DEVICE



9



8



7



T1F3-01-02-007



SIGNAL CONTROL VALVE 12



11 13



T176-01-02-002 T1F3-03-06-003



1 - Pilot Pump



5-



2 - Steering Pump



6-



3 - Pump 1



N sensor (Engine)



8-



Torque Control Solenoid Valve 7 - Pump 2 Control Pressure Sensor



Pump 2 Delivery Pressure Sensor 9 - Pump 1 Control Pressure Sensor 10 - Pump 1 Delivery Pressure Sensor



4 - Pump 2



T5-2-9



11 - Pressure Sensor (Front Attachment) 12 - Pressure Sensor (Auxiliary) 13 - Pressure Sensor (Swing)



TROUBLESHOOTING / Component Layout CONTROL VALVE



AUXILIARY CONTROL VALVE 1



4



2



T1F3-03-03-018 T176-01-02-003



3



3-UNIT SOLENOID VALVE UNIT



4-UNIT SOLENOID VALVE UNIT



9



5



6



7



8



10



11



T178-01-02-003



T1F3-01-02-010



1 - Pressure Sensor (Arm Roll-In) 2 - Main Relief Valve



4-



Overload Relief Valve (Auxiliary Control Valve) 5 - Solenoid Valve Unit (SC)



7-



Solenoid Valve Unit (SI)



8-



Solenoid Valve Unit (SG)



3 - Pressure Sensor (Boom Raise)



6-



9-



Max. Pump 1 Flow Rate Limit Solenoid Valve



Solenoid Valve Unit (SE)



T5-2-10



10 - Max. Pump 2 Flow Rate Limit Solenoid Valve 11 - Max. Pump 1 Flow Rate Shift Solenoid Valve



TROUBLESHOOTING / Component Layout TRAVEL SHOCKLESS VALVE/ ACCUMULATOR CHARGING VALVE



TRANSMISSION CONTROL VALVE 9 10



1



2



3



4



8



5



11



12 T1F3-01-02-006



7



6 T1F3-01-02-005



FILTER



TRAVEL DEVICE



17



13 14



18 15



19



16



MCBB-07-026



T1F3-01-02-009



1 - Travel Shockless Valve 2 - Pressure Sensor (Travel Forward) 3 - Travel Forward Pi Cut Solenoid Valve 4 - Pressure Sensor (Brake Oil Pressure Gauge) 5 - Accumulator Charging Valve



6-



Travel Reverse Pi Cut Solenoid Valve 7 - Pressure Sensor (Travel Reverse) 8 - Transmission Control Valve



11 - Accumulator (Transmission Circuit) 12 - Parking Brake Pressure Switch 13 - N sensor (Travel)



9-



14 - Transmission



Transmission Changeover Solenoid Valve 10 - Parking Brake Solenoid Valve



15 - Travel Motor



T5-2-11



16 - Travel Motor Drain Pressure Switch 17 - Pilot Filter 18 - Steering Pump Delivery Pressure Sensor 19 - Steering Filter



TROUBLESHOOTING / Component Layout COMPONENTS IN CONTROL VALVE



1



2



3



4



5



6



7



9



10



11



35 12 34 33 32 31 30



13



14 15 16



29 28



17



27



26



25



24 23 22



21



20 19 18



T1F3-03-03-014



T5-2-12



TROUBLESHOOTING / Component Layout



16 26



4 29



18, 19 7



21



12 9, 10



Front



T176-03-03-038



1 - Load Check Valve (Positioning Tandem Circuit) 2 - Load Check Valve (Positioning Parallel Circuit) 3 - Check Valve (Main Relief Circuit) 4 - Main Relief Valve 5 - Auxiliary Flow Combiner Valve 6 - Check Valve (Auxiliary Flow Combining Circuit) 7 - Check Valve (Main Relief Circuit) 9 - Bucket Flow Rate Control Valve (Selector Valve) 10 - Bucket Flow Rate Control Valve (Poppet Valve)



11 - Bucket Regenerative Circuit 12 - Overload Relief Valve (Bucket Rod Side) 13 - Overload Relief Valve (Bucket Bottom Side) 14 - Load Check Valve (Boom 1 Parallel Circuit) 15 - Boom Regenerative Circuit 16 - Overload Relief Valve (Boom Bottom Side)



20 - Load Check Valve (Arm 2 Tandem Circuit) 21 - Bypass Shut-Out Valve 22 - Check Valve (Orifice) (Arm 2 Parallel Circuit) 23 - Load Check Valve (Arm 1 Parallel Circuit) 24 - Load Check Valve (Arm 1 Tandem Circuit) 25 - Load Check Valve (Swing Circuit)



17 - Overload Relief Valve (Boom Rod Side) 18 - Boom Anti-Drift Valve (Check Valve)



26 - Arm Regenerative Valve (Selector Valve) 27 - Arm Regenerative Circuit



19 - Boom Anti-Drift Valve (Selector Valve)



28 - Overload Relief Valve (Arm Bottom Side)



T5-2-13



29 - Overload Relief Valve (Arm Rod Side) 30 - Arm Anti-Drift Valve (Check Valve) 31 - Arm Anti-Drift Valve (Selector Valve) 32 - Load Check Valve (Boom 2 Parallel Circuit) 33 - Aux. Flow Rate Control Valve (Poppet Valve) 34 - Aux. Flow Rate Control Valve (Selector Valve) 35 - Load Check Valve (Bucket Parallel Circuit)



TROUBLESHOOTING / Component Layout



1



2



3



4



5



6



7



9



10



11



35 12 13



34 33 32 31 30



14 15 16



29 28



17



27



26



25



24 23 22



21



20 19 18



T1F3-03-03-014



T5-2-14



TROUBLESHOOTING / Component Layout



30, 31



33, 34



28



Front



17



5 6



12345-



Load Check Valve (Positioning Tandem Circuit) Load Check Valve (Positioning Parallel Circuit) Check Valve (Main Relief Circuit) Main Relief Valve



Auxiliary Flow Combiner Valve 6- Check Valve (Auxiliary Flow Combining Circuit) 7- Check Valve (Main Relief Circuit) 9 - Bucket Flow Rate Control Valve (Selector Valve) 10 - Bucket Flow Rate Control Valve (Poppet Valve)



T176-03-03-036



13



35



11- Bucket Regenerative Circuit 12- Overload Relief Valve (Bucket Rod Side) 13- Overload Relief Valve (Bucket Bottom Side) 14- Load Check Valve (Boom 1 Parallel Circuit) 15- Boom Regenerative Circuit 16- Overload Relief Valve (Boom Bottom Side)



20- Load Check Valve (Arm 2 Tandem Circuit) 21- Bypass Shut-Out Valve 22- Check Valve (Orifice) (Arm 2 Parallel Circuit) 23- Load Check Valve (Arm 1 Parallel Circuit) 24- Load Check Valve (Arm 1 Tandem Circuit) 25- Load Check Valve (Swing Circuit)



17- Overload Relief Valve (Boom Rod Side) 18- Boom Anti-Drift Valve (Check Valve)



26- Arm Regenerative Valve (Selector Valve) 27- Arm Regenerative Circuit



19- Boom Anti-Drift Valve (Selector Valve)



28- Overload Relief Valve (Arm Bottom Side)



T5-2-15



29- Overload Relief Valve (Arm Rod Side) 30- Arm Anti-Drift Valve (Check Valve) 31- Arm Anti-Drift Valve (Selector Valve) 32- Load Check Valve (Boom 2 Parallel Circuit) 33- Aux. Flow Rate Control Valve (Poppet Valve) 34- Aux. Flow Rate Control Valve (Selector Valve) 35- Load Check Valve (Bucket Parallel Circuit)



TROUBLESHOOTING / Component Layout



1



2



3



4



5



6



7



9



10



11



35 12 13



34 33 32 31 30



14 15 16



29 28



17



27



26



25



24 23 22



21



20 19 18



T1F3-03-03-014



T5-2-16



TROUBLESHOOTING / Component Layout Cross Section A



F E



D



4



C B



7 A



3 35



6



5



a



NOTE: Valve (a) is not used.



T176-03-03-035



12345-



Load Check Valve (Positioning Tandem Circuit) Load Check Valve (Positioning Parallel Circuit) Check Valve (Main Relief Circuit) Main Relief Valve



Auxiliary Flow Combiner Valve 6- Check Valve (Auxiliary Flow Combining Circuit) 7- Check Valve (Main Relief Circuit) 9- Bucket Flow Rate Control Valve (Selector Valve) 10- Bucket Flow Rate Control Valve (Poppet Valve)



11- Bucket Regenerative Circuit 12- Overload Relief Valve (Bucket Rod Side) 13- Overload Relief Valve (Bucket Bottom Side) 14- Load Check Valve (Boom 1 Parallel Circuit) 15- Boom Regenerative Circuit 16- Overload Relief Valve (Boom Bottom Side)



T1F3-03-03-013



20- Load Check Valve (Arm 2 Tandem Circuit) 21- Bypass Shut-Out Valve 22- Check Valve (Orifice) (Arm 2 Parallel Circuit) 23- Load Check Valve (Arm 1 Parallel Circuit) 24- Load Check Valve (Arm 1 Tandem Circuit) 25- Load Check Valve (Swing Circuit)



17- Overload Relief Valve (Boom Rod Side) 18- Boom Anti-Drift Valve (Check Valve)



26- Arm Regenerative Valve (Selector Valve) 27- Arm Regenerative Circuit



19- Boom Anti-Drift Valve (Selector Valve)



28- Overload Relief Valve (Arm Bottom Side)



T5-2-17



29- Overload Relief Valve (Arm Rod Side) 30- Arm Anti-Drift Valve (Check Valve) 31- Arm Anti-Drift Valve (Selector Valve) 32- Load Check Valve (Boom 2 Parallel Circuit) 33- Aux. Flow Rate Control Valve (Poppet Valve) 34- Aux. Flow Rate Control Valve (Selector Valve) 35- Load Check Valve (Bucket Parallel Circuit)



TROUBLESHOOTING / Component Layout



1



2



3



4



5



6



7



9



10



11



35 12 13



34 33 32 31 30



14 15 16



29 28



17



27



26



25



24 23 22



21



20 19 18



T1F3-03-03-014



T5-2-18



TROUBLESHOOTING / Component Layout Cross Section B



Cross Section C Travel



Bucket



Positioning



Auxiliary



12



1



2



10



33



9 11 13



34



T1F3-03-03-012



T176-03-03-004



12345-



Load Check Valve (Positioning Tandem Circuit) Load Check Valve (Positioning Parallel Circuit) Check Valve (Main Relief Circuit) Main Relief Valve



Auxiliary Flow Combiner Valve 6- Check Valve (Auxiliary Flow Combining Circuit) 7- Check Valve (Main Relief Circuit) 9- Bucket Flow Rate Control Valve (Selector Valve) 10- Bucket Flow Rate Control Valve (Poppet Valve)



11- Bucket Regenerative Circuit 12- Overload Relief Valve (Bucket Rod Side) 13- Overload Relief Valve (Bucket Bottom Side) 14- Load Check Valve (Boom 1 Parallel Circuit) 15- Boom Regenerative Circuit 16- Overload Relief Valve (Boom Bottom Side)



20- Load Check Valve (Arm 2 Tandem Circuit) 21- Bypass Shut-Out Valve 22- Check Valve (Orifice) (Arm 2 Parallel Circuit) 23- Load Check Valve (Arm 1 Parallel Circuit) 24- Load Check Valve (Arm 1 Tandem Circuit) 25- Load Check Valve (Swing Circuit)



17- Overload Relief Valve (Boom Rod Side) 18- Boom Anti-Drift Valve (Check Valve)



26- Arm Regenerative Valve (Selector Valve) 27- Arm Regenerative Circuit



19- Boom Anti-Drift Valve (Selector Valve)



28- Overload Relief Valve (Arm Bottom Side)



T5-2-19



29- Overload Relief Valve (Arm Rod Side) 30- Arm Anti-Drift Valve (Check Valve) 31- Arm Anti-Drift Valve (Selector Valve) 32- Load Check Valve (Boom 2 Parallel Circuit) 33- Aux. Flow Rate Control Valve (Poppet Valve) 34- Aux. Flow Rate Control Valve (Selector Valve) 35- Load Check Valve (Bucket Parallel Circuit)



TROUBLESHOOTING / Component Layout



1



2



3



4



5



6



7



9



10



11



35 12 34 33 32 31 30



13



14 15 16



29 28



17



27



26



25



24 23 22



21



20 19 18



T1F3-03-03-014



T5-2-20



TROUBLESHOOTING / Component Layout Cross Section D Boom 1



Cross Section E Boom 2



Arm 2



19



Arm 1



31 16



29 30



18



14



32



20



22



23



24 27



15



28



17 T176-03-03-006



T176-03-03-005



12345-



Load Check Valve (Positioning Tandem Circuit) Load Check Valve (Positioning Parallel Circuit) Check Valve (Main Relief Circuit) Main Relief Valve



Auxiliary Flow Combiner Valve 6- Check Valve (Auxiliary Flow Combining Circuit) 7- Check Valve (Main Relief Circuit) 9- Bucket Flow Rate Control Valve (Selector Valve) 10- Bucket Flow Rate Control Valve (Poppet Valve)



11- Bucket Regenerative Circuit 12- Overload Relief Valve (Bucket Rod Side) 13- Overload Relief Valve (Bucket Bottom Side) 14- Load Check Valve (Boom 1 Parallel Circuit) 15- Boom Regenerative Circuit 16- Overload Relief Valve (Boom Bottom Side)



20- Load Check Valve (Arm 2 Tandem Circuit) 21- Bypass Shut-Out Valve 22- Check Valve (Orifice) (Arm 2 Parallel Circuit) 23- Load Check Valve (Arm 1 Parallel Circuit) 24- Load Check Valve (Arm 1 Tandem Circuit) 25- Load Check Valve (Swing Circuit)



17- Overload Relief Valve (Boom Rod Side) 18- Boom Anti-Drift Valve (Check Valve)



26- Arm Regenerative Valve (Selector Valve) 27- Arm Regenerative Circuit



19- Boom Anti-Drift Valve (Selector Valve)



28- Overload Relief Valve (Arm Bottom Side)



T5-2-21



29- Overload Relief Valve (Arm Rod Side) 30- Arm Anti-Drift Valve (Check Valve) 31- Arm Anti-Drift Valve (Selector Valve) 32- Load Check Valve (Boom 2 Parallel Circuit) 33- Aux. Flow Rate Control Valve (Poppet Valve) 34- Aux. Flow Rate Control Valve (Selector Valve) 35- Load Check Valve (Bucket Parallel Circuit)



TROUBLESHOOTING / Component Layout



1



2



3



4



5



6



7



9



10



11



35 12 34 33 32 31 30



13



14 15 16



29 28



17



27



26



25



24 23 22



21



20 19 18



T1F3-03-03-014



T5-2-22



TROUBLESHOOTING / Component Layout Cross Section F



Swing



26



25



21 T176-03-03-007



12345-



Load Check Valve (Positioning Tandem Circuit) Load Check Valve (Positioning Parallel Circuit) Check Valve (Main Relief Circuit) Main Relief Valve



Auxiliary Flow Combiner Valve 6- Check Valve (Auxiliary Flow Combining Circuit) 7- Check Valve (Main Relief Circuit) 9- Bucket Flow Rate Control Valve (Selector Valve) 10- Bucket Flow Rate Control Valve (Poppet Valve)



11- Bucket Regenerative Circuit 12- Overload Relief Valve (Bucket Rod Side) 13- Overload Relief Valve (Bucket Bottom Side) 14- Load Check Valve (Boom 1 Parallel Circuit) 15- Boom Regenerative Circuit 16- Overload Relief Valve (Boom Bottom Side)



20- Load Check Valve (Arm 2 Tandem Circuit) 21- Bypass Shut-Out Valve 22- Check Valve (Orifice) (Arm 2 Parallel Circuit) 23- Load Check Valve (Arm 1 Parallel Circuit) 24- Load Check Valve (Arm 1 Tandem Circuit) 25- Load Check Valve (Swing Circuit)



17- Overload Relief Valve (Boom Rod Side) 18- Boom Anti-Drift Valve (Check Valve)



26- Arm Regenerative Valve (Selector Valve) 27- Arm Regenerative Circuit



19- Boom Anti-Drift Valve (Selector Valve)



28- Overload Relief Valve (Arm Bottom Side)



T5-2-23



29- Overload Relief Valve (Arm Rod Side) 30- Arm Anti-Drift Valve (Check Valve) 31- Arm Anti-Drift Valve (Selector Valve) 32- Load Check Valve (Boom 2 Parallel Circuit) 33- Aux. Flow Rate Control Valve (Poppet Valve) 34- Aux. Flow Rate Control Valve (Selector Valve) 35- Load Check Valve (Bucket Parallel Circuit)



TROUBLESHOOTING / Component Layout



1



Auxiliary Control Valve



2 3



T1F3-03-03-014



T5-2-24



TROUBLESHOOTING / Component Layout Cross Section X-X X



2



1



3



T1GL-03-03-004



X T1GL-03-03-003



1 - Load Check Valve (Blade/Stabilizer Tandem Circuit)



2-



Overload Relief Valve (Blade/Stabilizer Rod Side)



T5-2-25



3-



Overload Relief Valve (Blade/Stabilizer Bottom Side)



TROUBLESHOOTING / Component Layout SIGNAL CONTROL VALVE PORT LOCATION Pilot Valve Side C



PH A



E M D H B



F



SB G



PI



Pilot Valve Side



N



K



I SH



J DF SA



L T178-03-06-016



Pilot Valve Side Port Name Port A Port B Port C Port D Port E Port F Port G Port H Port I Port J Port K Port L Port M Port N Port SA Port SB Port PI Port PH Port SH Port DF



Connecting to Right Pilot Valve Right Pilot Valve Left Pilot Valve Left Pilot Valve Left Pilot Valve Left Pilot Valve Right Pilot Valve Right Pilot Valve   Travel Shocless Valve (Travel Pilot Valve) Travel Shocless Valve (Travel Pilot Valve) Positioning/Auxiliary Pilot Valve Positioning/Auxiliary Pilot Valve Pump 1 Regulator Pump 2 Regulator 4-Unit Solenoid Valve Unit Pilot Shut-Off Valve Shuttle Valve (Swing Parking Brake) Hydraulic Oil Tank



T5-2-26



Note Boom Raise Pilot Pressure Boom Lower Pilot Pressure Arm Roll-Out Pilot Pressure Arm Roll-In Pilot Pressure Left Swing Pilot Pressure Right Swing Pilot Pressure Bucket Roll-In Pilot Pressure Bucket Roll-Out Pilot Pressure Plug Plug Travel Reverse Pilot Pressure Travel Forward Pilot Pressure Positioning Raise/Auxiliary Open Pilot Pressure Positioning Lower/Auxiliary Close Pilot Pressure Pump 1 Control Pressure Pump 2 Control Pressure Primary Pilot Pressure Primary Pilot Pressure (Heating Circuit) Brake Release Pressure Returning to Hydraulic Oil Tank



TROUBLESHOOTING / Component Layout



Control Valve Side 3



1



5



Pressure Sensor (Auxiliary)



13 4



2 SK



SE 8



Pressure Sensor (Swing)



14 Control Valve Side



7 9 6



10



SN



SL



11



12



Control Valve Side Port Name Port 1 Port 2 Port 3 Port 4 Port 5 Port 6 Port 7 Port 8 Port 9 Port 10 Port 11 Port 12 Port 13 Port 14 Port SE Port SN Port SP Port SL Port SK



Connecting to Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Hydraulic Oil Tank  Control Valve Control Valve Pilot Pressure Shift Valve Pilot Pressure Shift Valve   Shuttle Valve  Control Valve



SP



T1F3-03-06-003



Note Boom Raise Pilot Pressure Boom Lower Pilot Pressure Arm Roll-Out Pilot Pressure Arm Roll-In Pilot Pressure Left Swing Pilot Pressure Right Swing Pilot Pressure Bucket Roll-In Pilot Pressure Bucket Roll-Out Pilot Pressure Returning to Hydraulic Oil Tank Plug Travel Reverse Pilot Pressure Travel Forward Pilot Pressure Positioning Raise/Auxiliary Open Pilot Pressure Positioning Lower/Auxiliary Close Pilot Pressure Plug Plug Pump 1 Flow Rate Control Valve Control Pressure Plug Bucket Flow Rate Control Valve Control Pressure



T5-2-27



TROUBLESHOOTING / Component Layout NOTE: Machines equipped with optional auxiliary flow combining system. Control Valve Side SM



Control Valve Side



SN



T1F3-03-06-004



Control Valve Side Port Name Port SM Port SN



Connecting to Auxiliary Flow Combiner Solenoid Valve Auxiliary Flow Combiner Reducing Valve



NOTE: The reducing valve and the auxiliary flow combiner solenoid valve are installed only on the machines equipped with the optional auxiliary flow combining system.



T5-2-28



Note Auxiliary Flow Combiner Valve Shift Pressure Auxiliary Flow Combiner Valve Shift Pressure



TROUBLESHOOTING / Troubleshooting A TROUBLESHOOTING A PROCEDURE Refer to troubleshooting A procedure in case any fault codes are displayed after diagnosing the main controller (MC) using Dr. ZX (or the built-in diagnosing system).



• How to Read Troubleshooting Flow Charts



YES(OK)



・



(2)



(1) After completing the checking and/or measuring procedures in box (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).



(1)



NO(NOT OK)



・ · Key switch: ON



(3)



Instructions, reference, and/or inspection methods and/or measurements are occasionally described under the box. If incorrectly checked or measured, not only will troubleshooting be unsuccessful but also damage to the components may result.



・



Refer to “Electrical System Inspection” Group (Group 6) for descriptions in the dotted-line box.



・



Use Dr. ZX (or the built-in diagnosing system) for descriptions in the double-line box.



・



Causes of machine problems are stated in the thick-line box. Scanning quickly through the thick-line boxes allows you to estimate the possible causes before actually following the flow chart.



NOTE: All harness end connectors are seen from the open-end side.



Harness Open End Side



Harness End Connector T158-05-03-001



T5-3-1



TROUBLESHOOTING / Troubleshooting A FAULT CODE LIST Fault code 01 02 03 04



Problem Abnormal EEPROM Abnormal RAM Abnormal A/D Conversion Abnormal Sensor Voltage



• Faulty MC



06



Abnormal EC Sensor



07



Abnormal Engine Control Dial Angle



10 11



Abnormal Pump 1 Delivery Pressure Abnormal Pump 2 Delivery Pressure



12 13



Abnormal Pump 1 Pump Control Pressure Abnormal Pump 2 Pump Control Pressure



14 15 16 18 19



Abnormal Swing Pilot Pressure Sensor Abnormal Boom Raise Pilot Pressure Sensor Abnormal Arm Roll-In Pilot Pressure Sensor Abnormal Travel Pilot Pressure Sensor Abnormal Hydraulic Oil Temperature



20



Abnormal Travel Motor Drain Pressure Sensor



22



Abnormal Travel Motor



23 24



Abnormal Travel Forward Pilot Pressure Sensor Abnormal Travel Reverse Pilot Pressure Sensor



*26



Travel Motor Over-rev.



NOTE: In case the travel motor runs at an excessive speed, fault code 26 is displayed. Using Dr. ZX service mode, check the excessive speed rotation numbers (the excessive speed running is not caused by the faulty travel motor). Select the retry when deleting the fault code.



T5-3-2



Cause



• • • • • • • • • • • • • • • • • •



Faulty MC Faulty Harness Faulty Sensor Faulty MC Faulty Harness Faulty EC Sensor Faulty MC Faulty Harness Faulty Engine Control Dial Faulty MC Faulty Harness Faulty Pump Delivery Pressure Sensor Faulty MC Faulty Harness Faulty Pump Control Pressure Sensor Faulty MC Faulty Harness Faulty Pilot Pressure Sensor



• • • • • • • • • • • • •



Faulty MC Faulty Harness Faulty Hydraulic Oil Temperature Sensor Faulty MC Faulty Harness Faulty Travel Motor Drain Pressure Sensor Faulty MC Faulty Harness Faulty Travel Motor Drain Pressure Sensor Faulty MC Faulty Harness Faulty Travel Pilot Pressure Sensor Travel Motor Over-rev.



TROUBLESHOOTING / Troubleshooting A FAULT CODE 01 (ABNORMAL EEPROM) FAULT CODE 02 (ABNORMAL RAM) FAULT CODE 03 (ABNORMAL A/D CONVERSION) YES



* Faulty MC.



Check if engine and machine actuators operate normally. Faulty MC. NO · Refer to T4-6-1.



* Even if any fault codes are still displayed after retrying, as long as the engine and machine operate normally, the machine can be operated as it is.



FAULT CODE 04 (ABNORMAL SENSOR VOLTAGE) Faulty MC.



YES



· Refer to T4-6-1. Check if fault code is displayed as follows. (06, 07, 08, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 22, 23, 24)



Faulty sensor with the displayed fault code, or short-circuited harness between MC and sensor.



NO



T5-3-3



TROUBLESHOOTING / Troubleshooting A FAULT CODE 06 (ABNORMAL EC SENSOR)



YES



Disconnect EC sensor. Check if resistance between sensor side connector terminals #1 and #3 is less than 2.0±0.4 kΩ. Connect test harness between EC sensor and base machine side harness. Check if voltage changes in accordance with specifications when engine control dial is rotated.



YES



YES



Check harness between MC connector C (31P) terminal #18 and EC sensor terminal #2 for breakage or short circuit.



Disconnect EC sensor. Check if voltage between harness end connectors #1 and #3 is 5±0.5 V.



Faulty MC. NO



YES



Check if voltage between EC sensor harness end connector terminal #1 and vehicle frame matches specification.



· Key switch: ON NO



Faulty harness between MC and EC sensor.



NO



· Refer to T4-6-1. Broken harness between MC and EC sensor terminal #3.



Broken harness between MC and EC sensor terminal #1.



· Key switch: ON · Specification: 5±0.5 V Faulty EC sensor.



NO · Test Harness: ST 7129 · Specification: Refer to the table below.



EC Sensor Specification Slow Idle 2.5 to 2.7 V Fast Idle (HP mode 3.3 to 3.7 V Switch: OFF) Fast Idle (HP mode Voltage at Fast Idle (HP Mode Switch: ON) Switch: OFF) plus 0.2 V or more



· Refer to T4-6-1.



Connector (Harness End Connector Viewed from the Open End Side) MC Connector C C10



C1



C23



C31 #18



EC Sensor



1



T5-3-4



2



3



TROUBLESHOOTING / Troubleshooting A FAULT CODE 07 (ABNORMAL ENGINE CONTROL DIAL ANGLE)



Disconnect switch panel. Check if resistance between switch panel side connector terminals #2 and #4 is 5±0.5 kΩ. Reconnect switch panel. Insert tester probe into connector terminal #3 from the reverse side. Check if voltage varies as specified when engine control dial is turned.



Disconnect switch panel. Check if voltage between harness end connector YES terminals #2 and #4 is 5±0.5 V.



· Key switch: ON



Check harness between MC connector C (31P) harness end terminal #6 YES and switch panel terminal #3 for breakage or short circuit.



YES



Faulty harness between MC and engine control dial.



Faulty MC. NO



Check if voltage between YES switch panel harness end connector terminal #2 and vehicle frame matches specification.



NO



NO



· Refer to T4-6-1. Broken harness between MC and engine control dial terminal #4. Broken harness between MC and engine control dial terminal #2.



· Key switch: ON · Specification: 5±0.5 V Faulty engine control dial.



NO · Specification: Refer to the table below.



Engine Control Dial Specification Minimum Speed 0.3 to 1.0 V Maximum Speed 4.0 to 4.7 V



Connector (Harness End Connector Viewed from the Open End Side) MC Connector C #6 C10



C1



C23



C31



Switch Panel



#4



T5-3-5



#3



#2



TROUBLESHOOTING / Troubleshooting A FAULT CODE 10 (ABNORMAL PUMP 1 DELIVERY PRESSURE) FAULT CODE 11 (ABNORMAL PUMP 2 DELIVERY PRESSURE) Checking Instruction



• Both pump 1 and pump 2 delivery pressure sensors seldom fail at the same time. Accordingly, if both fault codes 10 and 11 are displayed simultaneously, faulty harness may be the cause of this problem.



NO



Check if fault codes are switched after switching pump 1 delivery pressure sensor with pump 2 delivery pressure sensor and retrying.



Disconnect pump delivery pressure sensor. Check if voltage between harness end connector terminals #1 and #3 is 5±0.5 V.



Check harness between MC connector C (31P) harness end terminal #1 (pump 1) or #4 (pump 2) and YES pump delivery pressure sensor terminal #2 for breakage or short circuit.



· Key switch: ON NO



Check if voltage between pump delivery pressure sensor harness end connector terminal #1 and vehicle frame matches specification.



YES



Connector (Harness End Connector Viewed from the Open End Side) MC Connector C #1



#4 C10



C23



C31



Pump Delivery Pressure Sensor



3



2



Faulty MC. NO · Refer to T4-6-1.



· Key switch: ON · Specification: 5±0.5 V



C1



YES



Faulty harness between MC and pump delivery pressure sensor.



1



T5-3-6



YES



Broken harness between MC and pump delivery pressure sensor terminal #3.



NO



Broken harness between MC and pump delivery pressure sensor terminal #1.



Faulty pump delivery pressure sensor.



TROUBLESHOOTING / Troubleshooting A FAULT CODE 12 (ABNORMAL PUMP 1 CONTROL PRESSURE) FAULT CODE 13 (ABNORMAL PUMP 2 CONTROL PRESSURE) Checking Instruction • Both pump 1 and pump 2 control pressure sensors seldom fail at the same time. Accordingly, if both fault codes 12 and 13 are displayed simultaneously, faulty harness may be the cause of this problem.



YES



Faulty harness between MC and pump control pressure sensor.



Faulty MC.



Disconnect pump control pressure sensor. Check if voltage between harness end connector terminals #1 and #3 is 5±0.5 V.



NO



Check if fault codes are switched after switching pump 1 control pressure sensor with pump 2 control pressure sensor and retrying.



Check harness between MC connector C (31P) harness end terminal #7 (pump 1) or #13 (pump 2) and pump control pressure YES sensor terminal #2 for breakage or short circuit.



NO · Refer to T4-6-1.



· Key switch: ON NO



Check if voltage between pump control pressure sensor harness end connector terminal #1 and vehicle frame matches specification.



YES



NO



Broken harness between MC and pump control pressure sensor terminal #3.



Broken harness between MC and pump control pressure sensor terminal #1.



· Key switch: ON · Specification: 5±0.5 V Faulty pump control pressure sensor. YES



Connector (Harness End Connector Viewed from the Open End Side) MC Connector C #13



#7 C10



C1



C23



C31



Pump Control Pressure Sensor



1



2



3



T5-3-7



TROUBLESHOOTING / Troubleshooting A FAULT CODE 14 (ABNORMAL SWING PILOT PRESSURE) FAULT CODE 15 (ABNORMAL BOOM RAISE PILOT PRESSURE) FAULT CODE 16 (ABNORMAL ARM ROLL-IN PILOT PRESSURE) FAULT CODE 18 (ABNORMAL TRAVEL PILOT PRESSURE) FAULT CODE 23 (ABNORMAL TRAVEL FORWARD PILOT PRESSURE) FAULT CODE 24 (ABNORMAL TRAVEL REVERSE PILOT PRESSURE)



NOTE: Fault code 18 (abnormal travel pilot pressure sensor) will be displayed together with fault code (23 or 24) simultaneously in case either the travel forward pilot pressure sensor or the travel reverse pilot pressure sensor is abnormal.



Checking Instruction



• All pressure sensors seldom fail at the same time.



YES



Accordingly, if fault codes 14, 15, 16, 18, 23 and 24 are displayed simultaneously, faulty harness may be the cause of this problem.



NO Check if fault code disappears after switching pressure sensor with another pressure sensor and retrying.



Connector C Terminal: #14: Pressure Sensor (Swing) #2: Pressure Sensor (Boom Raise) #5: Pressure Sensor (Arm Roll-In) #17: Pressure Sensor (Travel Forward) #23: Pressure Sensor (Travel Reverse)



Disconnect pressure sensor. Check if voltage between harness end connector terminals #1 and #3 is 5±0.5 V. · Key switch: ON



NO



Fault Code: 14: Pressure Sensor (Swing) 15: Pressure Sensor (Boom Raise) 16: Pressure Sensor (Arm Roll-In) 23: Pressure Sensor (Travel Forward) 24: Pressure Sensor (Travel Reverse)



Check harness between MC connector C (31P) harness end each corresponding terminal and pressure sensor terminal #2 for breakage or short circuit.



Check if voltage between pressure sensor harness end connector terminal #1 and vehicle frame matches specification.



· Key switch: ON · Specification: 5±0.5 V YES



T5-3-8



TROUBLESHOOTING / Troubleshooting A



Faulty harness between MC and pressure sensor.



YES



Faulty MC. NO · Refer to T4-6-1.



Broken harness between MC and pressure sensor terminal #3.



YES



Broken harness between MC and pressure sensor terminal #1. NO



Faulty pressure sensor.



Connector (Harness End Connector Viewed from the Open End Side) MC Connector C #2



Pilot Pressure Sensor #5 C10



C1



C23



1



2



3



C31 #23



#14



#17



T5-3-9



TROUBLESHOOTING / Troubleshooting A FAULT CODE 19 (ABNORMAL HYDRAULIC OIL TEMPERATURE)



Disconnect hydraulic oil temperature sensor. Check if sensor side connector resistance matches specification.



Connect hydraulic oil temperature sensor harness end connector terminal #1 to #2 with a clip. Remove connector B (25P) and connector C (31P) YES from MC. Check for continuity between connector B harness end terminal #22 and connector C terminal #24.



Faulty MC.



YES



· Refer to T4-6-1.



NO



Connect MC connector B (25P) harness end terminal #22 to vehicle frame. Check for continuity between hydraulic oil temperature sensor harness end connector terminal #2 and vehicle frame.



Broken harness between MC and YES hydraulic oil temperature sensor terminal #1.



NO



· Specification: Refer to the table below.



Faulty hydraulic oil temperature sensor.



NO



Oil Temperature Specification Oil Temperature Resistance (°C) (kΩ) −20 16.2±1.6 0 (5.88) 20 2.45±0.24 40 (1.14) 60 (0.534) 80 0.322



Broken harness between MC and hydraulic oil temperature sensor terminal #2.



Connector (Harness End Connector Viewed from the Open End Side) MC Connector B B8



B1



B19



B25 #22



MC Connector C C10



C1



C23



C31 #24



Hydraulic Oil Temperature Sensor 1



2



T5-3-10



TROUBLESHOOTING / Troubleshooting A FAULT CODE 20 (ABNORMAL TRAVEL MOTOR DRAIN PRESSURE SENSOR)



Check harness between MC connector C (31P) terminal #3 and YES pressure sensor terminal #2 for breakage or short circuit. Disconnect pressure sensor. Check if voltage between harness end NO connector terminals #1 and #3 is 5±0.5 V.



· · · · · ·



Faulty MC. NO · Refer to T4-6-1.



· Key Switch: ON Check if voltage between pressure sensor harness connector terminal #1 and vehicle NO frame matches specification.



Check if fault code is deleted when retry is performed after replacing pressure sensor with other pressure sensor.



Faulty harness beYES tween MC and pressure sensor.



Replaceable Pressure Sensor: Pressure Sensor (Swing) Pressure Sensor (Boom Raise) Pressure Sensor (Arm Roll-in) Pressure Sensor (Travel Forward) Pressure Sensor (Travel Reverse)



· Key Switch: ON · Specification: 5±0.5 V



Broken ground line YES cable of pressure sensor (terminal #3).



Broken harness between MC connector NO B terminal #20 and pressure sensor terminal #1.



Faulty pressure sensor.



YES



Connector (Harness End Connector Viewed from the Open End Side) MC: Connector C #2 C1



Travel Motor Drain Pressure Sensor



#3 C10 1



C23



C31



T5-3-11



2



3



TROUBLESHOOTING / Troubleshooting A FAULT CODE 22 (ABNORMAL TRAVEL MOTOR) • This fault code is displayed when input signal value from the travel motor drain pressure sensor is more than 1.6 MPa and when this status continues for longer than 50 ms. Faulty travel motor or MC may be the cause of this trouble. NOTE: 50 ms (milli-second)=0.05 second



T5-3-12



TROUBLESHOOTING / Troubleshooting B TROUBLESHOOTING B PROCEDURE Apply troubleshooting B procedure when no fault code is displayed on the Dr.ZX (or the built-in diagnosing system) although the machine’s operation is abnormal. On the front section pages of this group T5-4, are tables indicating the relationship between machine trouble symptoms and related parts which may cause such trouble if failed. Start the troubleshooting with more probable causes selected by referring to these tables.



• How to Read the Troubleshoting Flow Charts YES(OK)



・



• After checking or measuring item (1), select either YES (OK) or NO (NOT OK) and proceed to item (2) or (3), as appropriate.



(1) NO(NOT OK)



(3)



• Special instructions or reference item are indicated in the spaces under the box.



・ · Key switch: ON



・



(2)



Incorrect measuring or checking methods will render troubleshooting impossible, and may damage components as well.



• Explanation of how to use test harness kit required. Refer to “Electrical System Inspection” Group (Group 6) in this section.



・



• Use Dr.ZX (or the built-in diagnosing system) function.



・



• Causes are stated in a thick-line box. Scanning through thick-line boxes, possible causes can be seen without going through the flow chart.



T5-4-1



TROUBLESHOOTING / Troubleshooting B RELATIONSHIP BETWEEN MACHINE TROUBLE SYMPTOMS AND RELATED PARTS This table indicates the relationship between machine trouble symptoms and the potential problem parts, which may cause trouble if failed, and the evaluation methods of these components. Parts EC Motor



•



EC Sensor



•



Moves governor.



• Function



•



Governor lever doesn’t move.



•



Engine speed is controlled based on idle position set when key switch is turned ON. Therefore, engine speed is always controlled with error in idle position setting if set incorrectly.



•



Even if engine control dial is turned, engine speed doesn’t increase from slow idle speed. Engine start may be difficult though starter rotates. Engine will stall if discontinuity occurs in EC motor while engine is running at more than a specified speed. Engine will become uncontrollable if discontinuity occurs in EC motor while engine is running at lower than a specified speed. Engine cannot be stopped with key switch.



•



Error in setting will seldom occur so that change in machine operation will not be noticed. In case error is set on lower side, engine speed changes but runs slower than normal through the full range when engine control dial is turned. (Note: In case error is set on upper side, EC motor is driven so that it runs faster than the control range. However, motor, a worm gear type, holds governor lever at maximum constant position, preventing engine stall. When engine control dial is turned to minimum speed position, governor lever is returned to idle position.) When starting engine, engine speed fluctuates. Starting engine is occasionally difficult.



Symptoms in control system when trouble occurs.



• • • Symptoms in machine operation when trouble occurs.



•



• •



By Fault Code



Evaluation



Others NOTE Descriptions of Control (Operational Principle Section in T/M)



Fault code 06 is displayed.







By Monitor Function Using Test Harness



Detects minimum governor speed position (2.5 V) only when key switch is turned ON. Detects minimum and maximum speed position when engine learning is conducted.



Monitor Item: EC Angle (Displayed by built-in diagnosing system)







•



•



Install lamp harness (ST 7125) to check EC output signal and harness for any abnormality.



 Engine is stopped by EC motor. (Engine stop motor is not provided.) Fuel cut-off cable is provided.



T2-1







•



 If EC sensor is faulty, engine learning is not performed.



T2-1



T5-4-2



TROUBLESHOOTING / Troubleshooting B



Engine Control Dial



Pump Control Pressure Sensor



Pump 1 Delivery Pressure Sensor



•



Indicates governor lever position (engine target speed).



•



Monitors pump control pressure to control auto-acceleration system.



•



Monitors pump delivery pressure to control HP mode, auto-acceleration and forward/reverse travel pedal.



•



Engine speed doesn’t change even if engine control dial is turned. If discontinuity or short circuit occurs in engine control dial, slow idle is used as back-up value.



•



No signals arrive to MC



•



If pump delivery pressure sensor output is 0 or 5 V, following symptoms will be presented by back-up mode function.



Engine speed is kept unchanged from slow idle. (Engine can be stopped by key switch.)



•



Auto-acceleration control is inoperable (but not noticeable).



• • •



HP mode is inoperable. Auto-acceleration control is inoperable. When the machine travels, the engine speed doesn’t increase.



•



•



Fault code 07 is displayed.



Fault codes 12 and 13 are displayed.



Fault code 10 is displayed.



Monitor Item: Engine Target Speed, Dial Angle (Displayed by built-in diagnosing system)



Monitor Item: Pump 1 and 2 Pump Flow Control Pressure (Displayed by built-in diagnostic system)



Monitor Item: Pump 1 Delivery Pressure (Displayed by built-in diagnostic system)



   T2-1



•



















Evaluation by Dr. ZX Broken Circuit: 0.25 V or less Short Circuit: 0.75 V or more



T2-1



 T2-1



T5-4-3



TROUBLESHOOTING / Troubleshooting B



Parts



Pump 2 Delivery Pressure Sensor



Steering Pump Delivery Pressure Sensor



•



Monitors pump delivery pressure to control HP mode, auto-acceleration and arm regenerative.



•



Monitors pump delivery pressure to control steering pump torque decrease.



•



If pump delivery pressure sensor output is 0 or 5 V, following symptoms will be presented by back-up mode function.



•



Engine stalls if pump torque is increased.



• • •



HP mode is inoperable. Auto-acceleration control is inoperable. Arm is slow when arm roll-in and swing combined operation is made.



•



Engine stalls if pump torque is increased.



Function



Symptoms in control system when trouble occurs.



Symptoms in machine operation when trouble occurs.



By Fault Code



Evaluation



By Monitor Function



Monitor Item: Pump 2 Delivery Pressure (Displayed by built-in diagnostic system)



Using Test Harness Others



NOTE Descriptions of Control (Operational Principle Section in T/M)







Fault code 11 is displayed.



Monitor Item: Pump 3 Delivery Pressure



























T2-1



T2-1



T5-4-4



TROUBLESHOOTING / Troubleshooting B



Pressure Sensor (Travel Forward)



Pressure Sensor (Travel Reverse)



Pressure Sensor (Front Attachment)



•



Monitors travel forward pilot pressure to control forward/reverse travel pedal, auto-idle, auto-acceleration and idle speed-up.



•



Monitors travel reverse pilot pressure to control forward/reverse travel pedal, auto-idle, auto-acceleration and idle speed-up.



•



Monitors front attachment pilot pressure to control auto-idle, idle speed-up and parking brake alarm.



•



No signals arrive to MC



•



No signals arrive to MC



•



When the pressure sensor (front attachment) or the harness between the pressure sensor and the MC is faulty, the MC judges that the pressure sensor (front attachment) is ON.



•



Engine speed doesn’t increase even if auto-idle/auto-acceleration selector is auto-idle position. Even if the pedal is stepped on with the engine speed control mode selection switch in the pedal position, the engine speed doesn’t increase. Occasionally, engine speed hunts while traveling at slow idle. Even though the machine is driven with the forward/reverse travel pedal fully stepped on, the engine speed doesn’t increase. Even though the machine travels forward with the auto-acceleration switch ON, the engine speed doesn’t increase.



•



Engine speed doesn’t increase even if auto-idle/auto-acceleration selector is auto-idle position. Even if the pedal is stepped on with the engine speed control mode selection switch in the pedal position, the engine speed doesn’t increase. Occasionally, engine speed hunts while traveling at slow idle. Even though the machine is driven with the forward/reverse travel pedal fully stepped on, the engine speed doesn’t increase. Even though the machine travels reverse with the auto-acceleration switch ON, the engine speed doesn’t increase.



•



Engine speed doesn’t increase even if any front attachment actuator is operated with auto-idle/auto-acceleration selector is auto-idle position. Occasionally, engine speed hunts while operating front attachment at slow idle. When the parking brake is applied or when the front attachment is operated, the buzzer doesn’t sound.



• • • •



• • • •



• •







Fault codes 18 and 23 are displayed.



Fault codes 18 and 24 are displayed.



Monitor Item: Forward Travel Control Pilot Pressure (Displayed built-in diagnostic system) Monitor pressure change while traveling forward.



Monitor Item: Reverse Travel Control Pilot Pressure (Displayed built-in diagnostic system) Monitor Pressure change while traveling reverse.



























•



Judge if pressure sensor is faulty or port is clogged by switching pressure sensor with another pressure sensor.



T2-1



•



Judge if pressure sensor is faulty or port is clogged by switching pressure sensor with another pressure sensor.



T2-1



Monitor Item: Front ATT. Operation (Displayed built-in diagnostic system). Monitor pressure change while operating front attachment.



•



Judge if pressure sensor is faulty or port is clogged by switching pressure sensor with another pressure sensor.



T2-1



T5-4-5



TROUBLESHOOTING / Troubleshooting B



Parts



Pressure Sensor (Boom Raise)



Pressure Sensor (Swing)



• Monitors swing pilot pressure to control arm re-



•



Monitors boom raise pilot pressure to control HP mode, auto-acceleration and arm regenerative controls.



• No signals arrive to MC



•



No signals arrive to MC



• During arm level crowding operation, arm speed



•



Even if boom is raised with HP mode switch ON, engine speed doesn’t increase. Even if boom is raised with auto-idle/auto-acceleration selector is auto-acceleration position, engine speed doesn’t increase. Arm roll-in speed becomes slightly slower than normal in boom raise and arm roll-in combined operation as arm regenerative system doesn’t work. (Not remarkable) Arm roll-in and boom raise speeds become slightly slower at the beginning stage of arm level crowd operation.



generative system.



Function



Symptoms in control system when trouble occurs.



is slightly slow.



• • Symptoms in machine operation when trouble occurs.



By Fault Code By Monitor Function



•



Fault code 15 is displayed.



Fault code 16 is displayed.



Monitor Item: Swing Control Pilot Pressure (Displayed built-in diagnosing system) Monitor pressure change while swinging upperstructure.



Monitor Item: Boom Raise Pilot Pressure (Displayed built-in diagnosing system). Monitor pressure change while raising boom.











Evaluation Using Test Harness Others











• Judge if pressure sensor is faulty or port is



•



T2-1



T2-1



clogged by switching pressure sensor with another pressure sensor.



Judge if pressure sensor is faulty or port is clogged by switching pressure sensor with another pressure sensor.



NOTE



Descriptions of Control (Operational Principle Section in T/M)



T5-4-6



TROUBLESHOOTING / Troubleshooting B



Pressure Sensor (Arm Roll-In)



Travel Motor Drain Pressure Sensor



Pressure Sensor (Auxiliary) (Optional)



• Monitors arm roll-in pilot pressure to



•



Detects the travel motor drain pressure.



•



Monitors attachment pilot pressure when attachment is installed to control attachment operation speed increase, pump 1 and pump 2 flow rate limit, and auxiliary flow rate controls.



• No signals arrive to MC



•



No signals arrive to MC



•



No signals arrive to MC



•



•



When the MC judges that the sensor is abnormal, the MC displays any stored fault codes (indicator light) and continues to control the machine operation normally using the backup value (0 MPa).



•



Engine speed doesn’t increase when attachment is operated. When attachment is operated, operation speed increases.



control HP mode, auto-acceleration, and arm regenerative controls.



• •



Even if arm is rolled-in with HP mode switch ON, engine speed doesn’t increase. Even if arm is rolled-in with auto-idle/auto-acceleration selector is auto-acceleration position, engine speed doesn’t increase. Arm speed is slow in arm level crowd operation.







Fault code 16 is displayed. Monitor Item: Arm Roll-In Pilot Pressure (Displayed built-in diagnosing system). Monitor pressure change while rolling arm in.



Monitor Item: Travel Drain Pressure Monitor pressure change while Traveling.



 



 Monitor Item: ATT Control Pilot Pressure (Displayed built-in diagnosing system). Monitor pressure change while operating attachment.







• Judge if pressure sensor is faulty or port



• Judge



T2-1



T2-1



is clogged by switching pressure sensor with another pressure sensor.



•







if pressure sensor is faulty or port is clogged by switching pressure sensor with another pressure sensor.







•



 Judge if pressure sensor is faulty or port is clogged by switching pressure sensor with another pressure sensor.



T2-1



T5-4-7



TROUBLESHOOTING / Troubleshooting B



Parts



Torque Control Solenoid Valve



Solenoid Valve Unit (SE)



• Supplies control pressure to pumps 1 and 2 to • Releases the operate check valve provided in control speed sensing.



the axle lock cylinder



Function



• If



torque control solenoid valve is not activated, output pressure from solenoid valve is 2 0 MPa (0 kgf/cm ).



• When



the solenoid valve is seized, the operate check valve doesn’t open (close).



Symptoms in control system when trouble occurs.



• Occasionally



the engine stalls during travel



operation.



• The axle lock is not released even though the



brake switch is turned OFF. axle lock cylinder is not locked even though the brake switch is turned to the axle lock position.



• The



Symptoms in machine operation when trouble occurs.



Evaluation



By Monitor Function











By Fault Code



Monitor Item: Pump Torque P/S Valve Output







Using Test Harness











Others



















NOTE



Descriptions of Control (Operational Principle Section in T/M)



T2-1



T2-1



T5-4-8



TROUBLESHOOTING / Troubleshooting B



Solenoid Valve Unit (SG)



• When



the work mode is selected with the brake switch, the valve is shifted so that the pilot pressure shifts the brake valve (work brake control).



Solenoid Valve Unit (SC)



Solenoid Valve Unit (SI)



• Routes return oil from arm cylinder rod side • The valve is shifted when the superfine to bottom side when rolling arm in to increase arm speed.



•



• In



case solenoid valve unit (SG) is not activated, pressure at port SE becomes 2 0 MPa (0 kgf/cm ).



Solenoid valve unit (SG) is closed:



travel mode is selected so that the travel motor displacement angle is increased to the maximum (superfine travel speed control). When descending a slope, the travel motor displacement angle is increased to apply the hydraulic brake.



• In case solenoid valve unit (SC) is not ac- • In tivated, pressure at port SC becomes 0 2 MPa (0 kgf/cm ). Arm regenerative valve will not operate at this time.



Solenoid valve unit (SC) is closed:



case solenoid valve unit (SI) is not activated, pressure at port SI becomes 2 0 MPa (0 kgf/cm ).



Solenoid valve unit (SI) is closed: of the super fine travel mode is selected, the travel speed is not reduced.



• The work brake doesn’t operate.



• Arm speed is slow in arm level crowd op- • Even



Solenoid valve unit (SG) is open: • The work brake is kept apply so that the machine cannot travel.



• Arm speed is fast as the arm regeneration



eration.



Solenoid valve unit (SC) is open: is always operated.



Solenoid valve unit (SI) is open:



• Since the travel motor displacement an-



gle is constantly kept at the maximum, the travel speed doesn’t increase.















Monitor Item: Working Brake P/S Valve Output



Monitor Item: Arm Regenerative P/S Valve Output



Monitor Item: Travel Motor Tilt P/S Valve Output



• Install lamp harness (ST 7226) to check • Install output signals from MC and harness condition.



T2-1



lamp harness (ST 7226) to check output signals from MC and harness condition.



• Install lamp harness (ST 7226) to check output signals from MC and harness condition.



























T2-1



T2-1



T5-4-9



TROUBLESHOOTING / Troubleshooting B Max. Pump 1 Flow Rate Limit Solenoid Valve



Parts



• When



the front attachment is operated, the maximum flow rate of pump 1 is restricted.



Max. Pump 2 Flow Rate Limit Solenoid Valve



• When



operating attachment, maximum pump 2 flow rate.



limits



Function



• In case max. pump 1 flow rate limit solenoid • In case max. pump 2 flow rate limit sovalve is not activated, pressure at output 2 port becomes 0 MPa (0 kgf/cm ).



lenoid valve is not activated, pressure at 2 output port becomes 0 MPa (0 kgf/cm ).



Max. pump 1 flow rate limit solenoid valve is closed: • When operating attachment, operating speed increases.



Max. pump 2 flow late limit solenoid valve is closed: • Arm, boom and swing speeds are slow as maximum flow rate of pump 2 decreases.



Symptoms in control system when trouble occurs.



Max. pump 1 flow rate limit solenoid valve is open: • Travel, bucket, arm and boom speeds are slow as maximum flow rate of pump 1 decreases.



Max. pump 2 flow rate limit solenoid valve is open: • When operating attachment, operating speed increases.



By Fault Code











By Monitor Function











Using Test Harness











Others



















Symptoms in machine operation when trouble occurs.



Evaluation



NOTE



Descriptions of Control (Operational Principle Section in T/M)



T2-1



T2-1



T5-4-10



TROUBLESHOOTING / Troubleshooting B Max. Pump 1 Flow Rate Shift Solenoid Valve



• Shifts



the maximum pump 1 flow rate (maximum travel pump 1 flow rate shift control).



N Sensor (Engine Speed Sensor)



• Monitors



engine speed to operate engine speed sensing control.



N Sensor (Travel Speed Sensor)



• Detects the travel motor speed and sends a signal to the speed display meter.



• The travel motor speed is detected to ac-



tivate the superfine travel speed, to prevent the travel motor from excessive rotation, and/or to restrict the forward/reverse shifting.



• If



the maximum pump 1 flow rate shift solenoid valve is not activated, the oil pressure at the output port is reduced to 2 0 MPa (0 kgf/cm ). The pump 1 flow rate stays at the maximum flow rate at this time.



Max. pump 1 flow rate shift solenoid valve is closed: • Since the maximum pump 1 flow rate increases, the arm and boom operation speeds become faster than usual.



• Speed sensing control is inoperable.



• The speed display meter doesn’t operate. • The superfine travel speed, travel motor



excessive rotation, and/or the forward/reverse shifting restriction control is inoperable.



• Engine



stalls under adverse operating conditions such as at high altitude.



• The speed display meter doesn’t operate. • When descending a slope, the engine speed is not reduced.



Max. pump 1 flow rate shift solenoid valve is open: • When traveling, the pump 1 flow rate is not shifted to the maximum so that the travel speed doesn’t increase.















Monitor Item: Pump Flow Changeover P/S Valve Output



Monitor Item: Actual engine speed (If N sensor fails, engine speed is not measured.)































• Even



if signals from N sensor are not delivered due to broken circuit or poor sensor installation, few changes in operational performance occur, making troubleshooting difficult. Use monitor function.



T2-1



T2-1







T2-1



T5-4-11



TROUBLESHOOTING / Troubleshooting B



Parts



Hydraulic Oil Temperature Sensor



• Monitors



hydraulic oil temperature to control auto-warming up and arm regenerative control.



Engine Learning Switch



• Starts engine learning.



ON: 0 V→Learning OFF: 5 V→Normal Control



Function



• If circuit breakage occurs, system operates as • Engine learning is not performed. if hydraulic oil temperature is 120 °C (Dr. ZX or monitor will not indicate 120 °C in diagnosis operation).



Symptoms in control system when trouble occurs.



• Even



Symptoms in machine operation when trouble occurs.



By Fault Code Evaluation



By Monitor Function Using Test Harness Others



•



if oil temperature is lower than 0 °C, auto-warming up control doesn’t operate so that engine runs at idle speed when engine is started. When oil temperature is lower than 10 °C, arm regenerative control is inoperable.



Engine learning: will operate normally problem is caused by broken circuit or discontinuity of switch. (Only learning cannot be performed.) • If short circuit occurs, learning mode operation starts when key switch is turned ON. Therefore, engine will stall at 2 second or 20 seconds after engine starts.



• Machine



Fault code 19 is displayed. Monitor Item: Hydraulic Oil Temperature



• In



 Monitor Item: Engine Learning Control



















case temperature is extremely low (below -20°C), the control system is inoperable.







NOTE



Descriptions of Control (Operational Principle Section in T/M)



T2-1



T2-1



T5-4-12



TROUBLESHOOTING / Troubleshooting B



Engine Speed Control Mode Selection Switch



Shift Lever



Brake Switch



• Shifts



• Shifts the engine speed control mode by • The



• When



• Depending



the Hi/Low solenoid valve corresponding to operation of the shift lever (D, L, N).



broken or short circuit occurs in the switch, the Hi/Low solenoid valve is held in either Hi or Low position.



on failure of the switch, the engine control mode may not be selected. (Engine control dial, pedal, superfine travel speed)



• Even if the shift lever is placed in the D • Even • •



position, the fast travel speed mode is not selected. Even if the shift lever is placed in the L position, the slow travel speed mode is not selected. Even though the shift lever is placed to neutral, indicator (N) on the column box doesn’t light.



 Monitor Item: Neutral Switch, Mission Switch



work brake, parking brake, axle lock, and OFF, are selected by operating the switch.



operating the switch. (Engine control dial control, forward/reverse travel pedal control and superfine travel speed control)



•



though the engine control mode switch is turned to the pedal position, the engine speed cannot be controlled with the travel pilot valve. Even though the engine control mode switch is turned to the superfine position, the superfine travel speed mode isn’t operable.



 Monitor Item: Creeper Mode Switch, Pedal EC Switch



• Depending



on failure of the switch, the brake mode may not be selected. (Work brake, parking brake, axle lock, and OFF)



• Even though the work brake is selected,



the work brake isn’t operable. though the parking brake is selected, the parking brake isn’t operable. Even though the axle lock is selected, the axle cylinder is not locked. Even though the OFF position is selected, either the work brake, parking brake, or axle lock isn’t operable.



• Even • •



 Monitor Item: Working/Parking Switch







































T2-1



T5-4-13



TROUBLESHOOTING / Troubleshooting B



Parts



Auto-Idle/Auto-Acceleration Selector (Auto-Idle)



MC



• Controls engine, pump and valve operation.



• Activates auto-idle control.



• Depending



• Broken Circuit:



• Even



• Same as described above.



ON: 0 V → Auto-idle is operable. OFF: 5 V → Inoperable.



Function



on trouble situations, control system malfunction may differ. (The following symptoms in machine operation indicates that MC logic circuit has failed.)



Auto-idle system is inoperable. Short Circuit: Even if auto-idle/auto-acceleration selector is OFF, auto-idle control is always performed.



Symptoms in control system when trouble occurs.



Symptoms in machine operation when trouble occurs.



Evaluation



By Fault Code By Monitor Function Using Test Harness Others



NOTE



Descriptions of Control (Operational Principle Section in T/M)



•



if key switch is turned ON, step motor will not move to the START position so that engine cannot start. Even though engine starts, speed stays slow. Since pump displacement is held at minimum, all actuator speeds are slow.



Fault codes 01, 02, and 03 are displayed. Other fault codes may be displayed.



 Monitor Item: Auto-Idle/Auto-Accel Switch



 















• Before suspecting a failure in MC, be sure to



check the fuses in control system. If any sensor in 5 V system is short-circuited, all sensor fault codes will be displayed.



T2-1







T2-1



T5-4-14



TROUBLESHOOTING / Troubleshooting B



Auto-Idle/Auto-Acceleration Selector (Auto-Acceleration)



Power Mode Switch (HP Mode)



Power Mode Switch (E Mode)



• Activates auto-acceleration control.



• Selects HP mode.



• Selects E mode. ON: 0 V → E mode OFF: 5 V → Normal



• Broken Circuit:



• Broken Circuit:



• Broken Circuit:



•



•



ON: 0 V → Auto-acceleration is operable. OFF: 5 V → Inoperable.



•



Auto-acceleration control is inoperable. Short Circuit: Even if auto-idle/auto-acceleration selector is OFF, auto-acceleration control is always performed.



• Same as described above.



ON: 0 V → HP mode OFF: 5 V → Normal



Even if HP mode is selected, HP mode is inoperable. Short Circuit: Even if HP mode switch is turned OFF, HP mode system is not deactivated. Attachment speed increase control (optional) becomes inoperable.



• Same as described above.



 Monitor Item: Auto-Idle/Auto-Accel Switch



T2-1



Even if E mode is selected, engine speed doesn’t decrease. Short Circuit: Engine speed doesn’t increase to the maximum. Auto-idle control is inoperable.



• Same as described above







 Monitor Item: E/P/HP Mode Switch



Monitor Item: E/P/HP Mode Switch







































T2-1



T2-1



T5-4-15



TROUBLESHOOTING / Troubleshooting B



Work Mode Switch (Digging Mode)



Parts



• Allows normal control to be performed.



Work Mode Switch (Attachment Mode)



• Functions



only when optional attachment kit is equipped. (Attachment operation speed increase/limit control)



Function



• In



response to operation of the auxiliary valve, engine speed related to the attachment is controlled.



Symptoms in control system when trouble occurs.







• Even if auxiliary valve is operated, engine



speed doesn’t increase. if attachment mode is selected, maximum engine speed doesn’t decrease.



• Even Symptoms in machine operation when trouble occurs.



Evaluation



By Fault Code By Monitor Function Using Test Harness Others







NOTE Descriptions of Control (Operational Principle Section in T/M)







 Monitor Item: Work Mode Switch



Monitor Item: Work Mode Switch



























T2-1



T2-1



T5-4-16



TROUBLESHOOTING / Troubleshooting B



Auxiliary Mode Switch (Optional)



• Functions



only when optional attachment kit is equipped. (Attachment operation speed increase/limit control)



Bucket Flow Rate Control Valve



Auxiliary Flow Rate Control Valve



• Restricts oil flow to bucket during 3-combined • To be shifted by pilot pressure from auxoperation of bucket, arm roll-in and boom raise to allow boom to raise.



iliary flow rate control solenoid valve.



• In response to operation of the auxil- • If



• If



• Even



• If



switch valve is bound with valve activated, bucket circuit is always restricted.



iary valve, engine speed related to the attachment is controlled.



•



if auxiliary valve is operated, engine speed doesn’t increase. Even if attachment mode is selected, maximum engine speed doesn’t decrease.



T2-1



• If •



poppet valve is bound at fully closed position or if switch valve is bound when poppet valve is fully closed, bucket speed becomes slow. If poppet valve is bound at fully opened position or if switch valve is bound when poppet valve is fully opened, boom doesn’t move during 3-combined operation of bucket, arm roll-in, and boom raise.



spool is bound or spring is broken, orifice doesn’t vary.



•



bound at fully closed position, attachment speed becomes slow. If bound at fully opened position, boom doesn’t move during 3-combined operation of swing, arm roll-in, and boom raise.































































T3-3



T3-3



T5-4-17



TROUBLESHOOTING / Troubleshooting B



Parts



Boom Regenerative Valve



Arm Regenerative Valve



• Prevents boom cylinder hesitation by routing



• To be shifted by pilot pressure from solenoid



return oil from boom cylinder bottom side to rod side.



valve unit (SC). arm speed by routing return oil from arm cylinder rod side to bottom side.



• Increases



Function



• If check valve is kept closed, boom is not •



smoothly lowered. If check valve is kept open, machine cannot be raised off ground with front attachment.



• Arm regenerative function is inoperable.



Symptoms in control system when trouble occurs.



• Same as described above.



• Arm speed is extremely slow during arm level •



Symptoms in machine operation when trouble occurs.



Evaluation



By Fault Code By Monitor Function Using Test Harness Others NOTE



Descriptions of Control (Operational Principle Section in T/M)



crowd operation while arm regenerative valve is kept closed. The lever operated first is given priority during combined operation of arm roll-in and swing while arm regenerative valve is kept open.











































T3-3



T3-3



T5-4-18



TROUBLESHOOTING / Troubleshooting B



Bucket Regenerative Valve



• Prevents



bucket cylinder hesitation by routing return oil from bucket cylinder rod side to bottom side.



Boom Anti-Drift Valve



• Prevents



boom from drifting due to oil leaks in control valve. Check valve in boom lower return circuit is forcibly opened to allow boom to move only when boom is lowered.



• If check valve is kept closed, bucket is not • If •



switch valve is bound, check valve doesn’t open.



smoothly rolled in. If check valve is kept open, bucket power is weak.



• Same as described above.



• Prevents



arm from drifting due to oil leaks in control valve. Check valve in arm roll-in return circuit is forcibly opened to allow arm to move only when arm is rolled in.



• If



switch valve is bound, check valve doesn’t open.



• If



• If check valve is kept closed, arm roll-in



•



• If



•



T3-3



Arm Anti-Drift Valve



check valve is kept closed, boom doesn’t lower. If check valve is kept open, front attachment drift increases due to oil leaks in control valve. Boom moves jerky or arm speed becomes slow depending on valve bound conditions.



•



speed becomes slow. check valve is kept open, front attachment drift increases due to oil leaks in control valve. Arm moves jerky or arm speed becomes slow depending on valve bound conditions.



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T3-3



T3-3



T5-4-19



TROUBLESHOOTING / Troubleshooting B



Parts



Auxiliary Flow Combiner Valve



Bypass Shut-Out Valve



• Supplies



• Supplies pressure oil from pump 1 to aux-



• If



• If spool is bound in the fully open position,



pressure oil from pump 1 to auxiliary spool when auxiliary spool is operated.



iliary spool when auxiliary spool is operated.



Function



control valve is kept closed, operating speed doesn’t increase in single auxiliary operation.



• •



single attachment operation speed becomes slow. If spool is bound in the fully closed position, main relief valve continues to relieve with all control levers positioned in neutral. If spool is bound in opened position, when all control levers are in neutral, pump 1 pressure is higher than pump 2 pressure.



Symptoms in control system when trouble occurs.



• Same as described above.



• Same as described above.



Symptoms in machine operation when trouble occurs.



Evaluation



By Fault Code By Monitor Function Using Test Harness Others



NOTE



Descriptions of Control (Operational Principle Section in T/M)



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T3-3



T3-3



T5-4-20



TROUBLESHOOTING / Troubleshooting B



Pump 1 Flow Control Valve



Swing Parking Brake Release Spool



Pump 2 Flow Control Valve



• Supplies flow rate control pressure Pi to • Supplies



flow rate control pressure Pi to pump 2 regulator in response to lever stroke when boom (raise/lower), arm (roll out/in), swing (right/left), or auxiliary is operated.



pump 1 regulator in response to lever stroke when boom (raise/lower), arm (roll out/in), bucket (roll-out/in), right travel, or auxiliary is operated.



• Supplies



swing parking brake release pressure when shifted by boom, arm, bucket, or swing pilot pressure.



• If spool is bound in the fully open posi- • If spool is bound in the fully open position, • If spool is bound in the fully open posi• • •



tion, even if control lever is in neutral, pump 1 swash angle is tilted to maximum. If spool is bound in the fully open position, pump 1 control pressure sensor monitors the maximum pressure. If spool is bound in the fully closed position, even if control lever is operated, pump 1 swash angle is held to minimum. (Bucket speed is very slow.) If spool is bound in the fully open position, pump 1 control pressure sensor can’t monitor the pump control pressure.



• Same as described above.



T3-6



• • •



even if control lever is in neutral, pump 2 swash angle is tilted to maximum. If spool is bound in the fully open position, pump 2 control pressure sensor monitors the maximum pressure. If spool is bound in the fully closed position, even if control lever is operated, pump 2 swash angle is held to minimum. (Swing speed is very slow.) If spool is bound in the fully open position, pump 2 control pressure sensor can’t monitor the pump control pressure.



• Same as described above.



•



• •



tion, swing parking brake is kept released. (Machine vibrates while traveling.) If spool is bound in the fully open position, the pressure sensor (front) is always turned into ON. Thus, engine speed doesn’t decrease when the control lever is in neutral during auto-idle/acceleration control. If spool is bound in the fully closed position, swing parking brake is kept applied. (Dragging is felt.) If spool is bound in the fully closed position, the pressure sensor (front) is always turned into OFF. Thus, engine speed doesn’t increase when the control lever is operated during auto-idle/acceleration control.



• Same as described above.



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



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







T3-6



T3-3



T5-4-21



TROUBLESHOOTING / Troubleshooting B Bucket Flow Rate Control Valve Control Spool



Parts



Blade/Stabilizer Signal Shift Valve



• Supplies



• Supplies the pilot pressure to the 2-unit so-



• If



• Even though the blade/stabilizer lever is op-



boom raise pilot pressure to bucket flow rate control valve when shifted by arm roll-in pilot pressure.



lenoid valve (blade/stabilizer) when shifted by the blade/stabilizer pilot pressure.



Function



•



spool is bound in the fully open position, bucket speed becomes slow when boom raise and bucket combined operation is made. (Bucket flow rate control is inoperable.) If spool is bound in the fully closed position, boom doesn’t move during 3-combined operation of bucket, arm roll-in, and boom raise.



erated, the pilot oil pressure is not supplied to the 2-unit solenoid valve.



Symptoms in control system when trouble occurs.



• Same as described above.



• Even though the blade/stabilizer lever is operated, the blade and stabilizer don’t move.



Symptoms in machine operation when trouble occurs.



Evaluation



By Fault Code By Monitor Function Using Test Harness Others



NOTE



Descriptions of Control (Operational Principle Section in T/M)



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T3-6



T2-1



T5-4-22



TROUBLESHOOTING / Troubleshooting B Steering Valve



• Supplies



the pressure oil from the steering pump to the steering cylinder corresponding to the steering wheel rotation.



• The



pressure oil is not supplied to steering cylinder in proportion to steering wheel rotation. However, steering valve acts as a pump, steering cylinder can operate.



• Turning



Accumulator Charging Valve



Brake Valve



the the the the



force of the steering wheel increases.



• Supplies



the pressure oil to the front and rear axle brakes corresponding to the brake pedal operating stroke.



• Charges the pressure



oil into the accumulator provided in the brake circuit and holds the charged pressure oil for the set period of time.



• Even though the brake pedal is stepped on, • The pressure oil is not charged into the the brake is not applied. though the brake pedal is not operated, the brake is applied.



accumulator.



• Even



• The brake circuit oil pressure stays low.



• The same as described above.



• The service brake isn’t operable. • The service brake doesn’t work tively.



T3-3



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T2-2



T2-2



T5-4-23



effec-



TROUBLESHOOTING / Troubleshooting B Parts



Transmission Control Valve



• Includes



• When



• If



• Travel



parking brake solenoid valve and transmission changeover solenoid valve. Controls the parking brake and the D (Hi) mode / L (Low) mode in the transmission.



Function



•



the parking brake solenoid valve is seized, the parking brake doesn’t operate (or is kept applied) even if the brake switch is operated. If the transmission changeover solenoid valve is seized, shifting of the transmission is not achieved even if the travel mode switch is operated.



Travel Forward Pi Cut Solenoid Valve



the shift lever is placed to neutral, the travel forward pilot pressure oil flow is cut so that the travel forward system is inoperable.



•



forward Pi cut solenoid valve is closed: Even though the shift lever is in neutral, the machine travels forward. Travel forward Pi cut solenoid valve is open: Even when the shift lever is in position L or D, the machine doesn’t travel forward.



Symptoms in control system when trouble occurs.



• Same as described above.



• Same as described above.



Symptoms in machine operation when trouble occurs.



Evaluation



By Fault Code By Monitor Function Using Test Harness Others



 



NOTE



Descriptions of Control (Operational Principle Section in T/M)



 Monitor Item: Fw/Bk Cut Relay



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T2-1



T2-1



T5-4-24



TROUBLESHOOTING / Troubleshooting B Travel Reverse Pi Cut Solenoid Valve



• When the shift lever is placed to neutral,



the travel reverse pilot pressure oil flow is cut so that the travel reverse system is inoperable.



• Travel •



reverse Pi cut solenoid valve is closed: Even though the shift lever is in neutral, the machine travels reverse. Travel reverse Pi cut solenoid valve is open: Even when the shift lever is in position L or D, the machine doesn’t travel reverse.



• Same as described above.



 Monitor Item: Fw/Bk Cut Relay



 







T2-1



T5-4-25



TROUBLESHOOTING / Troubleshooting B CORRELATION BETWEEN TROUBLE SYMPTOMS AND PART FAILURES This table indicates the relationship between machine troubles and parts contributing to the cause of the trouble if failed.



: Related, required to check



: Related. However, in case this component fails, other trouble symptom will be more noticeable so that this component will not be the direct cause of the trouble concerned.



Engine System Troubleshooting Trouble Symptom



E-1 Starter doesn’t rotate



E-2 Although starter rotates, engine doesn’t start.



E-3 When engine control dial is fully rotated, engine stalls. Occasionally engine stalls during operation with engine control dial fully rotated and auto-idle ON. Engine speed is slower than specification in all operating range. Idle speed is faster or slower than specification.



Check batteries.



Check fuel system (filters and piping).



Check fuel cut-off handle and engine control cable. Be sure to perform engine learning after replacing engine.



Parts MC (Main Controller) QOS Controller EC Motor EC Sensor Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pressure Sensor (Travel) Pressure Sensor (Front Attachment) Pressure Sensor (Swing) Pressure Sensor (Boom Raise) Pressure Sensor (Arm Roll-In) Pressure Sensor (Auxiliary) N Sensor (Engine Speed Sensor) Hyd. Oil Temperature Sensor Coolant Temperature Sensor Key Switch Engine Control Dial Auto-Idle/Acceleration Selector Power Mode Switch Work Mode Switch Auxiliary Mode Switch Engine Learning Switch Battery Relay Grow Plug Relay Starter Relay Engine Electrical Equipment Engine Unit Governor Swing Parking Brake Release Spool (Signal Control Valve)



Remarks



T5-4-26



TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently. In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom. E-4 Even if engine control dial is rotated, engine speed remains unchanged.



E-5 Engine speed doesn’t increase after engine is started.



E-6 Faulty HP mode.



E-7 Even if key switch is turned OFF, engine doesn’t stop.



Check engine control cable.



T5-4-27



E-8 Faulty auto-idle system.



E-9 Faulty E mode.



TROUBLESHOOTING / Troubleshooting B



Trouble Symptom



E-10 Faulty auto-acceleration system.



Parts MC (Main Controller) QOS Controller Torque Control Solenoid Valve Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Control Pressure Sensor Pressure Sensor (Travel Forward) Pressure Sensor (Travel Reverse) Pressure Sensor (Front Attachment) Pressure Sensor (Swing) Pressure Sensor (Boom Raise) Pressure Sensor (Arm Roll-In) Pressure Sensor (Auxiliary) N Sensor (Engine Speed Sensor) Hyd. Oil Temperature Sensor Coolant Temperature Switch Parking Brake Pressure Switch Auto-Idle/Acceleration Selector Power Mode Switch Work Mode Switch Auxiliary Mode Switch Engine Learning Switch Brake Switch Shift Lever Engine Speed Control Mode Selection Switch Grow Plug Relay Engine Unit Governor Pump Regulator Remarks



: Related, required to check



: Related. However, in case this component fails, other trouble symptom will be more noticeable so that this component will not be the direct cause of the trouble concerned.



T5-4-28



E-11 When traveling or operating front attachment with engine running at slow idle, engine hunts.



E-12 Engine speed doesn’t increase even if attachment is operated in attachment mode.



TROUBLESHOOTING / Troubleshooting B E-13 When attachment mode is selected, engine speed doesn’t decrease.



E-14 Engine stalls within several seconds after engine has started.



E-15 Engine stalls during operation under adverse condition such as at high altitude.



Check fuel system for clogging.



E-16 Engine is difficult to start at low temperature.



Check batteries.



NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently. In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom.



T5-4-29



E-17 The engine speed remains unchanged even though the pedal is stepped on during traveling.



E-18 The engine speed remains unchanged even though the pedal is stepped on during excavation.



TROUBLESHOOTING / Troubleshooting B All Actuator System Troubleshooting Trouble Symptom



A-1 All actuator speeds are slow.



A-2 Positioning is slow. Single swing operation speed is slow. Arm is slightly slow during arm level crowding.



A-3 The travel speed is slow in travel single operation. Single bucket operation speed is slow. Boom is not raised properly during arm level crowding.



Parts MC (Main Controller) Torque Control Solenoid Valve Pump 2 Delivery Pressure Sensor Pressure Sensor (Swing) Pressure Sensor (Arm Roll-In) N Sensor Spool Main Relief Valve Main Pump Regulator Max. Pump 1 Flow Rate Limit Solenoid Valve Max. Pump 2 Flow Rate Limit Solenoid Valve Pilot Pump Pilot Valve Pilot Relief Valve Pump 1 Flow Rate Control Valve (Signal Control Valve) Pump 2 Flow Rate Control Valve (Signal Control Valve) Remarks



NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently. In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom.



: Related, required to check



: Related. However, in case this component fails, other trouble symptom will be more noticeable so that this component will not be the direct cause of the trouble concerned.



T5-4-30



TROUBLESHOOTING / Troubleshooting B



A-4 Actuator doesn’t stop even if control lever is returned to neutral.



A-5 Actuator speed is faster than normal. Precise control can not be performed.



T5-4-31



TROUBLESHOOTING / Troubleshooting B Front Attachment System Troubleshooting Trouble Symptom



F-1 All front attachment actuator power is weak.



Parts



MC (Main Controller) Solenoid Valve Unit (SC) Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pressure Sensor (Swing) Pressure Sensor (Boom Raise) Pressure Sensor (Arm Roll-In) Spool Main Relief Valve Overload Relief Valve Load Check Valve Boom Regenerative Valve Arm Regenerative Valve Bucket Regenerative Valve Bucket Flow Rate Control Valve Boom Anti-Drift Valve Arm Anti-Drift Valve Emergency Valve Shockless Valve (Signal Control Valve) Shuttle Valve (Signal Control Valve) Bucket Flow Rate Control Valve Control Spool (Signal Control Valve) Pilot Valve Cylinder Remarks



: Related, required to check



: Related. However, in case this component fails, other trouble symptom will be more noticeable so that this component will not be the direct cause of the trouble concerned.



T5-4-32



F-2 Some cylinder are inoperable or speeds are slow.



F-3 Arm speed is slow in a combined operation. Arm speed is slow during arm level crowding.



TROUBLESHOOTING / Troubleshooting B



F-4 Bucket is slow in bucket roll-in single operation. Bucket doesn’t move smoothly in bucket roll-in single operation.



F-5 When starting to move in combined operation, arm doesn’t smoothly move. Arm starts to move slow slightly in arm roll-in single operation. These troubles often occur when oil temperature is low.



F-6 When starting to move in combined operation, boom doesn’t smoothly move. Boom starts to move slow slightly in boom lower single operation.



NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently. In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom.



T5-4-33



F-7 When boom raise or arm roll-out is operated, boom or arm starts to move after slightly moving downward.



F-8 Front attachment drifts remarkably.



TROUBLESHOOTING / Troubleshooting B Swing System Troubleshooting Trouble Symptom



S-1 Swing is slow or unmoving.



Parts MC (Main Controller) Torque Control Solenoid Valve Solenoid Valve Unit (SC) Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Control Pressure Sensor Pressure Sensor (Travel) Pressure Sensor (Swing) Pressure Sensor (Arm Roll-In) Shift Lever Pump Device Spool Load Check Valve Swing Parking Brake Release Spool (Signal Control Valve) Pump 1 Flow Control Valve (Signal Control Valve) Pump 2 Flow Control Valve (Signal Control Valve) Shuttle Valve (Signal Control Valve) Swing Device Travel Device Center Joint Pilot Valve Remarks



NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently. In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom.



: Related, required to check



: Related. However, in case this component fails, other trouble symptom will be more noticeable so that this component will not be the direct cause of the trouble concerned.



T5-4-34



TROUBLESHOOTING / Troubleshooting B (Blank)



T5-4-35



TROUBLESHOOTING / Troubleshooting B



Travel/Brake System Troubleshooting Trouble Symptom



T-1 The machine doesn’t travel.



Parts MC (Main Controller) Monitor Controller Solenoid Valve Unit (SG) Solenoid Valve Unit (SI) Max. Pump 1 Flow Rate Shift Solenoid Valve Parking Brake Solenoid Valve Transmission Valve



Changeover



Solenoid



Transistor Unit 2 Relay Shift Lever Brake Switch Engine Speed Control Mode Selection Switch Control Valve Travel Shockless Valve Transmission Control Valve Accumulator Charging Valve Brake Valve Transmission Front Axle Rear Axle Travel Motor Center Joint Pilot Valve Remarks



: Related, required to check



: Related. However, in case this component fails, other trouble symptom will be more noticeable so that this component will not be the direct cause of the trouble concerned.



T5-4-36



T-2 Either forward or reverse travel system doesn’t operate or the travel speed is slow.



T-3 Both forward and reverse travel speeds are slow and the travel power is weak.



TROUBLESHOOTING / Troubleshooting B



T-4 Even though the travel pilot valve is released, the hydraulic brake is inoperable (the machine runs away.)



T-5 Maximum travel speed is slow (traction force is normal).



T-6 Hi/Low shift in the transmission is not performed.



B-1 The parking brake is not released.



NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently. In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom.



T5-4-37



B-2 The parking brake is inoperable (not applied).



B-3 The service brake isn’t operable.



TROUBLESHOOTING / Troubleshooting B



Steering/Other System Troubleshooting Trouble Symptom



H-1 The steering wheel can be turned but is difficult to rotate.



H-2 Even though the steering wheel is turned, the machine doesn’t change the travel direction.



O-1 Wiper is inoperable or not retracted.



O-2 Air Conditioner Malfunction.



Parts Steering Pump Steering Valve Center Joint Front Axle Other Electrical Equipment Remarks



NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently. In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom.



: Related, required to check



: Related. However, in case this component fails, other trouble symptom will be more noticeable so that this component will not be the direct cause of the trouble concerned.



T5-4-38



TROUBLESHOOTING / Troubleshooting B (Blank)



T5-4-39



TROUBLESHOOTING / Troubleshooting B ENGINE SYSTEM TROUBLESHOOTING E-1 Starter Does Not Rotate. Related Fault Code: None YES



• Measure each voltage by referring to the table below.



• Electronic system such as MC has nothing to do with the trouble obstructing the rotation of starter.



• When the brake switch is in the accelerator lock



Regardless of key switch position ON or START, voltage at terminal B is 0 volts.



or OFF position, the starter doesn’t rotate due to starter relay (R10) operation. (Refer to the SYSTEM / Electrical System group.) • Be sure to inspect wiring connections prior to troubleshooting. YES



· Key switch: ON ⇔ START



With key switch positioned as shown in table below, check if each terminal voltage at starter and starter relay is normal. Unit: V Key Switch



Terminal B



Check if battery voltage and electrolyte density are normal.



ON



START



24



24



C



0



24



S



0



24



R



0 to 5



0 to 5



NO



With key switch positioned at START, voltage at terminal S does not increase to 24 volts. · Key switch: START



· Voltage: 24 volts or more · Density: 1.26 or more With key switch positioned at START, voltages at terminals B, C, and S do not increase to 24 volts.



NO



(When key switch is turned to the START position, if voltage at terminal B is lower than 18 volts, battery may be faulty.)



T5-4-40



TROUBLESHOOTING / Troubleshooting B



Faulty starter.



When key switch is turned from the ON position to the OFF position, check if battery relay sounds. · Key switch: ON ⇔ OFF



YES



Faulty harness between battery relay and starter. Faulty battery relay or check diode D2.



NO YES



Voltage at terminal #1: 0 V



Measure each voltage at terminal #1 and #6 on key switch.



Check if fusible link (40 A) is normal (is not cut).



Faulty harness between fusible link and key switch.



Faulty fusible link.



· Visual check



NO



Voltage at terminal #1: 24 V Voltage at terminal #6: 0 V



Faulty key switch.



· Key switch: START



Voltage at terminal #1: 24 V Voltage at terminal #6: 24 V



Check if trouble improves when replacing engine starter relay (R10) and horn relay (R5) each other. · Use horn relay after sounding horn several times to check if operates normally.



NO



YES



Faulty harness between key switch terminal #6 and starter relay terminal S. Faulty engine starter relay (R10).



Faulty starter relay.



Faulty battery.



• Key Switch Voltage Check View A



NOTE: Remove the key switch from the console. V



ST



G1



B



G2



ACC



A



M T105-07-04-002



T5-4-41



TROUBLESHOOTING / Troubleshooting B E-2 Although starter rotates, engine doesn’t start. Related Fault Code: None



• Check the fuel cut lever position during cranking. If the position is normal, the engine unit and/or fuel system may have trouble. • Check for loose harness connections beforehand.



Faulty engine.



YES Check if governor lever moves to the START position when key switch is turned ON.



· Refer to engine shop manual.



YES · Key switch: ON



Faulty EC motor. · Refer to T4-6-1.



Check if EC motor drive circuit is normal. NO · Test harness: 4274589 (ST 7125)



• Governor Lever and Fuel Cut Lever 1



Faulty MC. NO · Refer to T4-6-1.



2



3



4



T1F3-05-04-002



1234-



Governor Cable (From EC Motor) Governor Lever Fuel Cut-Off Cable (Fuel Cut-Off Handle) Fuel Cut Lever



T5-4-42



TROUBLESHOOTING / Troubleshooting B • Governor Lever Position A - Key Switch OFF (Engine Stop Position) B - Key Switch ON (Engine Start Position) STOP



B



FULL



A



STOP



FULL



T1F3-05-04-002



• Fuel Cut Lever Position A - Fuel Cut-Off Handle Pulled Position B - Fuel Cut-Off Handle Returned Position



B



A



T1F3-05-04-002



T5-4-43



TROUBLESHOOTING / Troubleshooting B E-3 When engine control dial is fully rotated, engine stalls. Occasionally engine stalls during operation with engine control dial fully rotated and auto-idle ON. Engine speed is slower than specification in all operating ranges. Idle speed is faster or slower than specification. Related Fault Code: 06



• In case engine learning has not been performed



• Refer to pages for Engine Learning in the SYS-



or engine learning has been incorrectly performed, engine speed becomes slower than specification across the operating range. • In case the EC sensor is faulty, engine speed is controlled based on the governor lever position, which is judged as the idle position when the key switch is turned ON. Accordingly, discrepancies in engine speed from specification will result. Depending on where the governor lever is positioned when the key switch is turned ON, discrepancy will differ, causing this trouble to be not reproducible.



TEM/Control System group in the T/M (Operational Principle). • Check for loose harness connections beforehand.



Return fuel cut lever to original position.



YES Check if fuel cut lever has been moved up to half way stroke.



Faulty EC sensor.



YES



· Refer to T4-6-1.



Check if fault code 06 is displayed. NO



NO



Check if problem is corrected after engine learning.



· Refer to T4-6-1 for engine learning procedures.



YES



NO



End.



Monitor engine learning status.



· Monitor item: Engine learning control



T5-4-44



TROUBLESHOOTING / Troubleshooting B



YES



OK



Check if governor lever comes in contact with stopper when performing engine learning. NO



Faulty engine and/or fuel system.



Faulty control cable and/or incorrectly adjusted engine governor lever.



· Adjust engine speed. (Refer to T4-6-1.) Faulty MC, faulty learning switch, or broken harness between learning switch and MC. NOT OK · Refer to T4-6-1.



T5-4-45



TROUBLESHOOTING / Troubleshooting B E-4 Even if engine control dial is rotated, engine speed remains unchanged. Related Fault Code: 07



• If the EC motor fails, the engine will not stop with the key switch OFF.



• Check for loose harness connections beforehand. Faulty engine control dial or broken harness between engine control dial and MC. YES Check if fault code 07 is displayed. Using Dr. ZX, monitor engine control dial angles (standard voltages). Check if voltages are normal. Install test harness (ST 7125) to EC motor. Check if lamp comes ON while turning engine control dial. · Standard voltages Slow idle position: 0.3 to 1 V Fast idle position: 4.0 to 4.7 V · Possible to display with built-in diagnosing system.



YES



Faulty EC motor.



· Refer to T4-6-1.



NO Faulty MC or broken harness between MC and EC motor. NO · Refer to T4-6-1.



T5-4-46



TROUBLESHOOTING / Troubleshooting B E-5 Engine speed doesn’t increase after engine is started. Related Fault Code: 19



• Refer to the pages for the Auto Warming Up Control in the SYSTEM / Control System group in the T/M (Operational Principle). • Check for loose harness connections beforehand. When starting engine, oil temperature is over 0°C or below -20°C.



NO



Monitor oil temperature.



· Monitor item: Hydraulic oil temperature · Possible to display with built-in diagnosing system



Faulty MC. When starting engine, oil temperature is between -19°C and 0°C.



Check if fault code 19 is displayed.



Normal.



· Refer to T4-6-1.



Faulty hyd. oil temperature sensor or broken harness between oil temperature sensor and MC.



YES



T5-4-47



TROUBLESHOOTING / Troubleshooting B E-6 Faulty HP mode



• Even if power mode switch is turned to the HP mode position, HP mode is inoperable. (General mode normally operates.) Related Fault Codes: 10, 11, 15, and 16



• Sensors detect the conditions necessary to oper-



• Refer to the pages for HP Mode Control in the



ate the HP mode. Therefore, if any of these sensor fails, the HP mode becomes inoperable. • Pressure sensors (arm roll-in and boom raise) and pump 1 and 2 delivery pressure sensors are also engaged in the HP mode control. However, if these sensors fail, other operating functions will be also affected. (Refer to the relationship between machine trouble symptoms and related parts on page T5-4-2.)



SYSTEM / Control System group in the T/M (Operational Principle). • Check for loose harness connections beforehand.



Faulty power mode switch or broken harness between power mode switch and MC.



NO



NO



Monitor power mode switch. Check if indication HP is highlighted when power mode switch is turned to “HP mode”.



Check if the symptom disappears after completing engine learning.



YES



YES Check if any fault codes are displayed.



· Monitor item: E/P/HP mode switch



NO



End.



Faulty MC or faulty engine. · Refer to T4-6-1. Faulty corresponding sensor or broken harness between sensor and MC.



YES



· Fault codes: Pump 1 delivery pressure sensor: 10 Pump 2 delivery pressure sensor: 11 Pilot pressure sensor (boom raise): 15 Pilot pressure sensor (arm roll-in): 16



T5-4-48



TROUBLESHOOTING / Troubleshooting B • Although the power mode switch isn’t turned to the HP mode position, HP mode is operable.



• Boom raise and arm roll-in must be operated when the average delivery pressures of pump 1 and 2 are high, if HP mode control is performed. The sensors related to this condition may not be broken at the same time. Short circuited harness between MC and power mode switch.



YES



Monitor the power mode switch. Check if “HP” is displayed.



· Monitor item: E/P/HP mode switch · Power mode switch: P mode



NO



Check if the symptom disappears after completing engine learning.



YES



End.



Faulty MC or faulty engine. NO · Refer to T4-6-1.



T5-4-49



TROUBLESHOOTING / Troubleshooting B E-7 Even if key switch is turned OFF, engine doesn’t stop. (In case the engine doesn’t stop, stop the engine by pulling the engine stop handle located under the seat stand. Then, begin inspection.) Related Fault Codes: 06 and 07



• Probably symptoms such as “Engine speed is slower than specification in all operating ranges” or “Even if engine control dial is rotated, engine speed remains unchanged” will come up. Perform troubleshooting for these symptoms.



T5-4-50



TROUBLESHOOTING / Troubleshooting B E-8 Faulty auto-idle system



• Even if control lever is turned to neutral. Auto-idle system is inoperable. Related Fault Code: 18



• In case trouble symptoms E1 to E7 are recog-



• Refer to the pages for Auto-Idle Control in the



nized, perform the troubleshooting of these troubles beforehand. • Although the failure in pressure sensors (travel and front attachment) will have relevance to malfunction of the auto-idle control. However, if these sensors fail, other operating functions will also be affected. (Refer to the relationship between machine trouble symptoms and related parts on page T5-4-2.)



SYSTEM / Control System group in the T/M (Operational Principle). • Check for loose harness connections beforehand.



Faulty MC or harness between the MC and the front attachment pressure sensor.



YES



YES



Check, on monitor, if “Fr (outline type font)” is displayed when pressure sensor (front attachment) is activated. · Engine: Running · Monitor item: Front attachment operation



Monitor auto-idle switch. Check if displayed “AI” is turned OFF or ON in response to auto-idle / auto- acceleration selector operation.



· Refer to T4-6-1. Faulty pressure senYES sor (front attachment).



NO



Check if symptom is corrected when pressure sensor (front attachment) is replaced with another sensor. NO



Bound swing parking brake release spool in the signal control valve.



Faulty auto-idle / autoacceleration selector or broken harness between auto-idle switch and MC.



· Monitor item: Auto-idle / auto-accel switch NO



T5-4-51



TROUBLESHOOTING / Troubleshooting B



• Although the auto-idle / auto-acceleration selector is turned OFF, the auto-idle control is operated.



• Be sure to separate auto-idle control from auto-acceleration control. Monitor auto-idle / auto-acceleration selector. Check if “AI” is displayed.



YES



Short circuited harness between MC and auto-idle / auto-acceleration selector.



Faulty MC. · Monitor item: Auto-idle / auto-accel switch · Auto-idle / auto-acceleration selector: OFF



NO · Refer to T4-6-1.



T5-4-52



TROUBLESHOOTING / Troubleshooting B E-9 Faulty E mode



• Even if power mode switch is turned to the E mode position, engine speed remains unchanged. (Engine speed doesn’t decrease.) Related Fault Code: None



• In case trouble symptoms E-1 to E-8 are recognized, perform the troubleshooting of these troubles beforehand. • Refer to the pages for E Mode Control in the SYSTEM / Control System group in the T/M (Operational Principle). • Check for loose harness connections beforehand. Monitor power mode switch. Check if displayed “E Mode” is turned OFF or ON in response to power mode switch operation.



NO



Faulty power mode switch or broken harness between power mode switch and MC.



Faulty MC. YES · Monitor item: E/P/HP mode switch



· Refer to T4-6-1.



• Although power mode switch isn’t turned into E mode, engine speed decrease. Short circuited harness between MC and power mode switch.



YES Monitor power mode switch. Check if “E” is displayed.



Faulty MC. · Monitor item: E/P/HP switch · Power mode switch: P mode



NO · Refer to T4-6-1.



T5-4-53



TROUBLESHOOTING / Troubleshooting B E-10 Faulty auto-acceleration system



• Auto-acceleration system is inoperable. Related Fault Code: 10, 11, 12, 13, 14, 15, 16, and 18



• The auto-acceleration system doesn’t operate if



• Although the failure in pressure sensors (travel,



the following conditions are not met. Engine Speed Control Mode Selection Switch: Dial or Creeper Position Auto-Idle/Auto-Acceleration Selector: Auto-Idle Position Power Mode Switch: HP or P Position • In case trouble symptoms E-1 to E-9 are recognized, perform the troubleshooting of these troubles beforehand.



swing, boom raise, and arm roll-in), pump 1 and 2 delivery pressure sensors, and pump 1 and 2 control pressure sensors will have relevance to malfunction of the auto-acceleration control. However, if these sensors fail, other operating functions will also be affected. (Refer to the relationship between machine trouble symptoms and related parts on page T5-4-2.) • Refer to the pages for Auto-Acceleration Control in the SYSTEM / Control System group in the T/M (Operational Principle).



YES YES Monitor auto-idle / auto-acceleration selector. Check if displayed “AA” is turned OFF or ON in response to auto-acceleration switch operation. · Monitor item: Auto-idle/auto-accel switch



Faulty engine speed control mode selection switch, or faulty harnesses and relays



Monitor pedal EC switch. Check if indicator comes ON. · Monitor item: Pedal EC switch



Faulty MC. NO · Refer to T4-6-1. Faulty auto-idle / auto-acceleration selector or broken harness between auto-acceleration switch and MC.



NO



T5-4-54



TROUBLESHOOTING / Troubleshooting B



• Although auto-idle / auto-acceleration selector is turned OFF, the auto-idle acceleration control is operated.



• Be sure to separate the auto-idle control from the Short circuited harness between MC and auto-idle / auto-acceleration selector.



auto-acceleration control. YES Monitor auto-idle / auto-acceleration selector. Check if “AA” is displayed.



Faulty MC. · Monitor item: Auto-idle / auto-accel switch · Auto-idle / auto-acceleration selector: Auto-idle position



NO · Refer to T4-6-1.



T5-4-55



TROUBLESHOOTING / Troubleshooting B E-11 When traveling or operating front attachment with engine running at slow idle, engine hunts. Related Fault Code: 18, 23, 24



• Although the failure in pressure sensors (travel and front attachment) will have relevance to malfunction of the engine speed increase control. However, if these sensors fail, other operating functions will also be affected. (Refer to the relationship between machine trouble symptoms and related parts on page T5-4-2.) • Refer to the pages for Idle Speed-Up Control in the SYSTEM / Control System group in the T/M (Operational Principle).



Faulty engine.



YES Check if engine speed is faster than increased idle speed.



· Refer to the Engine Shop Manual. Faulty MC.



· Monitor item: Engine target speed · Possible to display with built-in diagnosing system



NO · Refer to T4-6-1.



T5-4-56



TROUBLESHOOTING / Troubleshooting B E-12 Engine speed doesn’t increase even if attachment is operated in attachment mode. Related Fault Code: None



• In case trouble symptoms E-1 to E-11 are recog-



• Refer to the pages for Attachment Operation



nized, perform the troubleshooting of these troubles beforehand. • Although the failure in pressure sensor (auxiliary) and power mode switch will have relevance to the malfunction of the attachment operation speed increase control. However, if these sensor and switches fail, other operating functions will also be affected. (Refer to the relationship between machine trouble symptoms and related parts on page T5-4-2.)



Speed Increase Control in the SYSTEM / Control System group in the T/M (Operational Principle). • Check for loose harness connections beforehand.



Set to “Increase (+)”.



NO



NO



Check if attachment speed adjustment has been set to “Increase (+)” in Dr. ZX service mode.



Check if P speed adjustment has been set to “Decrease” in Dr. ZX service mode.



Monitor attachment pilot pressure. Check if pressure varies in response to lever stroke.



YES



To A



Faulty auxiliary pressure sensor. NO · Monitor item: Att. control pilot pressure



YES



YES



A



YES



Monitor work mode switch. Check if display switches in response to work mode switch operation.



Normal (If set to “Decrease”, this control system is deactivated.)



Faulty MC. · Refer to T4-6-1.



Faulty work mode switch. NO · Monitor item: Work mode switch



T5-4-57



TROUBLESHOOTING / Troubleshooting B E-13 When attachment mode is selected, engine speed doesn’t decrease. Related Fault Code: None



• In case trouble symptoms E-1 to E-11 are recognized, perform the troubleshooting of these troubles beforehand. • Refer to the pages for Attachment Operation Speed Limit Control in the SYSTEM / Control System group in the T/M (Operational Principle). • Check for loose harness connections beforehand.



YES



Monitor work mode switch. Check if display switches in response to work mode switch operation.



YES



Faulty MC.



· Refer to T4-6-1.



Faulty work mode switch.



Check if attachment speed adjustment has been set to “Decrease (-)” in Dr. ZX service mode.



NO · Monitor item: Work mode switch



Set to “Increase (+)”. NO



T5-4-58



TROUBLESHOOTING / Troubleshooting B E-14 Engine stalls within several seconds after engine has started. Related Fault Code: None



• Refer to the pages for Engine Learning Control in the SYSTEM / Control System group in the T/M (Operational Principle). • If the engine-learning switch is turned to the learning position, the engine will stall in 5 seconds after the engine starts. • Check for loose harness connections beforehand.



Normal (Return switch to neutral.)



YES Check if engine learning switch is turned to the learning position.



Faulty learning switch, or short-circuited harness between learning switch and MC, or check fuel system for clogging.



NO



T5-4-59



TROUBLESHOOTING / Troubleshooting B E-15 Engine stalls during operation under adverse condition such as at high altitude. Related Fault Code: 05



• If speed-sensing control is inoperable, the engine will stall under adverse operating conditions.



• Check for loose harness connections beforehand.



NO



Monitor torque control solenoid valve output. Install pressure gauge to output port so that pressure can be measured by pressure gauge and Dr. ZX. Check if both measured pressure values by pressure gauge and Dr. ZX vary identically.



NO



Disconnect torque control solenoid valve. Connect test harness (ST 7226) between solenoid valve and harness. Check if test harness lamp comes ON.



Disassemble to check regulator. YES



Monitor actual engine speed. Check if engine speed is abnormal.



· Monitor item: Pump torque proportional solenoid valve output · Refer to the Operational Performance Test section.



· Monitor item: Engine actual speed



Faulty N sensor, or faulty harness between N sensor and MC. YES



Faulty torque control solenoid valve.



YES



A Broken harness between torque control solenoid valve and MC.



NO



T5-4-60



To A



TROUBLESHOOTING / Troubleshooting B (Blank)



T5-4-61



TROUBLESHOOTING / Troubleshooting B E-16 Engine is difficult to start at low temperature. (During cold weather or in cold districts, the engine is difficult to start or doesn’t start although pre-heated.) Related Fault Code: None



• Check if electricity is routed to the glow plugs. Check the glow plugs for any abnormality. • The pre-heat system operates only when coolant temperature is below 10 °C (50 °F). When coolant temperature is higher than 10 °C (50 °F), the pre-heat system doesn’t operate.



• Check battery at the same time. • Check for loose harness connections beforehand.



Faulty coolant temperature switch.



YES Disconnect coolant temperature switch. Check if voltage at glow plug is 20 to 24 V. YES



Faulty QOS controller.



Disconnect QOS controller. Ground harness end connector terminal #4 to vehicle frame. Check if problem is corrected.



· Key switch: ON NO



Measure each glow plug resistance. · Using a clip, ground from the reverse side of the connector without disconnecting.



NO · Key switch: OFF · Before measuring, remove copper plates connecting each glow plug.



• Measurement of Glow Plug Voltage and Resistance Voltage Check Resistance Check



Remove the copper plate. Specification: 20 to 24 V Specification: Below 10 T105-07-04-006



Ω T105-07-04-007



T5-4-62



TROUBLESHOOTING / Troubleshooting B Connector (Harness End Connector Viewed from the Open End Side) QOS Controller



Glow Plug Relay



1



2



3



4



4



5



6



3



1



2



Faulty glow plug.



∞Ω



YES



Below 10 Ω



Disconnect glow plug relay. Check if voltage at glow plug relay harness end connector terminals #1 or #3 is 20 to 24 V.



Disconnect glow plug relay. Connect harness end connector terminal #4 to vehicle frame. Check if voltage is 20 to 24 V.



· Key switch: ON



NO



YES



Faulty glow plug relay, or broken harness between glow plug relay and glow plug.



Broken harness between glow plug relay and QOS controller, or faulty engine unit. · Refer to the engine shop manual.



In case voltage at terminal #1 is 0 V, harness between glow relay and batteries is broken. In case voltage at terminal #3 is 0 V, harness between glow relay and key switch terminal M is broken.



· Key switch: ON



NO



· Verify that fuse #19 is normal.



T5-4-63



TROUBLESHOOTING / Troubleshooting B E-17 The engine speed remains unchanged even though the pedal is stepped on during traveling.



Connector (Harness End Connector Viewed from the Open End Side MC: Connector B



Related Fault Code: 18, 23, 24



#3



• Check that:



#9



Brake switch: OFF or Axle Lock Position Engine Speed Control Mode Selection Switch: Pedal Position Shift Lever: D or L Position • Faulty pressure sensor (travel forward and reverse) may be the cause of this problem. In this case, other functions should become abnormal.



B8



B1



B19



B25



Faulty brake switch or short-circuited harness between MC and brake switch.



YES



“Wk (outline type font)” is displayed.



Check if continuity between harness end terminal #9 and vehicle frame exists when MC connector B is removed.



Faulty MC NO · Refer to T4-6-1.



Monitor working / parking switch with Dr. ZX



Faulty travel system, or parking brake system. Refer to the travel system troubleshooting and the brake system troubleshooting.



YES



“Pk (outline type font)” is displayed.



Check if column box parking brake indicator is ON.



NO



Check if continuity between harness end terminal #3 and vehicle frame exists when MC connector B is removed.



YES



Short-circuited harness between MC and parking brake pressure switch. Faulty MC



NO · Refer to T4-6-1. Faulty engine speed control mode selection switch, or broken harness between MC and engine speed control mode selection switch.



“PEC” is displayed.



“Wk/Pk” is displayed.



Monitor pedal EC switch with Dr. ZX.



“N” is displayed. Faulty MC



“PEC (outline type font)” is displayed.



Monitor neutral switch with Dr. ZX. “N (outline type font)” is displayed.



T5-4-64



· Refer to T4-6-1. Faulty shift lever or broken harness between MC and shift lever.



TROUBLESHOOTING / Troubleshooting B E-18 The engine speed remains unchanged even though the pedal is stepped on during excavation.



Connector (Harness End Connector Viewed from the Open End Side MC: Connector B



Related Fault Code: 18, 23



#3



• Check that: Brake switch: Work Position Engine Speed Control Mode Selection Switch: Pedal Position Shift Lever: N Position • Faulty pressure sensor (travel forward and reverse) may be the cause of this problem. In this case, other functions should become abnormal.



#9



B8



B1



B19



B25



YES “Wk/Pk” is displayed.



Faulty MC



Check if continuity between harness end terminal #9 and vehicle frame exists when MC connector B is removed.



· Refer to T4-6-1.



Faulty brake switch or short-circuited harness between MC and brake switch.



NO Monitor working / parking switch with Dr. ZX.



Faulty travel system, or parking brake system. Refer to the travel system troubleshooting and the brake system troubleshooting.



YES



“Pk (outline type font)” is displayed.



Check if column box parking brake indicator is ON.



NO



Check if continuity between harness end terminal #3 and vehicle frame exists when MC connector B is removed.



YES



Short-circuited harness between MC and parking brake pressure switch. Faulty MC



NO · Refer to T4-6-1. Faulty engine speed control mode selection switch, or broken harness between MC and engine speed control mode selection switch.



“PEC” is displayed.



“Wk (outline type font)” is displayed.



Monitor pedal EC switch with Dr. ZX.



“N (outline type font)” is displayed. Faulty MC



“PEC (outline type font)” is displayed.



· Refer to T4-6-1.



Monitor neutral switch with Dr. ZX.



T5-4-65



“N” is displayed.



Faulty shift lever or broken harness between MC and shift lever.



TROUBLESHOOTING / Troubleshooting B ALL ACTUATOR SHOOTING



SYSTEM



TROUBLE-



A-1 All actuator speeds are slow. Related Fault Code: None



• Reduction in pump 1 and 2 flow rate due to some



• Although speed is satisfactory, in case power is



reasons or faulty pilot system may cause this trouble. • Also, check for fuse of the torque control solenoid valve.



weak, refer to the troubleshooting for faulty relief valve (F-1). • Check for loose harness connections beforehand.



NO



Check if same symptom still appears after disassembling, cleaning, and adjusting pilot relief valve.



Faulty pilot pump or clogged pilot filter or faulty accumulator charging valve.



YES



End. NO Check if primary pilot pressure is normal. Faulty N sensor or broken harness in N sensor circuit.



YES · Fully boom raised or arm roll-in · Monitor item: Boom raise pilot pressure, arm roll-in pilot pressure YES



Monitor actual engine speed. Check if abnormal speed is indicated.



· Monitor item: Engine actual speed · Possible to display in service mode of monitor.



YES



NO



Monitor pump torque P/S valve. Check if output from torque control solenoid valve is normal. · Monitor item: Pump Torque P/S Valve · Measurement: Refer to the Operational Performance Test Section.



T5-4-66



NO



TROUBLESHOOTING / Troubleshooting B



Torque Control Solenoid Valve



Connector (Harness End Connector from the Open End Side)



MC: Connector A



#5



#6 A11



A1 T1F3-05-04-003



Port a3 A25



Remove connector A (32P) from the MC and disconnect the torque control solenoid valve. Check if continuity between MC harness end connector terminal #5 and the vehicle frame, and terminal #6 and the vehicle frame is present respectively.



YES



Connect the disconnected connectors. Install a pressure gauge to the port a3 on the torque control solenoid valve. Check if the pointer moves.



A32



YES



Faulty pump device.



NO



Faulty torque control solenoid valve.



Faulty harness between MC and torque control solenoid valve.



NO



· Key Switch: OFF Faulty MC. · Refer to T4-6-1.



T5-4-67



TROUBLESHOOTING / Troubleshooting B A-2 Positioning cylinder and swing single eration speeds are slow. Arm speed comes slightly slow in level crowding eration. (All these symptoms occur at same time.)



opbeopthe



Related Fault Code: None



• The pump 2 flow rate is minimized due to some reasons. Accordingly, the positioning and swing motor, which are driven by pressure oil from pump 2, moves very slow. • Pressure oil from pump 1 is also routed to the arm and boom cylinders so that the arm and boom can move at a slightly slow speed in single operation. However, in level crowd operation, pressure oil is routed to the boom prior to the arm so that arm speed becomes very slow. • Refer to the SYSTEM / Hydraulic System group in the T/M (Operational Principle).



Monitor pump 2 pump control pressure. Check if pressure increases in proportion to swing lever stroke.



· Monitor item: Pump 2 flow control pressure · Possible to display with built-in diagnosing system.



Faulty pump 2 regulator.



YES



NO



Check if symptom is corrected when maximum pump 2 flow rate limit solenoid valve is disconnected.



YES



· Refer to T4-6-1.



NO



T5-4-68



Faulty MC.



Seized pump 2 flow rate control valve in signal control valve or faulty maximum pump 2 flow rate limit solenoid valve.



TROUBLESHOOTING / Troubleshooting B A-3 Travel is inoperable during single travel operation. Single bucket operation speed is slow. Boom is not raised properly during arm level crowding. (All problems occur at the same time.) Related Fault Code: None



• The pump 1 flow rate is minimized due to some reasons. Accordingly, the travel motor and bucket cylinder, which are actuated by pressure oil from pump 1, moves very slow. • Pressure oil from pump 2 is also routed to the arm and boom cylinders so that the arm and boom can move at a slightly slow speed in single operation. However, in level crowd operation, pressure oil is routed to the arm prior to the boom so that boom is scarcely raised. • Refer to the SYSTEM / Hydraulic System group in the T/M (Operational Principle).



Monitor pump 1 pump control pressure. Check if pressure increases in proportion to travel lever stroke.



· Monitor item: Pump 1 flow control pressure · Possible to display with built-in diagnosing system.



Faulty pump 1 regulator.



YES



YES



NO



Check if symptom is corrected when maximum pump 1 flow rate limit solenoid valve is disconnected.



· Refer to T4-6-1.



NO



T5-4-69



Faulty MC.



Seized pump 1 flow rate control valve in signal control valve or faulty maximum pump 1 flow rate limit solenoid valve.



TROUBLESHOOTING / Troubleshooting B A-4 Actuator doesn’t stop even if control lever is returned to neutral. Related Fault Code: None



• Bound spool in the pilot valve or bound main spool in the control valve is suspected. Faulty pilot valve. YES · When control lever is in neutral, pilot pressure is routed to spool end in control valve.



Check if actuator stops when pilot control shut-off lever is raised.



Faulty control valve. NO · Although pilot pressure is not routed to spool end in control valve, spool is kept opened due to binding of spool.



T5-4-70



TROUBLESHOOTING / Troubleshooting B A-5 Actuator speed is faster than normal Machine mistracks when travel lever is operated at half stroke. Precise control cannot be performed. Related Fault Code: None



• The pump 1 or 2 flow rate is maximized due to some reasons. Therefore, the maximum flow rate is supplied and actuator speed is faster though the control lever doesn’t reach the full stroke. • Refer to the SYSTEM / Hydraulic System group in the T/M (Operational Principle). YES Install a pressure gauge to outlet port of max. pump 1 YES flow rate shift solenoid valve to check if pressure is 0 MPa.



Faulty max. pump 1 flow rate shift solenoid valve.



Faulty pump regulator. Monitor pump control pressure of pump 1 and 2. Check if the pressure changes in response to the lever operation.



NO



Bound pump flow rate control valve in signal control valve. · Pump 1: Bucket operation · Pump 2: Swing operation · Monitor item: Pump 1 and 2 pump control pressures · Possible to display with built-in diagnosing system.



NO



T5-4-71



TROUBLESHOOTING / Troubleshooting B FRONT ATTACHMENT SYSTEM TROUBLESHOOTING F-1 All front attachment actuator power is weak. Related Fault Code: None



• In case operating speeds are extremely slow, pump control may be malfunctioning (A-2 and/or A-3). Faulty pilot system may also cause this trouble. 34.3 to 36.3 MPa (350 to 370 kgf/cm2)



Main relief valve should be normal. Find out cause of trouble by tracing other trouble symptoms.



Monitor pump 1 and 2 delivery pressures.



· Monitor item: Pump 1 and 2 delivery pressure · Possible to display with built-in diagnosing system · Relieve boom, arm, and bucket circuits. · Power mode switch: OFF · Work mode: Digging



Adjust main relief valve. Less than 34.3 MPa (Less than 350 kgf/cm2)



T5-4-72



TROUBLESHOOTING / Troubleshooting B F-2 Some cylinders are inoperable or speeds are slow. Related Fault Code: None



• When other actuators (travel and swing motors) • • • •



operate normally, the pilot pump (primary pilot pressure) is considered to be normal. In case single bucket operation speed is slow, refer to F-5. In case single arm roll-in operation speed is slow, refer to F-6. In case single boom lower operation speed is slow, refer to F-7. In case a hose-rupture safety valve is equipped, check operation of the hose-rupture safety valve also.



YES



YES



Bound control valve spool or faulty cylinder (faulty seal kit).



Check if overload YES relief pressure is normal.



Monitor pump control pressure. Check if pump control pressure changes smoothly while moving control lever slowly.



NO



Faulty overload relief valve.



Faulty shuttle valve in signal control valve. Monitor or measure secondary pilot pressure. Check if secondary pilot pressure is normal.



· Secondary pilot pressure: Refer to Operational Performance Test Section. · Monitor item: Boom raise pilot pressure, arm roll-in pilot pressure · Possible to display with built-in diagnosing system



· Monitor item: Pump 1 flow control pressure, pump 2 flow control pressure · Possible to display with built-in diagnosing system



NO



YES



NO



Check if secondary pilot pressure at outlet port to signal control valve. NO · Check only when boom is not raised. In case cylinders other than boom are abnormal, skip this step and proceed to the NO line.



T5-4-73



Bound shockless valve spool.



Faulty pilot valve or shuttle valve in signal control valve.



TROUBLESHOOTING / Troubleshooting B F-3 Arm speed is slow in a combined operation. Arm speed is slow during arm level crowding. Related Fault Codes: 11, 14, 15 and 16



• Refer to the pages for the Arm Regenerative Control in the SYSTEM / Control System group in the T/M (Operational Principle). • In case a hose-rupture safety valve is equipped, check operation of the hose-rupture safety valve also.



Monitor output from solenoid valve unit (SC). Install pressure gauge to port SC. NO Compare pressure measured by Dr. ZX with that measured by pressure gauge. Check if both pressure values vary identically.



Check if any fault codes are displayed.



· Fault codes: 11: Pump 2 delivery pressure sensor 14: Pressure sensor (Swing) 15: Pressure sensor (Boom raise) 16: Pressure sensor (Arm roll-In)



· Monitor item: Arm regenerative proportional solenoid valve output · Perform boom raise and arm roll-in combined operation. · Refer to the Operational Performance Test.



Disconnect solenoid valve unit (SC). Connect test harness (ST 7226) between solenoid valve unit (SC) and harness. Check if NO test harness lamp comes ON.



YES Faulty solenoid valve unit (SC).



NO · Perform boom raise and arm roll-in combined operation.



YES



Check if arm regenerative valve in 5-spool section of control valve is scored or bound.



Broken harness between solenoid valve unit (SC) and MC.



Faulty arm flow rate YES control valve control spool (signal control valve).



Find out cause of trouble by tracing other NO trouble symptoms.



Faulty corresponding sensor or faulty MC, or broken harness between MC and sensor.



YES



NOTE: In



case other fault codes are displayed, perform troubleshooting corresponding to the displayed fault code.



· Refer to T4-6-1.



T5-4-74



TROUBLESHOOTING / Troubleshooting B F-4 Bucket is slow in bucket roll-in single operation. Bucket doesn’t move smoothly in bucket roll-in single operation. Related Fault Code: None



• Faulty bucket flow rate control valve or bucket regenerative valve may cause this trouble. • Refer to the COMPONENT OPERATION / Control Valve group in the T/M (Operational Principle).



NO



Check if bucket flow rate control valve in control valve is bound or scored.



Install pressure gauge to hose SK connecting signal control valve to bucket flow rate control valve in control valve. Check if relief pressure is approx. 3.9 MPa (40 kgf/cm2) while performing 3-function combined operation of boom raise, arm roll-in, and bucket roll-in.



Check if bucket reYES generative valve in bucket spool is bound or scored. NO



NO



Find out cause of trouble by tracing other trouble symptoms.



Bound bucket flow rate control valve control spool in signal control valve.



Faulty bucket flow rate control valve. (Disassemble and clean, or replace.)



YES



Signal Control Valve



Hose (SK)



Bucket Flow Rate Control Valve



YES



Faulty bucket regenerative valve. (Disassemble and clean, or replace.)



T1GL-05-04-002



T5-4-75



TROUBLESHOOTING / Troubleshooting B F-5 When starting to move in combined operation, arm doesn’t smoothly move. Arm starts to move slightly slow in arm roll-in single operation. These troubles often occur when oil temperature is low. Related Fault Code: None



• Refer to the COMPONENT OPERATION / Control Valve group in the T/M (Operational Principle). • In case a hose-rupture safety valve is equipped, check operation of the hose-rupture safety valve also. NO



YES



Faulty arm regenerative valve. (Disassemble to clean, or replace.)



Check if arm regenerative valve is bound or scored.



Check if arm anti-drift valve is bound or scored.



NO



Find out cause of trouble by tracing other trouble symptoms.



Faulty arm anti-drift valve. (Disassemble to clean, or replace.)



YES



F-6 When starting to move in combined operation, boom doesn’t move smoothly. Boom starts to move slow slightly in boom lower single operation. Related Fault Code: None



• Refer to the COMPONENT OPERATION / Control Valve group in the T/M (Operational Principle). • In case a hose-rupture safety valve is equipped, check operation of the hose-rupture safety valve also. NO



NO



Find out cause of trouble by tracing other trouble symptoms.



Check if boom regenerative valve is bound or scored. Faulty boom regenerative valve. (Disassemble to clean, or replace.)



Check if boom anti-drift valve is bound or scored.



YES



Faulty boom anti-drift valve. (Disassemble to clean, or replace.)



YES



T5-4-76



TROUBLESHOOTING / Troubleshooting B F-7 When boom raise or arm roll-out is operated, boom or arm starts to move after moving slightly downward. Related Fault Code: None



YES



Faulty anti-drift valve.



Check if anti-drift valves (arm and boom) are YES bound or scored. Oil leaks in cylinder. Check if load check valve in control valve is normal.



NO



· Disassemble / Visual Inspection



Faulty load check valve. NO



NOTE: 1. During the initial stage of operation, oil pressure and flow rate from the pump is low. Therefore, if the load check valve is malfunctioning, the oil in the bottom side of the boom cylinder flows back into the circuit through the load check valve, causing the boom cylinder to temporarily retract. 2. Since oil pressure and flow rate from the pump is low, if oil leaks from bottom side (A) to rod side (B) due to faulty boom cylinder piston or cylinder barrel, the boom cylinder is temporarily retracted during the initial stage of operation. In addition, cylinder force is reduced, increasing the cylinder drift in this case.



T5-4-77



(B) When the Load Check Valve is Faulty:



(A)



T105-07-04-012



TROUBLESHOOTING / Troubleshooting B F-8 Front attachment drifts remarkably. Related Fault Code: None



• In case the hose-rupture safety valves (boom and arm) are equipped on the machine, disconnect the drain hoses and the pilot hoses from the hose-rupture safety valves. Then, measure the amount of drain oil and the discharged oil from the drain ports and pilot ports. If the amounts of drain oil are large, faulty hose-rupture safety valves may be the cause of this trouble. Normal. YES



Check if each front attachment cylinder drift is within specification.



NO NO



NO



Check if emergency valve at boom 1 section in control valve 4-spool block is correctly adjusted.



Check if cylinder drift is reduced when pilot shut-off valve is closed.



YES



Correctly adjust emergency valve and lock it up.



Check if symptom is deleted when overload relief valve is temporarily switched with another overload relief valve.



Faulty pilot valve. YES



T5-4-78



TROUBLESHOOTING / Troubleshooting B



Emergency Valve



1 2



NO



NO Check if oil leaks in cylinders.



Scored control valve spool, broken spring, or loose spool end.



Faulty cylinder. (Replace seal kit.)



Adjustment Procedure: Turn screw (1) counterclockwise to the stop, then tighten lock nut (2).



YES



YES



T155-06-04-001



Faulty overload relief valve.



: 4 mm : 20 N⋅m (2 kgf⋅m, 14.5 lbf·ft)



• Boom Cylinder Internal Leakage Check 1. With the bucket cylinder fully retracted and the arm cylinder slightly extended from the fully retracted position, lower the bucket tooth tips onto the ground. 2. Disconnect hoses from the boom cylinder rod side. Drain oil from the hoses and cylinders. (Plug the disconnected hose ends.) 3. Retract the arm cylinder to lift the bucket off the ground. If oil flows out of the hose disconnected pipe ends and the boom cylinders are retracted at this time, oil leaks in the boom cylinders. In case no oil flows out of the hose disconnected pipe ends but the boom cylinders are retracted, oil leaks in the control valve.



T5-4-79



T216-05-04-001



TROUBLESHOOTING / Troubleshooting B SWING SYSTEM TROUBLESHOOTING S-1 Swing is slow or unmoving. Related Fault Code: None • Check whether the pilot system is faulty or the main circuit is faulty. • In case other functions (front attachment and travel) operate normally, the pilot pump is considered to be normal. If the pilot system is displaying a problem, the cause of the trouble may exist in the circuit after the pilot valve.



• In case the left travel speed is also slow, refer to A-2.



Check if swing parking brake release valve is YES scored or bound.



Monitor secondary pilot pressure. Check if secondary pilot pressure is normal.



Monitor pump control pressure while slowly operating swing lever. YES Check if pump control pressure varies smoothly.



Check if swing parking brake release pressure is YES approx. 3.9 MPa (40 kgf/cm2).



· Relieve arm circuit. · Monitor item: · Front attachment operation · Possible to display with built-in diagnosing system



· Monitor item: · Pump 2 flow control pressure · Possible to display with built-in diagnosing system



· Specification: · Refer to Operational Performance Test Section. · Monitor item: · Swing control pilot pressure · Possible to display with built-in diagnosing system



NO



Bound pump 2 flow rate control valve in signal control valve.



NO



Faulty pilot valve. NO



T5-4-80



TROUBLESHOOTING / Troubleshooting B



YES Check if swing motor drain YES oil amount is normal. NO



Faulty swing motor.



Check if swing relief pressure is normal.



· Relieve swing circuit. · Monitor item: Pump 2 delivery pressure · Specification: · Refer to Operational Performance Test Section.



Faulty swing reduction gear.



· Measurement: · Refer to Operational Performance Test Section.



NO



Faulty swing relief valve.



NO



Faulty swing motor parking brake release valve.



YES



Faulty swing parking brake pressure selection shuttle valve.



YES Check if secondary pilot pressure at signal control valve outlet is normal.



Faulty swing parking brake release spool in signal control valve.



NO



T5-4-81



TROUBLESHOOTING / Troubleshooting B TRAVEL SYSTEM TROUBLESHOOTING T-1 The machine doesn’t travel.



• The travel system is inoperable unless the fol-



• Air mixing in the transmission hydraulic circuit



lowing conditions are met. Shift Lever: D or L position Brake Switch: OFF or Axle Lock Position • In case the travel motor fails, it can be determined by means of the indicator in the column box and the buzzer. • Failure in the transmission and/or axle (front and/or rear) may be the cause of the trouble. Check if a noise is emitted from each section. • Check if the parking brake indicator is OFF.



may cause the parking brake to drag. Bleed air from the transmission by referring to T5-4-116. • When other actuators (front attachment and swing motor) operate normally, the pilot pump, pilot filter and pilot relief valve are considered to be normal. • Check for loose harness connections beforehand.



YES



YES



Check by operating if brake pedal is difficult to move as if the brake is applied.



Check if trouble is corrected when solenoid valve unit (SE) is disconnected.



Faulty either front or rear NO axle. NO



Check by monitoring with Dr. ZX if pump 1 delivery pressure increases in proportion to travel lever stroke. · Monitor Item: Pump 1 delivery pressure · Specification: Refer to the Performance Test section.



Check if trouble is corrected when travel forward and reverse Pi-cut solenoid valves are disconnected. YES



YES



Faulty control valve (seized spool).



NO



Check if continuity between harness end connector terminals #1 and vehicle frame, and #2 and vehicle frame exists respectively with transistor unit 2 disconnected.



YES



Faulty MC or short-circuited harness between MC and transistor unit 2. · Refer to T4-6-1. Faulty transistor unit 2.



NO



Check if trouble is corrected when transistor unit 2 is disconnected.



NO



T5-4-82



Faulty shift lever or short-circuited harness between shift lever and travel forward and reverse Pi-cut relay.



TROUBLESHOOTING / Troubleshooting B



Short circuited harness between MC and brake switch.



YES



YES



Check if continuity between harness end connector terminal #9 and vehicle frame exists when MC connector B is removed.



Faulty MC. NO · Refer to T4-6-1. Faulty solenoid valve unit (SE).



NO



Connector (Harness End Connector Seen from Open End Side)



MC Connector B



Transister Unit 2



7



#9



1



#2



#1



B1



B19



T5-4-83



B8



B25



TROUBLESHOOTING / Troubleshooting B T-2 The machine doesn’t travel in both forward and reverse directions or moves slowly.



• Failure in the transmission and/or axle (front and/or rear) may be the cause of the trouble. Check if a noise is emitted from each section. • When other actuators (front attachment and swing motor) operate normally, the pilot pump, pilot filter and pilot relief valve are considered to be normal. • Check for loose harness connections beforehand. NO NO



Check if control valve travel spool is abnormal.



Check if trouble is corrected NO when travel motor relief valves are switched between those in forward and reverse systems.



YES



Faulty control valve (seized spool).



Faulty travel motor relief valve.



YES Monitor pump 1 delivery pressure with Dr. ZX. Check if relief pressure in travel forward and reverse operation is normal.



Check if travel motor counterbalance valve is abnormal.



NO Faulty travel pilot valve. Check if travel shockless NO valves (travel forward and reverse Pi-cut solenoid valves) are abnormal.



· Specification: Refer to the Performance Test section.



YES



Check if trouble is corrected when either travel forward or YES reverse Pi-cut solenoid valve is disconnected.



Faulty travel shockless valve.



Check if continuity beNO tween vehicle frame and terminals shown below exists with transistor unit 2 connected. Check if trouble is corrected when travel forward Pi-cut relay is YES switched with travel reverse Pi-cut relay.



· Travel Forward: Terminal #1 · Travel Reverse: Terminal #2



YES



T5-4-84



Faulty travel forward Pi-cut relay or travel reverse Pi-cut relay.



TROUBLESHOOTING / Troubleshooting B



Faulty counterbalance valve.



YES



YES



Faulty make-up valve.



Check if make-up valve in control valve is abnormal.



NO



Faulty center joint. NO



Faulty MC or Short-circuited harness between MC and transistor unit 2.



YES



· Refer to T4-6-1.



Faulty transistor unit 2. NO Connector (Harness End Connector Seen from Open End Side) Transistor Unit 2 7



1



#2



#1



T5-4-85



TROUBLESHOOTING / Troubleshooting B T-3 Travel speed is slow and travel power is weak in both forward and reverse directions.



• In case the travel motor fails, it can be deter-



• When other actuators (front attachment and



mined by means of the indicator in the column box and the buzzer. • Failure in the transmission and/or axle (front and/or rear) may be the cause of the trouble. Check if a noise is emitted from each section. • Air mixing in the transmission hydraulic circuit may cause the parking brake to drag. Bleed air from the transmission by referring to T5-4-116.



swing motor) operate normally, the pilot pump, pilot filter and pilot relief valve is considered to be normal. • Pump 1 flow rate reduction may be the cause of this trouble when bucket single operation speed is slow. Refer to A-3. • Check for loose harness connections beforehand.



NO Check if travel spool in YES control valve is abnormal. Faulty control valve. YES NO



Install a pressure gauge to outlet port of solenoid valve unit (SI) to check if pressure is 0 MPa.



NO Faulty (seized) solenoid valve unit (SI). Check if pressure stays at 0 MPa when soleNO noid valve unit (SI) is disconnected.



Monitor creeper mode switch with Dr. ZX to check if creeper mode is operable.



Faulty MC or short-circuited harness between MC and YES solenoid valve unit (SI). · Refer to T4-6-1.



NO



YES



Disconnect connector C from MC. Check if continuity between harness end connector terminal #8 and vehicle frame exists.



Faulty MC. · Refer to T4-6-1.



YES



T5-4-86



Faulty engine speed control mode selection switch or short-circuited harness between MC and engine speed control mode selection switch.



TROUBLESHOOTING / Troubleshooting B



YES



Faulty center joint.



Check by measuring if drain amount from travel motor is normal. · Refer to the Operational Performance Test section.



Faulty travel motor. NO



Connector (Harness End Connector Seen from Open End Side)



MC Connector C #8 C1



C23



C10



C31



T5-4-87



TROUBLESHOOTING / Troubleshooting B T-4 Even though foot is left from the travel pilot valve, the hydraulic brake doesn’t operate (the machine continues to runaway). • Similar symptom may appear when the travel pilot valve, travel shuttle valve and/or travel spool is faulty.



NO



NO Switch travel motor relief valves between forward and reverse sides. Check if trouble is corrected.



Faulty control valve.



Check if travel motor counterbalance valve is abnormal.



Faulty counterbalance valve. YES



Faulty travel motor relief valve.



YES



T5-4-88



TROUBLESHOOTING / Troubleshooting B T-5 Maximum travel speed is slow (traction force is normal).



• Refer to the descriptions for ”Travel Pump 1 Flow Rate Shit Control” in the SYSTEM / Travel Pump group. • Similar symptom may occur if the travel pilot valve, travel shockless valve, or travel spool fails. Check these parts at the same time. • If the travel motor fails, the indicator lights and the buzzer sounds in the column box, informing that the travel motor is faulty. • In case any fault code is displayed, first repair and check the machine according to the faulty code. Remove connector A from MC with maximum pump 1 flow rate shift solenoid valve disconNO nected. Check if continuity between terminals described below is present.



YES



Check by disassembling if maximum pump 1 flow rate shift solenoid valve is abnormal.



NO



NO



Check if the trouble symptom is corrected when maximum pump 1 flow rate shift solenoid valve is disconnected.



· Between maximum pump 1 flow rate shift solenoid valve connector terminal #1 and MC connector A terminal #19. · Between maximum pump 1 flow rate shift solenoid valve connector terminal #2 and MC connector A terminal #20.



YES



Check by monitoring the vehicle speed with Dr. ZX if the speed meter on column box indicates the same vehicle speed.



YES



NO



Connector (Harness End Connector Seen from Open End SIde)



MC: Connector A A11



A1



A25



A32 #19



YES



#20



T5-4-89



Faulty maximum pump 1 flow rate shift solenoid valve.



Faulty pump 1 regulator or MC.



Broken harness between MC and maximum pump 1 flow rate shift solenoid valve.



Faulty MC.



Faulty harness between column box and MC.



TROUBLESHOOTING / Troubleshooting B T-6 Travel mode (Hi/Low) doesn’t shift.



• Air mixed in the transmission hydraulic circuit may prevent the transmission from being shifted. Bleed air from the transmission by referring to T5-4-116. • Place the brake switch in the position other than the parking position. Perform the troubleshooting. • Check for loose harness connections beforehand.



NO



YES



Install pressure gauges to ports A and B on transmission control valve. Check if pressure at each port varies as shown below when shift lever is operated.



· Shift Lever: L position



· When shift lever is in the L position: → Pressure at port A: 0 MPa → Pressure at port B: 3.0 MPa YES · When shift lever is in the D position: → Pressure at port A: 3.0 MPa → Pressure at port B: 0 MPa



Check if column box indicator normally lights when shift lever is operated.



Port B



Disconnect blown colored connector from transmission control valve transmission changeover solenoid valve. Check if voltage at harness end connector terminal #1 is 24 V.



Faulty transmission.



Transmission Control Valve



Port A



Machine Front Side



T1F3-05-04-001



NO



NO



Check if trouble is corrected when neutral relay and transmission changeover relay are switched with other function relays. YES



T5-4-90



Faulty shift lever, or faulty harness between neutral relay and transmission changeover relay or shift lever and transmission changeover relay.



Faulty neutral relay or transmission changeover relay.



TROUBLESHOOTING / Troubleshooting B



Broken harness between transmission changeover solenoid valve and transmission changeover relay.



NO



Faulty transmission changeover solenoid valve (seized spool).



YES Check if continuity between harness end connector terminal #2 and vehicle frame exists with transmission YES changeover solenoid valve disconnected.



Broken ground cable of transmission changeover solenoid valve.



NO



T5-4-91



TROUBLESHOOTING / Troubleshooting B BRAKE SYSTEM TROUBLESHOOTING B-1 Parking brake is difficult to release.



• First check brake lining, bleed air from brake system and transmission by following the Operator’s Manual. • In case even though the parking brake is released, the machine doesn’t travel (parking brake indicator stays ON), faulty parking brake pressure switch or short-circuited harness between MC and parking brake pressure switch may be the cause of this trouble. • Check for loose harness connections beforehand.



Front View of the Transmission Control Valve Reducing Valve



Port M



T1F3-03-03-002



Disconnect gray color connector from parking brake solenoid valve. Check if voltage at harness end connector terminal #1 is 24 V.



NO



After stopping engine, install pressure gauge to port M on transmission control valve. Check if measured pressure is over 3.0 MPa when engine is started. · Shift Lever: D or L position · Brake Switch: Position other than parking IMPORTANT: Accumulators are provided in the circuit connected to port M. Sufficiently relieve the circuit pressure before installing the pressure gauge.



Check if continuity beYES tween harness end connector terminal #2 and vehicle frame exists with parking brake solenoid valve disconnected.



NO



Check if trouble is corrected when parking brake relays 1, 2, and 3 are switched with other function relays.



Faulty transmission. YES



T5-4-92



TROUBLESHOOTING / Troubleshooting B Parking Brake Circuit Diagram Key Switch From Alternator Terminal L Monitor Controller From Fusible Link (45A) Column Box (Brake Switch)



From Fusible Link (65A)



Parking Brake Relay 3



Parking Brake Relay 1



Parking Brake Relay 2



Parking Brake Solenoid Valve



Faulty pressure reducing valve in transmission control valve.



NO YES



Disassemble to check parking brake solenoid valve for any abnormalities.



Faulty (seized) parking brake solenoid valve.



YES



Faulty (broken) ground line cable of parking brake solenoid valve.



NO YES



NO



T1GL-05-04-001



Faulty parking brake relay 1, 2, or 3. Check if each harness between electrical components is broken or short-circuited while referring the parking brake circuit illustrated above. Is any abnormality found?



YES



Faulty harness.



NO



Faulty monitor controller.



T5-4-93



TROUBLESHOOTING / Troubleshooting B B-2 Parking brake doesn’t operate (is not applied).



• Bleed air from the transmission by referring to T5-4-116 before starting troubleshooting. Relief Valve



Front View of the Transmission Control Valve



Port M



T1F3-03-03-002



NO



NO



After stopping engine, install pressure gauge to port M on transmission control valve. Check if measured pressure is below 1.2 MPa when engine is started. · Shift Lever: N position · Brake Switch: Parking position IMPORTANT: Accumulators are provided in the circuit connected to port M. Sufficiently relieve the circuit pressure before installing the pressure gauge.



Disassemble to check if relief valve in transmission control valve is abnormal.



YES



NO



Check if pressure is reduced to below 1.2 MPa when parking brake solenoid valve is disconnected.



YES



Faulty relief valve in transmission control valve.



Faulty parking brake solenoid valve.



Check if trouble is corrected when parking brake relays 1, 2, and 3 are switched with other function relays.



Faulty transmission. YES



T5-4-94



TROUBLESHOOTING / Troubleshooting B Parking Brake Circuit Diagram Key Switch From Alternator Terminal L Monitor Controller From Fusible Link (45A) Column Box (Brake Switch)



From Fusible Link (65A)



Parking Brake Relay 3



Parking Brake Relay 1



Parking Brake Relay 2



Parking Brake Solenoid Valve



YES



NO



T1GL-05-04-001



Faulty parking brake relay 1, 2, or 3. Check if each harness between electrical components is broken or short-circuited while referring to the parking brake circuit illustrated above. Is any abnormality found?



YES



Faulty harness.



NO



Faulty monitor controller.



T5-4-95



TROUBLESHOOTING / Troubleshooting B B-3 Service brake doesn’t operate, or is not applied effectively.



• The front and rear wheel service brake circuits are independently designed each other. When either the front or the rear wheel brake circuit fails, overall service brake system will operate ineffectively. Check the brake lining and the accumulator for any abnormalities, and bleed air from the brake system by referring to the Operator’s Manual before starting the troubleshooting. • When other actuators (front attachment, travel and swing motors) operate normally, the pilot pump is considered to be normal. • Check for loose harness connections beforehand.



Faulty accumulator charging valve



YES



Does brake pressure gauge on column box indicates less than 12.3 MPa.



NO



Disconnect hose from brake valve outlet port. Install pressure gauge to brake valve port. Check if pressure increases to 7 MPa when brake pedal is stepped on.



YES



Faulty axle side brake device.



To A



NO



· Brake Switch: Position other than work.



YES



A



Install pressure gauge to outlet port on solenoid valve unit (SG). Check if pressure is over 3 MPa. · Brake Switch: Work position.



Faulty brake valve.



YES



NO



Disconnect solenoid valve unit (SG). Connect test harness (ST 7226) to the section between solenoid valve unit (SG) and harness end. Check if lamp lights.



T5-4-96



NO



Faulty solenoid valve unit (SG).



Faulty harness between solenoid valve unit (SG) and MC.



TROUBLESHOOTING / Troubleshooting B STEERING SYSTEM TROUBLESHOOTING H-1 Steering Wheel Rotates, But Steering is Heavy. • Check the steering filter beforehand.



Faulty steering pump.



YES



Disconnect hoses from steering pump and pilot pump output port. Check if the symptom disappears by connecting hoses each other to the other side. NO



YES



Faulty steering valve.



NO



Faulty the relief valve into steering valve.



Monitor to check with Dr. ZX if steering pump delivery pressure is normal. · Monitor item: Pump 3 delivery pressure



H-2 Steering is Impossible Even if Steering Wheel is Rotated.



• In case the machine can steer to only either right or left direction, faulty center joint or overload relief valve in the steering valve may be the cause of this trouble.



T5-4-97



TROUBLESHOOTING / Troubleshooting B OTHER SYSTEM TROUBLESHOOTING O-1 Wiper is inoperable or not retracted. Related Fault Code: None Checking Instructions



• The wiper is driven by electric power routed via



• If the front window is open, the wiper won’t oper-



the relay circuit controlled by the monitor assembly. In case the wiper is inoperable, first check the wiper motor and links for any abnormality using an auxiliary electric power and the test harness.



ate. Check that the front window is securely closed.



Faulty front window open/close switch or short-circuited harness between front window open/close switch and monitor.



YES



Disconnect front window open / close switch. Check if wiper operates.



· Key switch: ON



NO



Connect test harness (ST 7227) between auxiliary electric power (fuse box #12) and wiper motor as illustrated to the right. Check if wiper operates.



Remove test harness and reconnect circuit to the original position. Replace wiper relay YES one at a time to see if wiper operates.



YES Faulty wiper relay.



NO



To A



· Key switch: ON Faulty wiper motor or links.



· Key switch: ON NOTE: When the wiper motor is normal, lamp S lights while the wiper is moving within the operating range. Both lamps B and S light for a moment at the same time only when the wiper reaches the intermittent stop position.



NO or test harness lamp doesn’t light normally.



A



Replace monitor assembly to see if wiper operates.



YES End (Faulty monitor).



Faulty cab harness. NO



T5-4-98



TROUBLESHOOTING / Troubleshooting B



Test Harness Application Circuit Fuse Box #12



M



B



Lamp S



S



Lamp B



Wiper Motor



L



E Ground



T178-05-04-004



Wiper Operating Range



Intermittent Stop Position



Retracted Position



Operating Range



T178-05-04-005



Test Harness Connection Method



Wiper Motor



Lamp B Lamp S



Test Harness



Fuse Box T157-07-04-004



T5-4-99



TROUBLESHOOTING / Troubleshooting B O-2 Air Conditioner Malfunction The air conditioner has a self-diagnosis function. The self-diagnosis functions to: 1) Display Fault Codes 2) Change Displayed Fault Codes 3) Delete Fault Code 4) End Fault Code Display



• Display Fault Code 1. Press the fan OFF switch to turn the fan OFF. 2. Press and hold both the upper and lower sides of the temperature control switch on the air conditioner control panel at the same time for more than 3 seconds with the key switch ON. NOTE: After operation has been performed, the buzzer will sound. 3. If any fault codes are found, the LCD displays the fault codes as E . NOTE: If more than one fault code is found, the lower number fault code will be displayed first.



T5-4-100



Temperature Control Switch



Fan OFF Switch



LCD



M178-01-017



TROUBLESHOOTING / Troubleshooting B Fault Code List Location in Trouble Abnormal circulation air sensor



Fault Code E11 E12



Cause Broken circuit in air circulation sensor Short-circuited circulation air sensor Broken circuit in fresh air sensor Short-circuited fresh air sensor



Abnormal fresh air sensor



E13 E14



Abnormal solar radiation sensor



E18



Short-circuited solar radiation sensor



Abnormal evaporator sensor



E21



Broken circuit in evaporator sensor Short-circuited evaporator sensor Abnormal air vent damper Abnormal air mix damper Abnormal circulation/fresh air damper Broken circuit in water temperature sensor Short-circuited water temperature sensor Abnormal high/low refrigerant pressure



E22 Abnormal damper



E43 E44 E45



Water temperature sensor



E15 E16



Abnormal refrigerant



E51



T5-4-101



Symptom Y value (air flow-in temperature) cannot be adjusted in response to the set-temperature. Operation is controlled under such circumstance as no fresh air sensor is provided. Operation is controlled under such circumstance as no solar radiation sensor is provided. Operation is controlled under such circumstance as the evaporator temperature is set to 10 °C (50 °F). Corresponding damper servo becomes inoperable.



Operation is controlled under such circumstance as the water temperature is set to 60 °C (140 °F). (Warm-up control is not performed.) The compressor clutch is disengaged. (The compressor stops.)



TROUBLESHOOTING / Troubleshooting B • Change Displayed Fault Code 1. When displaying more than one fault code, press either the upper or bottom side of the temperature control switch key. The following fault code is displayed. NOTE: Each time the displayed fault code is changed, the buzzer sounds. In case only one fault code exists, the displayed fault code remains unchanged.



Temperature Control Switch



LCD



• Delete Fault Code



LCD



1. Press and hold both the circulation air switch and the fresh air vent switch for more than 3 seconds at the same time to delete the fault code. NOTE: After the fault code is deleted, the buzzer will sound. 2. After the fault code has been deleted, the LCD displays E .



M178-01-017



Circulation Air Switch



Fresh Air vent Switch



M178-01-017



Fan OFF Switch



• End Fault Code Display 1. Press the fan OFF switch, or press the upper side of the fan switch key. The self-diagnostic mode is complete.



Fan Switch



T5-4-102



M178-01-017



TROUBLESHOOTING / Troubleshooting B (Blank)



T5-4-103



TROUBLESHOOTING / Troubleshooting B ※ Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to Hitachi Tsuchiura Works Quality Assurance Dept. after experiencing a problem with your machine’s air conditioning system. < AIR CONDITIONER TROUBLE REPORT > File No. (1) What Checked by: Model (Serial No. ) Operation Type Manual Semi-Auto Full-Auto Delivery Date Year Month (2) When Date Year Month Day Operating Hour ( h) Time Morning Daytime Evening Night Frequency Every Day Once a Week Once a Month Times per (3) Where Job Site Address State County Town Access Road Condition Paved Not Paved (Gravel Sand Soil) (4) How (Operating Conditions) Weather Fine Cloudy Rain Snow Atmospheric Temperature Very Hot Hot Cold Very Cold Operating Conditions Parking Traveling Working Temperature Control Paint blanks equal to red indicators. / Fill in set-temperature when full-auto operation A/C ON OFF Air Induction Re-Circulation Fresh Air Circulation Control Panel AUTO ON OFF Not Available Fill following items when operated in manual mode or when manual control type unit is used. Vent Position Front Front / Rear Foot Front / Rear and Foot Fan First Second Third Fourth Fifth Sixth (5) How (Problem Symptom) Abnormal Compressor Operation



Symptom Not turned ON (1) Is problem reproducible ? Not turned OFF Reproducible Others Not reproducible Uncontrollable air temperature (2) Pressure (To be measured at gauge manifold) Symptom No cool air Low Pressure No warm air High Pressure Others (3) Which parts have been replaced ? Uncontrollable air volume 1 Symptom Air flows in Hi mode only No air flows 2 Small air volume Others ∗ Before replacing the control amplifier, be sure to Uncontrollable vent hole check that the connectors are correctly connected Symptom Vent hole isn’t selected while repeatedly disconnecting and reconnecting Others connectors. Abnormal panel indication Faulty Indicator Vent Hole A/C AUTO Fresh Air Circulation Fan OFF Fan (Lo • •• Hi) Temperature Control Symptom Stays OFF Stays ON Blinks Others



T5-4-104



TROUBLESHOOTING / Troubleshooting B Refrigerant Quantity ....................... 1000±50 g Compressor Oil Quantity................ 180 cm3



T5-4-105



TROUBLESHOOTING / Troubleshooting B Cooling Circuit Refrigerant pressure in both high and low-pressure sides is low.



Bubbles can be seen in sight glass.



No bubbles are seen in sight glass.



Piping and/or parts are stained with oil, respond to gas detector. No oil stain is found or gas detector doesn’t respond. Refrigerant has not been refilled for longer than one season.



After cooling at fast speed continuously, cooling power is reduced. Air flow volume remains unchanged.



Air flow volume is reduced.



Insufficient Cooling Power



Refrigerant pressure in low-pressure side is high.



Bubbles can be seen in sight glass.



Compressor cylinder is extremely hot, emitting a smell.



Refrigerant pressure in high-pressure side is low.



Compressor cylinder is extremely hot, emitting a smell.



Heater unit emits hot air.



Refrigerant pressure in high-pressure side is high.



Bubbles can be seen in sight glass.



Refrigerant pressure in low-pressure side is low.



Condenser is stained and clogged. Even if condenser is sprayed with water, few bubbles appear. Receiver dryer temperature is low.



After cooling at fast speed continuously, cooling power is reduced. Air flow volume is reduced.



Frost forms.



Thermistor doesn’t cool. Thermistor cools.



T5-4-106



TROUBLESHOOTING / Troubleshooting B Gas leaks from pipe joints and/or parts.



Re-tighten or replace parts.



Normal leakage of refrigerant from hoses.



Refill refrigerant.



Improper adjustment (excessive restriction) of expansion valve.



Readjust or replace expansion valve.



Clogged expansion valve.



Remove clog, or replace receiver and/or expansion valve.



Clogged low-pressure circuit and/or evaporator.



Remove clog, or replace parts.



Frozen expansion valve or water in circuit.



After evacuation, refill refrigerant and/or replace receiver dryer.



Gas leaks from case.



Seal gaps using vinyl tape or packing compound.



Poor contact of expansion valve temperature sensing cylinder.



Make good contact. Replace temperature sensing stay.



Improper adjustment (excessive open) of expansion valve.



Readjust or replace.



Insufficient compressor discharge (faulty gasket and/or valve).



Replace.



Improper water stop valve wire adjustment and/or faulty stop valve.



Check and readjust or replace.



Poor airtight fitting of outside air damper (outside air induction type).



Repair.



Clogged high-pressure circuit before receiver dryer.



Remove clog, or replace parts. Clean Condenser.



Excessive refrigerant.



Remove excessive refrigerant to proper level.



Air is mixed in system.



After evacuation, refill refrigerant and/or replace receiver dryer.



Incorrect thermistor location.



Correct thermistor location.



Gas leaks from case.



Seal gaps using vinyl tape or packing compound.



Faulty thermistor (stays ON).



Disconnected thermistor cord.



Even if function and performance are normal, when air-conditioner is kept operated for a long time with thermistor in max. cooling position and air flow in M or L mode, frost may form.



Instruct user on correct air-conditioner operation. (Reset thermistor to either minimum or middle cooling position or increase air flow.)



T5-4-107



TROUBLESHOOTING / Troubleshooting B Cooling Circuit



Case connection.



Louver resonance. Fan contacts case, or foreign matter enters case.



Blower fan connection.



Noise



Brush friction noise, metal and/or thrust washer contact noise.



Gas blowing sound (roaring).



Gas vibration noise (compressor discharge and/or suction gas noise).



Expansion valve connection, whistle sound, gas blowing sound.



Abnormal noise from expansion valve (Expansion valve is normally functioning.).



Faulty clutch bearing, and/or idle pulley bearing. Clutch disengaging sound. Contact of clutch amature due to resonance, or loose belt and/or screws. Noisy compressor. Compressor rotating sound. Vibration and/or loose screws due to excessive drive belt looseness.



Broken heater core and/or hose. Water leak and/or splash. Clogged case drain port and/or drain hose. Others Absorbed cigarette and dust smell on evaporator fins.



Abnormal smell.



T5-4-108



TROUBLESHOOTING / Troubleshooting B



Repair or replace. Remove foreign matter. Readjust fan motor location. Slight noise is unavoidable. Replace if loud.



No functional problem exists. Provide silencer if intolerable.



Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.



Replace. Repair or replace clutch. Re-tighten screws.



Repair or replace. Re-adjust drive belt.



Replace. Clean.



Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in L mode for more than 10 minutes, flush smell out by condensed water.



T5-4-109



TROUBLESHOOTING / Troubleshooting B Compressor Compressor doesn’t rotate.



Clutch terminal voltage is normal 24 V.



Inoperable cooling system.



Clutch terminal voltage is low.



Clutch terminal voltage is 0 V. Bubbles exist even after refrigerant is refilled. Both high and low side pressures are low. Both compressor and blower motor rotate.



Check for oil and refrigerant leaks from parts other than compressor and pipe joints using gas detector. Check for oil and refrigerant leaks from compressor (no leaks from parts other than compressor) using gas detector. (Refer to NOTE 2 on page T5-4-113.) Stain on exterior. (Refer to NOTE 1 on page T5-4-113.) Refrigerant has not been refilled for longer than one season. Refrigerant is discharged within 1 to 2 months after being recharged. Check for refrigerant leaks using gas detector. Refrigerant is kept charged for longer than 2 years.



High pressure side is slightly low and low pressure side is high.



Bubbles can be seen through sight glass.



Compressor cylinder is not hot. (Refrigerant returns to compressor in liquid form.) No refrigerant returns in liquid form. High pressure side is low. Others



High pressure side is high.



Refer to the Cooling Circuit Troubleshooting Table on page T5-4-106.



Temperature is not cooled when compressor is operated at fast speed continuously. Air flow from blower is insufficient.



T5-4-110



TROUBLESHOOTING / Troubleshooting B



Seized clutch.



Replace.



Improper gap between amature and rotor (improper air gap). Replace. Broken or short-circuited core cable. Shaft doesn’t rotate (internally locked).



Replace.



Faulty Electrical System.



Faulty Electrical System. Oil leaks from mechanical seal, gasket, and/or charge valve. Replace. Oil leaks from oil plug.



Oil and refrigerant leaks from front housing, and/or cylinder block joint. Normal leaks from hoses.



Replace. Charge refrigerant.



No leaks (normal).



Refer to the Cooling Circuit Troubleshooting Table on page T5-4-106. Broken valve (Refer to NOTE 3 on page T5-4-113.) Replace. Blown gasket (Refer to NOTE 3 on page T5-4-113.)



Check and adjust oil level.



Excessive oil.



T5-4-111



TROUBLESHOOTING / Troubleshooting B Compressor Compressor rotation is abnormally draggy. Overheating is susceptible to occur. Trouble other than compressor.



Noise is heard when clutch is OFF.



Abnormal noise



Noise is heard when clutch is ON.



T5-4-112



Refer to the Cooling Circuit Troubleshooting Table on page T5-4-106.



TROUBLESHOOTING / Troubleshooting B



Broken clutch bearing due to overly tightened belt.



Replace.



Shaft doesn’t rotate. Replace. Shaft rotates draggy.



Broken clutch bearing. Replace. Contact or slip due to poor air gap. Faulty idle pulley bearing. Refer to the Cooling Circuit Troubleshooting Table on page T5-4-106.



Saggy belt. Loose screws.



Broken valve. Replace. Blown gasket. Abnormal internal noise.



Replace.



Vibration due to saggy belt.



Refer to the Cooling Circuit Troubleshooting Table on page T5-4-106.



Loose screws.



NOTE: 1. Don’t quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A slight oil seepage will appear due to the seal construction. However, this oil seepage will not cause malfunction. Be sure to accurately check whether oil is leaking or seeping only. 2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose surface may be detected. As long as the specified rubber hoses are used, the problem should not occur. (In case a large leaks is detected, the hose may be broken.) 3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between high-pressure side and low-pressure side is 0.49 MPa (5 kgf/cm2) or less. When the clutch is turned OFF, the pressure difference between high-pressure side and low-pressure side will disappear within about 10 seconds.



T5-4-113



TROUBLESHOOTING / Troubleshooting B EXCHANGE INSPECTION Exchange inspection method is a troubleshooting method to find the trouble location by exchanging the suspected part / component with another part /component having identical characteristics. Many sensors and solenoid valves used on this machine are identical. Therefore, using this switch-check method, faulty part /component, and/or harness can be easily found. Example: Abnormal pump 1 delivery pressure (Fault code: 10) Check Method: 1. Switch two delivery pressure sensor connectors located. 2. Retry troubleshooting. Result: In case the pump 2 delivery pressure is abnormal (fault code 11), the pump 1 delivery pressure sensor is considered to be faulty. In case the pump 1 delivery pressure is abnormal (fault code 10), the pump 1 delivery pressure sensor harness is considered to be faulty.



T5-4-114



Pump 1 Pump 2 (4-Spool (5-Spool Section) Section) Delivery Pressure Sensor T1F3-01-02-007



TROUBLESHOOTING / Troubleshooting B Applicability of Switch-Check Method Fault Code Trouble 01 Abnormal EEPROM 02 Abnormal RAM 03 Abnormal A/D Conversion 04 Abnormal Sensor Voltage 06 Abnormal EC Angle Sensor 07 Abnormal EC Dial 10 Abnormal Pump 1 Delivery Pressure 11 Abnormal Pump 2 Delivery Pressure 12 Abnormal Pump 1 Control Pressure 13 Abnormal Pump 2 Control Pressure 14 Abnormal Swing Pilot Pressure 15 Abnormal Boom Raise Pilot Pressure 16 Abnormal Arm Roll-In Pilot Pressure 18 Abnormal Travel Pilot Pressure 20 Abnormal Travel Motor Drain Pressure Sensor 23 Abnormal Travel Forward Pilot Pressure Sensor 24 Abnormal Travel Reverse Pilot Pressure Sensor Abnormal Hydraulic Oil Temperature 19 Sensor



Applicability Not Applicable



Not Applicable Not Applicable Applicable (Harness) Applicable (Harness) Applicable (Harness/Sensor)



Not Applicable



22



Abnormal Travel Motor



Not Applicable



26



Travel Motor Over-rev.



Not Applicable



T5-4-115



TROUBLESHOOTING / Troubleshooting B BLEEDING AIR FROM TRANSMISSION IMPORTANT: Be sure to bleed air from the transmission after disconnecting and reconnecting the pipe lines, or changing the hydraulic oil. If air is mixed in the transmission gearshift circuit, malfunction of the transmission may result.



1



NOTE: Bleed air by the teamwork of two or more persons. 1. Start the engine. Park the machine on a level solid ground. Lower the bucket on the ground. 2. Turn the brake switch on the column box to the S (working) position. NOTE: Air is not bled when the brake switch is in the P (parking) position.



MCBB-07-021



1



3. Connect transparent vinyl tube (2) to the tip end of air bleed plug (1) on the transmission. Put the other end of vinyl tube (2) into transparent vessel filled (3) with hydraulic oil. 4. Reciprocate shift lever (4) between positions D (Hi) and L (Low) 4 to 5 times. 5. Place shift lever (4) in position D (Hi). Loosen air bleed plug (1). Allow the hydraulic oil together with air to flow out for 15 to 20 seconds. Tighten air bleed plug (1). 6. Place shift lever (4) in position L (Low). Keep the lever in that position and wait for 15 to 20 seconds. 7. Repeat step 5 to 6 until no bubbles are found in the discharged oil. 8. Tighten air bleed plug (1).



2



3



M202-07-023



4



T5-4-116



MCBB-01-010



TROUBLESHOOTING / Troubleshooting B BLEEDING AIR FROM BRAKE (AXLE) IMPORTANT: If air is mixed in the brake system, the brake function is reduced, possibly resulting in serious hazard. Be sure to bleed air from the brake system after disconnecting and reconnecting the pipe lines, or changing the hydraulic oil. Bleed air until hydraulic oil of approx. 500 mL (0.13 US gal.) is drained from each wheel (4 places) after air bubbles disappear.



1



NOTE: Bleed air from four wheels by the teamwork of two or more persons. 1. Turn the brake switch on the column box to position P (parking). Start the engine to increase the brake hydraulic oil pressure. 2. Connect transparent vinyl tube (2) to the tip end of air bleed plug (1). Put the other end of vinyl tube (2) into transparent vessel filled (3) with hydraulic oil. 3. Fully stroke brake pedal (4) several times. Then, hold brake pedal (4) in the fully stepped position. 4. While holding brake pedal (4) in the fully stepped position, loosen air bleed plug (1). Keep discharging hydraulic oil and air for several seconds. 5. Tighten air bleed plug (1). 6. Repeat steps 3 to 5 until no air bubble is found in the discharged hydraulic oil. NOTE: Even after hydraulic oil of 500 mL (0.13 US gal.) is discharged, if air bubbles are still remaining in the discharged hydraulic oil, continuously repeat steps 3 to 5.



MCBB-07-044



1



2



3



M202-07-023



7. Bleed air from other three places by the same procedure explained in steps 3 to 5. IMPORTANT: After bleeding air from all four places, bleed air from all four places once more. After bleeding air by following steps 3 to 6 twice, make sure that air is completely bled.



MCBB-01-008



4



T5-4-117



TROUBLESHOOTING / Troubleshooting B EMERGENCY BOOM LOWERING PROCEDURE (without hose-rupture safety valve) CAUTION: Never allow anyone to come under the front attachment while performing the emergency boom lowering procedure.



Rear



1



Boom 1



2



If the engine stalls and cannot be restarted, lower the boom and the bucket to the ground referring to the emergency boom lowering procedure stated below. 1. Remove rubber caps (1) and (2) from the boom I section of the 4-spool control valve. 2. Remove lock nut (8) using a wrench (17 mm). Be sure to turn the wrench counterclockwise to remove lock nut (8). Control Valve



3. Turn socket-head screw (7) clockwise to the stop using an allen wrench (4 mm).



6 3 4



4. Turn lock nut (5) counterclockwise to loosen it, using a wrench (17 mm). 5. Loosen socket-head screw (6) clockwise using an allen wrench (4 mm) while closely watching the boom lower. Note that the loosened degree of screw (6) determines the boom lowering speed. Adjust the boom lowering speed with the allen wrench as required. Take care not to remove snap ring (3) and washer (4) at this time. Also, do not loosen screw (6) excessively or cause washer (4) to be deformed.



M175-05-001



1 5 7 2 8



6. After the bucket is lowered to the ground, turn screws (6) and (7) counterclockwise to the stop. Loosen screw (7) 1/8 of a turn clockwise. Tighten lock nuts (5) and (8). Tightening Torque: 19.5 N⋅m (2 kgf⋅m) 7. Re-install rubber caps (1) and (2). Be sure to return them to their original positions. NOTE: Be sure to work on screw (7) first, then, on screw (6), as stated above.



T5-4-118



M154-05-001



TROUBLESHOOTING / Troubleshooting B EMERGENCY BOOM LOWERING PROCEDURE (with hose-rupture safety valve)



Hose-Rupture Safety Valve



CAUTION: Prevent personal injury. Confirm that no one is under the front attachment before starting the procedure below. If the engine stalls and cannot be restarted, lower the boom to lower the bucket to the ground referring to the emergency boom lowering procedure stated below. 1. Loosen lock nut (1). 2. Loosen very slowly adjusting screw (2) in order to lower the front attachment till to ground.



M1G6-05-017



2



1



NOTE: Never loosen screw (2) more than 1.5 turns. Adjusting screw (2) may come off. 3. After the front attachment is lowered to the ground, retighten adjusting screw (2), then lock nut (1) to the specifications below. Lock Nut (1) : 17 mm : 30±2 N⋅m



M1G6-05-013



Adjusting Screw (2) : 6 mm



1



2



NOTE: It is enough to perform the above procedure only on one of the hose-rupture safety valve.



M1G6-05-014



T5-4-119



TROUBLESHOOTING / Troubleshooting B (Blank)



T5-4-120



TROUBLESHOOTING / Troubleshooting C TROUBLESHOOTING C (TROUBLESHOOTING FOR MONITOR) PROCEDURE Use troubleshooting C when any monitors, such as gauges or indicators malfunction.



• How to Read the Troubleshoting Flow Charts YES(OK)



・



(2)



• After checking or measuring item (1), select either YES (OK) or NO (NOT OK) and proceed to item (2) or (3), as appropriate.



(1) NO(NOT OK)



(3)



• Special instructions or reference item are indicated in the spaces under the box.



・



Incorrect measuring or checking methods will render troubleshooting impossible, and may damage components as well.



· Key switch: ON



・



• Use Dr.ZX (or the built-in diagnosing system) function.



・



• Causes are stated in a thick-line box. Scanning through thick-line boxes, possible causes can be seen without going through the flow chart.



NOTE: All harness end connector are seen from the open-end side.



Harness End Connector



Open End Side



Harness



T6L4-05-03-001



T5-5-1



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PERATURE GAUGE



COOLANT



TEM-



• Check for loose harness connections beforehand. Faulty coolant temperature sensor.



YES Gauge pointer doesn’t move at all.



Disconnect coolant temperature sensor. Ground harness end terminal to vehicle frame. Check if pointer swings to (H) side.



· Key switch: ON



NO



Remove connector B (20P) from monitor. Check if voltage at monitor harness end connector terminal #18 is 5 V.



YES



Broken harness between monitor and sensor.



Faulty monitor. NO



Faulty coolant temperature sensor.



YES



Gauge pointer swings over scale.



Disconnect coolant temperature sensor. Check if pointer returns to zero. · Key switch: ON



YES



NO



Remove connector B (20P) from monitor. Check if voltage at monitor harness end terminal #18 is 5 V.



Short-circuited harness between monitor and sensor.



Faulty monitor. NO



Gauge pointer keeps moving unstably.



Disconnect coolant temperature sensor. Ground harness end terminal to vehicle frame, Check if pointer swings and is stabilized to (H) side.



Faulty coolant temperature sensor.



YES



Faulty monitor. · Key switch: ON



NO



T5-5-2



TROUBLESHOOTING / Troubleshooting C



Coolant Temperature Gauge



M178-01-104



Coolant Temperature Sensor Coolant Temperature °C (°F) 25 (77) 40 (104) 50 (122) 80 (176) 95 (203) 105 (221) 120 (248)



Resistance (kΩ) 7.6±0.76 4.0±0.35 2.7±0.22 0.92±0.07 0.56±0.04 0.42±0.03 0.28±0.01



Connector (Harness end connector terminals seen from the open end side) Monitor Connector B (20P) 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



T5-5-3



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF FUEL GAUGE • Check for loose harness connections beforehand.



Fuel gauge pointer doesn’t move at all.



Disconnect fuel sensor. Connect harness end connector terminal #1 to terminal #2 using jumper wire such as clip. Check if pointer swings to (FULL) side. · Key switch: ON



YES



NO



Faulty fuel sensor.



Remove connector B (20P) from monitor. Check if voltage at monitor terminal #19 is 5 V.



Broken harness between YES monitor and sensor.



Faulty monitor. NO



YES



Fuel gauge pointer swings over scale.



Disconnect fuel sensor. Check if pointer returns to zero. · Key switch: ON NO



Faulty fuel sensor.



Remove connector B (20P) from monitor. Check if voltage monitor harness end terminal #19 is 5 V.



Short-circuited harness beYES tween monitor and sensor.



Faulty monitor. NO



Fuel gauge pointer keeps moving unstably.



Disconnect fuel sensor. Connect harness end connector terminal #1 to terminal #2 using jumper wire such as clip. Check if pointer swings and is stabilized to (FULL) side.



Faulty fuel sensor.



YES



Faulty monitor. NO · Key switch: ON



T5-5-4



TROUBLESHOOTING / Troubleshooting C



Fuel Sensor



Fuel Gauge



Float



Upper Limit



FULL



1/2 R381.9 mm



257 mm



3/4



Lower Limit



93 mm 70.5 mm



M178-01-105



1/2 204 mm



338 mm



1/4



EMPTY T178-05-05-001



NOTE: 1 mm = 0.03937 in Float Position Upper Limit (FULL) 3/4 1/2 1/4 Warning Level Lower Limit (EMPTY)



Resistance (Ω) 10+0-4 26 38±5 53 85±3 90+10-0



Connector (Harness end connector terminals seen from the open end side) Monitor Connector B (20P) 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



Fuel Sensor



1



2



T5-5-5



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF INDICATOR CHECK SYSTEM



LIGHT



• Check for loose harness connections beforehand.



YES Indicator doesn’t light when indicator light check operation is performed.



Disconnect monitor connector C. Check if there is continuity between harness end connector terminal #1(power input) and fuse box terminal #5(switch box).



Check if all indicators don’t light.



YES



Burnt fuse or broken harness between fuse #5 and monitor.



Faulty monitor. NO



Conduct troubleshooting of each indicator, which does not light.



NO



Connector (Harness end connector terminals seen from the open end side) Monitor Connector C (20P) 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



T5-5-6



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PREHEAT INDICATOR • The preheat system operates only when coolant temperature is below 10 °C (50 °F), lighting the preheat indicator for 8 seconds. (Refer to the SYSTEM /Electrical Circuit group.)



• In case the preheat system malfunctions, refer to the troubleshooting B for E-16 Engine is difficult to start at low temperature. • Check for loose harness connections beforehand.



Faulty coolant temperature switch.



YES Preheat indicator lights even though preheat system doesn’t operate (coolant temperature is more than 10 °C (50 °F)).



Remove connector from coolant temperature switch. Check if indicator goes OFF.



· Key switch: ON



Faulty QOS controller.



YES



Disconnect QOS controller. Check if indicator goes NO OFF. · Key switch: ON



Without connecting QOS controller, remove connector B (20P) from monitor. Check for continuity between monitor harness end conNO nector terminal #20 and vehicle frame.



YES



Short-circuited harness between QOS controller and monitor.



Faulty monitor. NO



Preheat indicator doesn’t light although preheat system operates (coolant temperature is lower than 10 °C (50 °F)).



Remove connector from coolant temperature switch. Check if indicator comes ON by grounding harness end connector to vehicle frame.



· Key switch: ON



Faulty coolant temperature switch.



YES



YES Disconnect QOS controller. Check if indicator comes ON by grounding harness end connector terminal #6 NO to vehicle frame. NO



Faulty QOS controller.



Ground monitor connector B (20P) terminal #20 to vehicle frame. Check if indicator comes ON.



YES



Broken harness between QOS controller and monitor.



Faulty monitor. NO



· Key switch: ON



Connector (Harness end connector terminals seen from the open end side) Monitor Connector B (20P) 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



QOS Controller 1 2 3 4 5 6



T5-5-7



· Without disconnecting connector, ground connector to vehicle frame using jumper wire such as clip from the back of connector.



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF OVERHEAT INDICATOR • Check for loose harness connections beforehand. YES Remove connector (red and blue cable) from overheat switch. Check if indicator lights when YES harness end terminal is grounded to vehicle frame. NO Indicator doesn’t light even if engine overheats.



Faulty overheat switch.



Reconnect overheat switch. Check if indicator lights when monitor connector B (20P) terminal #6 is grounded to vehicle frame.



To A



· Key switch: ON



Check if indicator lights when key switch is turned ON.



· Key switch: ON · Without disconnecting connector, ground connector to vehicle frame using such jumper wire as clip from the back of connector.



· Key switch: ON



Burned indicator bulb. NO



YES



Broken harness between monitor and overheat switch.



A



Faulty monitor. NO



YES



Indicator lights even if coolant temperature is low.



Faulty overheat switch.



Check if indicator goes OFF when overheat switch is disconnected.



· Key switch: ON · Engine: Stopped



YES



NO



Check if indicator goes OFF when connector B (20P) is disconnected from monitor.



Short-circuited harness between monitor and overheat switch.



Faulty monitor. · Key switch: ON



T5-5-8



NO



TROUBLESHOOTING / Troubleshooting C



Overheat Switch Coolant Temperature Operation Lower than 105 °C OFF (221 °F) 105 °C (221 °F) or ON higher



Connector (Harness end connector terminals seen from the open end side) Monitor Connector B (20P) 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



T5-5-9



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF AIR FILTER RESTRICTION INDICATOR • Check for loose harness connections beforehand.



Disconnect air filter restriction switch at plug receptacle with green and blue cable. Check if indicator lights when YES harness end plug connector is grounded to vehicle frame. Even if air filter is clogged, indicator doesn’t light.



Check if indicator lights when key switch is turned ON.



YES



NO · Key switch: ON



Faulty air filter restriction switch.



Remove connector B (20P) from monitor. Check for continuity between monitor harness end connector and air filter restriction switch at plug receptacle.



To A



· Key switch: ON Burned indicator bulb. NO



YES



Faulty monitor.



NO



Broken harness between monitor and air filter restriction switch.



A



Faulty air filter restriction switch.



YES



Although air filter is not clogged, indicator lights. · Disassemble and visually inspect. · Verify that air filter is not moist.



Check if indicator goes OFF when air filter restriction switch is disconnected.



· Key switch: ON



NO



Check if indicator goes OFF when connector B (20P) is disconnected from monitor.



YES



Short-circuited harness between monitor and air filter restriction switch.



Faulty monitor. · Key switch: ON



T5-5-10



NO



TROUBLESHOOTING / Troubleshooting C



Air Filter Restriction Switch Pressure 5.1 kPa (520 mmH2O) 6.2 kPa (630 mmH2O)



Operation OFF ON



Connector (Harness end connector terminals seen from the open end side) Monitor Connector B (20P) 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



T5-5-11



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF FUEL LEVEL INDICATOR • Check for loose harness connections beforehand.



YES



YES



Indicator does not come ON even if fuel gauge pointer reaches "E".



Disconnect fuel sensor. Check if indicator comes ON by grounding harness end connector to vehicle frame.



Turn key switch to ON position. Check if indicator comes ON.



NO



NO



YES



Indicator comes ON even if fuel still remains.



Disconnect fuel sensor. Check if indicator goes OFF.



YES



· Key switch: ON NO



Check if indicator goes OFF when connector B (20P) is disconnected from monitor.



· Key switch: ON NO



T5-5-12



Disconnect monitor connector B (20P). Check if voltage at monitor connector terminal #19 is 5 V.



TROUBLESHOOTING / Troubleshooting C



Faulty fuel sensor.



YES



Broken harness between monitor controller and fuel sensor.



Faulty monitor controller. NO Burned indicator bulb, or faulty monitor controller.



Connector (Harness end connector terminals seen from the open end side)



Faulty fuel sensor.



Monitor Connector B (20P)



Short-circuited harness between monitor controller and fuel sensor.



Faulty monitor controller.



T5-5-13



10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ALTERNATOR INDICATOR • Check for loose harness connections beforehand.



NOTE: *Regulator terminals L are water-resistant type connectors so that it is not practical to measure voltage at these terminals. Measure voltage at starter relay terminal R instead. Check for continuity between starter relay terminal R and regulator terminal L beforehand.



Between 12 V Measure voltage at monitor connector A and 35 V (16P) terminal #2. Alternator indicator stays ON after engine is started.



Measure voltage at regulator terminal L.*



· Engine: Running



· Engine: Running Less than 12 V or higher than 35 V



YES



YES Although alternator output is low, alternator indicator doesn’t light.



NO



· Key switch: ON NO



Connector (Harness end connector terminals seen from the open end side) Starter Relay E S



R



· Engine: Running



Does engine start?



Check if indicator lights when key switch is turned ON.



Monitor Connector A (16P) 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9



T5-5-14



Measure voltage at regulator terminal L.*



TROUBLESHOOTING / Troubleshooting C



Between 12 V and 35 V



Faulty monitor.



Broken harness between regulator terminal L and monitor.



Less than 12 V or higher than 35 V



Faulty regulator or alternator.



Between 12 V and 35 V



Measure voltage at monitor connector A (16P) terminal #2. · Engine: Running



Between 12 V and 35 V



Less than 12 V or higher than 35 V



Faulty monitor. Broken harness between regulator terminal L and monitor. Faulty regulator.



Less than 12 V or higher than 35 V



Go to the troubleshooting B (engine troubleshooting).



Burned indicator light.



T5-5-15



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR • Check for loose harness connections beforehand.



NOTE: During one or two minutes after the engine is stopped, engine oil pressure may still exist. When the engine is restarted under this condition, the indicator may not light.



Disconnect engine oil pressure switch. Check if indicator lights when harness end connector terminal #1 (white and YES red cable) is grounded to vehicle frame.



Indicator doesn’t light even if engine oil pressure is low.



· Key switch: ON



Check if indicator lights when key switch is turned ON.



YES



NO



Faulty engine oil pressure switch.



Reconnect engine oil pressure switch. Check if indicator lights when monitor connector C (20P) terminal #18 is grounded to vehicle frame.



To A



· Key switch: ON · Without disconnecting connector, ground connector to vehicle frame using such jumper wire as clip from the back of connector.



· Key switch: ON · Engine: Stopped



Burned indicator light. NO



YES



Broken harness between monitor and engine oil pressure switch.



A



Faulty monitor. NO



Faulty engine oil pressure switch or engine oil pressure system, or clogged oil filter.



YES



Indicator stays ON after engine is started. · Check oil filter for clogging.



Check if indicator goes OFF when engine oil pressure switch is disconnected.



· Key switch: ON · Engine: Stopped



YES



NO



Check if indicator goes OFF when connector C (20P) is disconnected from monitor.



Short-circuited harness between monitor and engine oil pressure switch.



Faulty monitor. · Key switch: ON



T5-5-16



NO



TROUBLESHOOTING / Troubleshooting C



Engine Oil Pressure Switch Pressure Operation Approx. 98 kPa (1.0 kgf/cm2, 14.22 psi) ON or less Approx. 98 kPa (1.0 kgf/cm2, 14.22 psi) OFF or higher



Connector (Harness end connector terminals seen from the open end side) Monitor Connector C (20P) 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



T5-5-17



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF HYDRAULIC OIL FILTER INDICATOR (OPTIONAL) • Check for loose harness connections beforehand.



Disconnect hydraulic oil filter restriction switch at plug receptacle with white and blue cable. Check if indicator YES lights when harness end plug connector is grounded to vehicle frame.



Even if hydraulic oil filter is clogged, indicator doesn’t light.



· Key switch: ON



Check if indicator lights when key switch is turned ON.



YES



NO



Reconnect hydraulic oil filter restriction switch. Check if indicator lights when monitor connector C (20P) terminal #14 is grounded to vehicle frame.



· Key switch: ON · Without disconnecting connector, ground connector to vehicle frame using jumper wire such as clip from the back of connector.



· Key switch: ON



NO



YES Although hydraulic oil filter is not clogged, indicator lights.



Check if indicator goes OFF when hydraulic oil filter restriction switch at plug receptacle with white and blue cable is disconnected.



· Key switch: ON · Engine: Stopped



NO



Check if indicator goes OFF when connector C (20P) is disconnected from monitor.



· Key switch: ON



T5-5-18



TROUBLESHOOTING / Troubleshooting C



Faulty hydraulic oil filter restriction switch.



YES



Broken harness between monitor and hydraulic oil filter restriction switch.



Faulty monitor. NO



Connector (Harness end connector terminals seen from the open end side) Monitor Connector C (20P)



Burned indicator bulb.



10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



Faulty hydraulic oil filter restriction switch.



YES



Short-circuited harness between monitor and hydraulic oil filter restriction switch.



Faulty monitor. NO



T5-5-19



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF OVERLOAD ALARM INDICATOR (OPTIONAL) • By bulb blow inspection, check that bulb is not



Connector (Harness end connector terminals seen from the open end side) Monitor Connector C (20P)



blown. • Check that cancellation switch is at ON position (cancellation release position). • Check for loose harness connections beforehand. Alarm indicator does not go ON even when lifting a load over the setting.



10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



Connector (Monitor end connector terminals seen from the open end side) Connector (1) 1 2 3 4 5 6 7 8 9 10



Disconnect monitor connector C (20P) and connector (1). Check for continuity between monitor harness YES end connector terminal #20 and connector (1) terminal #8. YES



Check if alarm buzzer sounds.



YES



NO YES



· Boom raise (When relieving) NO



Check if alarm indicator goes ON when overload alarm relay and work light relay 2 (R4).



· Key switch: ON Using Dr. ZX, monitor boom bottom pressure and overload alarm. Check if the following conditions are met:



· Monitor items: Conditions Boom bottom pressure : 14.7 MPa or higher Tr/Sw/Overload alarm : Load are displayed by outline type fonts.



NO



T5-5-20



Disconnect overload alarm relay connector. Check if alarm indicator goes ON when connecting relay NO terminal #2 to the body.



TROUBLESHOOTING / Troubleshooting C



Monitor From Fuse #18 Connector (1)



MC



Boom Bottom Pressure Sensor Diode



Cancellation Switch



Transistor Unit



Overload Alarm Relay T1GL-05-05-001



Faulty Monitor. Broken harness between monitor and connector (1). Faulty overload alarm relay. Faulty transistor unit, or broken harness between overload alarm relay terminal #2 and transistor unit terminal #4.



YES



NO



Disconnect cancellation switch connector. Check if there is continuity between cancellation switch connector terminals A and C.



Disconnect overload alarm circuit connector (1). Check if there is continuity at YES the following harnesses:



YES



NO



Faulty diode. Broken harness across connection without continuity.



· between connector (1) terminal #8 and diode A terminal · between diode terminal K and overload alarm relay terminal #3 · between overload alarm relay terminal #5 and cancellation switch C terminal · between cancellation switch terminal A and connector (1) terminal #3



Faulty cancellation switch. NO Faulty boom bottom pressure sensor or faulty MC.



· Refer to T4-6-1.



T5-5-21



TROUBLESHOOTING / Troubleshooting C Connector (Harness end connector terminals seen from the open end side) Monitor Connector C (20P) 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



Connector (Monitor end connector terminals seen from the open end side) Connector (1) 1 2 3 4 5 6 7 8 9 10



Normally, alarm indicator goes ON.



YES



Using Dr.ZX, monitor boom bottom pressure and overload alarm to check if the following conditions are met:



· Monitor items: Conditions Boom bottom pressure : 14.7 MPa or higher Tr/Sw/Overload alarm: Load are displayed by outline type fonts.



YES



Check if alarm indicator goes OFF when overload alarm relay and work light relay 2 (R4) are switched.



Check if load alarm buzzer sounds. NO



NO



T5-5-22



Check if alarm indicator goes OFF when disconnecting monitor connector C (20P).



TROUBLESHOOTING / Troubleshooting C



Monitor From Fuse #18 Connector (1)



MC



Boom Bottom Pressure Sensor Diode



Cancellation Switch



Transistor Unit



Overload Alarm Relay T1GL-05-05-001



Faulty boom bottom pressure sensor or faulty MC. · Refer T4-6-1. Faulty overload alarm relay.



YES



NO



Check if alarm indicator goes OFF when exchanging transistor unit with transistor unit 1 on the body.



YES



Faulty transistor unit.



NO



Short-circuited harness between overload alarm relay and transistor unit.



Short-circuited harness between monitor and diode A terminal.



YES



Faulty monitor. NO



T5-5-23



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF AUTO-ACCELERATION INDICATOR • Check for loose harness connections beforehand.



YES Auto-acceleration indicator does not go ON even when selecting auto-acceleration.



Disconnect monitor end connector B (20P). Check if voltage at monitor end connector terminal #11 is 5 V. NO



· Engine speed control mode selection switch: Dial or Creeper position



Check if indicator goes ON when exchanging auto-acceleration cancellation relay (R26) with parking brake alarm relay (R23).



YES



NO



YES Auto-acceleration indicator goes ON even if auto-acceleration is not selected.



Check if indicator goes OFF when disconnecting switch box connector.



· Auto-idle/acceleration selection switch: Auto-Idle or OFF



· Key switch: ON NO



Disconnect switch box connector. Check if indicator goes ON when connecting harness end connector terminal #9 to the body.



Faulty switch box.



Check if indicator goes OFF when disconnecting monitor end connector B (20P).



YES



NO · Key switch: ON



T5-5-24



Short-circuited harness between monitor and switch box.



Faulty monitor.



TROUBLESHOOTING / Troubleshooting C



Blown indicator bulb or faulty monitor. Faulty auto-acceleration cancellation relay (R26).



YES



Faulty switch box.



Broken harness between switch box and auto-acceleration cancellation relay (R26).



NO



Connector (Harness end connector terminals seen from the open end side) Switch Box



Monitor Connector B (20P) 4



3



2



1



16 15 14 13 12 11



10



9



8



7



6



5



●



10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



T5-5-25



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF AUTO-IDLE INDICATOR • Check for loose harness connections beforehand.



Check if indicator does not go ON even when auto-idle is working.



Disconnect monitor end connector B (20P). Check if voltage at monitor end connector terminal #10 is 5 V.



Blown indicator bulb or faulty monitor.



YES



Broken harness between switch box and monitor. NO



YES



Indicator goes ON even if auto-idle is not working.



Reconnect connector. Check if indicator goes ON when disconnecting monitor end connector B (20P).



Disconnect switch box connector. Check if indicator goes ON.



YES



Faulty monitor.



NO



Short-circuited harness between switch box and monitor.



Faulty switch box. NO



Connector (Harness end connector terminals seen from the open end side) Switch Box



4



3



2



1



16 15 14 13 12 11



10



9



8



7



6



5



●



Monitor Connector B (20P)



10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



T5-5-26



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF DIGGING INDICATOR OR ATTACHMENT INDICATOR



MODE MODE



• If digging mode indicator or attachment mode indicator is malfunctioning, blown bulb or faulty monitor is suspected, respectively. If malfunctioning is not remedied even after replacing a faulty bulb with a new one, replace monitor assembly.



T5-5-27



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF LCD • The following items are described: 1 to 3: To be displayed in the standard mode. 4 to 8: To be displayed in the user’s mode. 9 to 24: To be displayed with built-in diagnosing system • In case only LCD is abnormal, the machine will normally operate.



Display Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24



Description Hour Meter Trip 1 Trip 2 Actual Engine Speed Hydraulic Oil Temperature



Load Alarm Hydraulic Oil Filter Fault Code ML Switch Pump 1 Delivery Pressure Pump 2 Delivery Pressure Pump 1 Control Pressure Pump 2 Control Pressure Target Engine Speed EC Angle Dial Angle Boom Raise Lever Stroke Arm Roll-In Lever Stroke Swing Lever Stroke Travel Lever Stroke Front Attachment Lever Stroke Attachment Lever Stroke Work Mode



Cause of Trouble Refer to the next page. Faulty Monitor. In case Dr. ZX can display data, monitor is abnormal or communication between monitor and MC is interrupted. In case Dr. ZX doesn’t display data, corresponding signal sensor is faulty. (The machine must have any abnormality in the control system. Refer to Troubleshooting B.) Faulty monitor or interrupted communication between ML controller and monitor. Faulty monitor or interrupted communication between ICX controller and monitor. In case Dr. ZX can display data, monitor is abnormal or communication between monitor and MC is interrupted. In case Dr. ZX doesn’t display data, corresponding signal sensor is faulty. (The machine must have any abnormality in the control system. Refer to Troubleshooting B.)



T5-5-28



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF HOUR METER • Check for loose harness connections beforehand.



NOTE:



∗



Regulator terminals L are water-resistant type connectors so that it is not practical to measure voltage at these terminals. Measure voltage at starter relay terminal R instead. Check for continuity between starter relay terminal R and regulator terminal L beforehand.



Lower than 12 V Hour meter doesn’t count operating hours with engine running.



Measure voltage at ∗ regulator terminal L.



Higher than 12 V -1



· Engine: Running



Faulty regulator or alternator.



· Engine speed: 900 min (rpm) or faster



Measure voltage at monitor connector A Higher than (16P) terminal #2. 12 V Lower than 12 V



Connector (Harness end connector terminals seen from the open end side) Monitor Connector A (16P) 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9



Starter Relay E S



R



T5-5-29



Faulty monitor.



Broken harness between regulator terminal L and monitor.



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF BLADE/STABILIZER INDICATOR • Check that indicator bulb is not blown. • Check for loose harness connections beforehand.



Connector (Harness end connector terminals seen from the open end side) Monitor Connector C (16P) 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9



Connector (1) 2 1 4 3



Blade/Stabilizer Selection Switch



Front/Rear Selection Switch



Left/Right Selection Switch



1 2 3 4 5 6



1 2 3 4 5 6



1 2 3 4 5 6



YES YES



Check if voltage at diode (D2) terminal #1 is 12 V.



Disconnect connector (1). Check if voltage at monitor end connector terminal #2 is 12 V.



NO



Indicator does not go ON even if blade/ stabilizer selection switch is ON. · Blade/Stabilizer Selection Switch: ON · Front/Rear Selection Switch: Front · Left/Right Selection Switch: Right



Check if stabilizer (front right) operates. Check if there is continuity YES across the following connections.



Disconnect each switch connector. Check if there is continuity across the following NO connections.



· Blade/stabilizer selection switch between terminals #1 and #2 · Front/rear selection switch between terminals #1 and #2 · Left/right selection switch between terminals 4 and #5



T5-5-30



· Between diode (D2) terminal #2 and front/rear selection switch terminal #1 · Between front/rear selection switch terminal #2 and left/right selection switch terminal #4 · Between left/right selection switch terminal #5 and blade/stabilizer selection switch terminal #1 · Between blade/stabilizer selection switch terminal #2 and body



NO



TROUBLESHOOTING / Troubleshooting C Monitor Blade/Stabilizer Selection Switch



Left/Right Selection Switch



Front/Rear Selection Switch



Diode (D2)



Connector (1) T1GL-05-05-002



Faulty diode (D2). YES



Broken harness between connector (1) and diode (D2). YES



NO



Check if voltage at monitor end connector terminal #14 is 12 V.



Broken harness between monitor and connector (1). Faulty monitor.



NO YES



Faulty diode (D2).



Broken harness without continuity. NO



Faulty switch without continuity.



T5-5-31



TROUBLESHOOTING / Troubleshooting C



Connector (Harness end connector terminals seen from the open end side) Connector (1)



Monitor Connector C (16P) 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9



2 1 4 3



Blade/Stabilizer Selection Switch



Front/Rear Selection Switch



Left/Right Selection Switch



1 2 3 4 5 6



1 2 3 4 5 6



1 2 3 4 5 6



YES



Indicator goes ON even if blade/stabilizer selection switch is OFF.



· Blade/Stabilizer Selection Switch: OFF · Front/Rear Selection Switch: Front · Left/Right Selection Switch: Right



Check if indicator goes OFF when disconnecting blade/ stabilizer selection switch connector.



YES



NO



Check if continuity between left/right selection switch harness end connector terminal #5 and blade/stabilizer selection switch harness end connector terminal #1.



Check if indicator goes OFF when disconnecting left/right selection switch connector.



NO



T5-5-32



Check if indicator goes OFF when disconnecting front/rear selection switch connector.



TROUBLESHOOTING / Troubleshooting C Monitor Blade/Stabilizer Selection Switch



Left/Right Selection Switch



Front/Rear Selection Switch



Diode (D2)



Connector (1) T1GL-05-05-002



Faulty blade/stabilizer selection switch.



Short-circuited harness between left/right selection switch terminal #5 and blade/stabilizer selection switch terminal #1.



YES



Faulty left/right selection switch. NO Check if continuity between front/rear selection switch harness end connector terminal #2 and left/right YES selection switch harness end connector terminal #4.



Short-circuited harness between front/rear selection switch terminal #2 and left/right selection switch terminal #1.



YES



Faulty front/rear selection switch. NO Short-circuited harness between connector (1) and front/rear selection switch.



YES



NO



Check if indicator goes OFF when disconnecting connector (1)



NO



Check if indicator goes OFF when disconnecting monitor end connector C (16P).



YES



Faulty monitor. NO



T5-5-33



Short-circuited harness between monitor and connector (1).



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF BUZZER • Check for loose harness connections beforehand.



NOTE: *Regulator terminals L are water-resistant type connectors so that it is not practical to measure voltage at these terminals. Measure voltage at starter relay terminal R instead. Check for continuity between starter relay terminal R and regulator terminal L beforehand.



Faulty engine oil pressure system.



YES Buzzer continues to sound when engine is started.



Check if engine oil pressure indicator lights.



YES



Overheat of engine.



Check if overheat indicator lights. NO



Faulty monitor. NO



Buzzer doesn’t sound even if engine oil pressure indicator or overheat indicator lights with engine running.



NO



Normal.



Check if engine speed is 900 min-1 (rpm) or faster.



NO



YES



Perform troubleshooting of indicator staying ON.



Check if alternator indicator lights.



YES



Measure voltage at regulator terminal L.* -1



· Engine speed: 900 min (rpm) or faster.



T5-5-34



TROUBLESHOOTING / Troubleshooting C



Connector (Harness end connector terminals seen from the open end side) Monitor Connector A (16P)



Starter Relay



8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9



E S



R



Lower than 12 V or more than 35 V



Faulty regulator and alternator.



Lower than 12 V or higher than 35 V



Between 12 V and 35 V



Broken harness between regulator terminal L and monitor.



Measure voltage at monitor connector A (16P) terminal #2. Faulty monitor.



-1



· Engine speed: 900 min (rpm) or faster



Between 12 V and 35 V



T5-5-35



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF TURN SIGNAL INDICATOR • Check for loose harness connections beforehand.



• If turn signal does not flash, MALFUNCTION of flasher relay is suspected.



YES Although turn signal switch is turned ON, turn light on one side and turn signal indicator do not flash.



Check if all turn lights and turn signal indicators go ON or flash when hazard switch is turned ON.



NO



Faulty turn signal switch.



Check if phenomena is reversed between left and right when left turn signal relay (R15) and right turn signal (R16) are exchanged.



YES



· Left: Relay R15 · Right: Relay R16



NO



YES Turn light and turn signal indicator flash even if turn signal switch is not turned ON.



Check if phenomenon is reversed between left and right when left turn signal relay (R15) and right relay (R16) are exchanged.



Faulty turn signal relay.



Blown bulb or broken harness between column box and turn signal relay.



Faulty turn signal relay. · Left: Relay R15 · Right: Relay R16



NO



T5-5-36



Faulty turn signal switch, or short-circuited harness between column box and turn signal relay.



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF TRAVEL MOTOR INDICATOR • Malfunction of travel motor can be found by



Connector (Harness end connector terminals seen from the open end side)



buzzer and indicator.



• Notice that buzzer does not sound, and indicator does not go ON if both column box buzzer circuit and travel motor indicator circuit are faulty, even in the case of malfunction of travel motor. In this case, make judgment depending on traveling conditions. Refer to troubleshooting B “T-1 The machine doesn’t travel” and “T-3 Travel speed is slow and travel power is weak in both forward and reverse directions”. • Check for loose harness connections beforehand.



Column Box: Connector D (12P)



１



2



6



7



3



○ 8



· Brake oil pressure indicator must be OFF.



Check if fault code 20 is displayed. · 20: Abnormal travel motor drain pressure sensor · Refer to T5-3-11.



Check if indicator goes ON when travel motor alarm relay (R22) and travel reverse Pi cut relay NO (R25) are exchanged.



Faulty travel motor alarm relay (R22).



YES



NO



Disconnect column box connector D (12P). Check if voltage at harness end connector terminal #11 is 24 V.



Faulty travel motor indicator.



NO



Broken harness between travel motor alarm relay (R22) and column box.



YES



Check if fault code 20 is displayed. · 20: Faulty travel motor drain pressure sensor · Refer to T5-3-11.



Check if indicator goes OFF when travel motor alarm relay (R22) and travel reverse Pi cut relay NO (R25) are exchanged.



Refer to troubleshooting A.



YES



Faulty travel motor alarm relay (R22).



Faulty column box. NO



T5-5-37



To A



YES



A



Indicator goes ON even if buzzer does not sound.



5



Refer to troubleshooting A.



YES



Buzzer sounds, but indicator does not go ON.



4



9 10 11 12



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF WORK LIGHT INDICATOR • Confirm that work light switch (switch box) and light switch (column box) are ON.



• If clearance light indicator cannot goes ON, malfunction of common circuit for both clearance light indicator and work light indicator is suspected. Refer to “Malfunction of Clearance Light Indicator”. • Check for loose harness connections beforehand.



Disconnect column box connector D (12P). Check if voltage at harness conYES nector #12 terminal is 24 V. Work light indicator does not go ON even if work light switch is turned ON.



NO



Check if work light goes ON.



NO



Check if voltage at work light relay 1 (R3) terminal #3 is 24 V.



Check if indicator goes OFF when work light reYES lays 1 (R3) and 2 (R4) are exchanged. Work light indicator goes ON even if work light switch is at OFF position.



YES



Faulty work light indicator. Broken harness between work light relay 1 (R3) and column box.



NO



Blown fuse #11, or broken harness between fuse #11 and work light relay 1 (R3).



YES



Check if indicator goes ON when work light relays 1 (R3) and 2 (R4) are exchanged.



YES



Faulty work light relay 1 (R3).



NO



Check if work light goes ON.



Short-circuited harness between work light relay 1 (R3) and column box.



NO



T5-5-38



TROUBLESHOOTING / Troubleshooting C



Faulty work light relay 1 (R3).



YES



Disconnect switch box connector. Check if voltage at harness end connector termiNO nal #13 is 24 V.



Check if there is continuity between switch box end conYES nector terminal #13 and body.



Reconnect disconnected connector. Disconnect column box connector D YES (12P). Check if voltage at harness end connector terminal #12 is 24 V.



YES Faulty work light.



NO



Faulty work light switch. NO · Work light switch: ON



Broken harness between work light relay 1 (R3) and switch box.



NO



Check if indicator goes OFF when switch box connector is disconnected.



YES



Faulty work light switch. Short-circuited harness between work light relay 1 (R3) and switch box.



NO Connector (Harness end connector terminals seen from the open end side) Column Box: Connector D (12P)



１



2



6



7



○ 8



9



Broken harness between wok light relay 1 (R3) and column box.



3



4



10



11 12



5



Switch Box



4



3



2



1



16 15 14 13 12 11



10



9



8



7



T5-5-39



6



5



●



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF SHIFT LEVER INDICATOR • Check for loose harness connections beforehand. NOTE: An example of faulty indicator N is described below.



Check if indicator goes ON when neutral relay (R21) and travel alarm relay YES (R22) are exchanged. Indicator N does not go ON even if shift lever is moved to N position.



Check if voltage at neutral relay (R21) terminals #3 and #1 is 24 V.



NO



YES



Faulty neutral relay (R21).



NO



Disconnect shift lever connector. Check if voltage at harness end connector terminal #1 is 24 V.



YES



Faulty fuse #28.



Check if indicator goes ON when fuses #28 and #29 are exchanged. NO



YES Indicator N goes ON even if shift lever is moved to position other than N position.



Broken harness between fuse #28 and neutral relay (R21).



Faulty neutral relay (R21).



Check if indicator N goes OFF when neutral relay (R21) and travel alarm relay (R22) are exchanged.



Check if indicator N goes OFF when shift lever connector is disconnected.



NO



T5-5-40



TROUBLESHOOTING / Troubleshooting C



Reconnect disconnected connector. Disconnect column box connector D (12P). Check if voltage at YES harness end connector terminal #5 is 24 V.



Check if there is continuity between shift lever conYES nector end terminals #1 and #5.



YES



Faulty column box.



Broken harness between neutral relay (R21) and column box.



NO



Faulty shift lever. NO YES



Broken harness between diode (D9) and shift lever.



Check if voltage at diode YES (D9) terminal #2 is 24 V.



NO



Faulty diode (D9).



Check if voltage at diode (D9) terminal #1 is 24 V.



NO Faulty diode (D9), or broken harness between neutral relay (R21) and diode (D9).



NO



YES



Faulty shift lever.



Short-circuited harness between diode (D9) and shift lever.



YES



NO



Remove diode (D9). Check if voltage at diode (D9) terminal #1 is 24 V.



Short-circuited harness between neutral relay (R21) and diode (D9).



NO Connector (Harness end connector terminals seen from the open end side) Column Box: Connector D (12P)



１



2



6



7



○ 8



9



Shift Lever



3



4



5



1



2



3



10



11 12



4



5



6



T5-5-41



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF WORK BRAKE INDICATOR • Check for loose harness connections beforehand.



Indicator goes ON even if brake switch is not at S (work) position.



Check if indicator goes OFF when column box connector B (9P) is disconnected.



Reconnect disconnected connector. Check if indicator goes OFF when work brake YES indicator relay (R18) and left turn signal relay (R15) are exchanged.



NO



YES



Faulty work brake indicator (R18).



NO



Short-circuited harness between work brake indicator (R18) and brake switch.



Faulty logic circuit in column box.



YES



Indicator does not go ON even if brake switch is at S (work) position.



Disconnect brake switch connector. Check if indicator goes ON when harness end connector #3 is connected to body.



NO



Connector (Harness end connector terminals seen from the open end side) Column Box: Connector B (9P)



１



2



3



4



5



6



7



8



9



T5-5-42



Check if indicator goes ON when work brake indicator relay (R18) and left turn signal relay (R15) are exchanged.



TROUBLESHOOTING / Troubleshooting C



Faulty brake switch.



Faulty work brake indicator relay (R18).



YES



NO



Disconnect brake switch connector. Check if voltage at harness end connector #3 is 24 V.



Disconnect column box connector B (9P). Check if voltage at YES harness end connector terminal #5 is 24 V.



NO



T5-5-43



YES



Faulty logic circuit in column box or blown bulb.



NO



Broken harness between work brake indicator relay (R18) and column box.



Broken harness between work brake indicator relay (R18) and brake switch.



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PARKING BRAKE INDICATOR • Check for loose harness connections beforehand. NOTE: Operating condition of parking brake pressure switch: (Holding pressures of transmission High/Low Selection Circuit) ON: 2.1 to 2.6 MPa OFF: 2.6 MPa



YES Check if indicator goes OFF when parking brake pressure switch connector is disconnected.



Indicator goes ON even if brake switch is not at P (parking) position.



YES



NO



Check if indicator goes OFF when diode (D19) is removed.



NO



Reconnect disconnected connector. Check if voltage at diYES ode (D19) terminal #1 is 24 V. Indicator does not go ON even though brake switch is at P (parking) position.



Disconnect column box connector B (9P). Check if voltage at column box connector terminal #8 is 24 V. NO



Connector (Harness end connector terminals seen from the open end side) Column Box: Connector B (9P)



１



2



3



4



5



6



7



8



9



YES



T5-5-44



NO



TROUBLESHOOTING / Troubleshooting C



Faulty parking brake pressure switch.



Short-circuited harness between diode (D19) and parking brake pressure switch.



Check if indicator goes OFF when column box connector B (9P) is disconnected.



YES



Short-circuited harness between column box and diode (D19).



Faulty logic circuit in column box. NO Disconnect parking brake pressure switch connector. Check if voltage at harness end connector terminal #2 is 24 V.



YES



NO



Faulty parking brake pressure switch.



Faulty diode (D19) or broken harness between diode (D19) and parking brake pressure switch.



Broken harness between column box and diode (D19).



Faulty logic circuit in column box or blown bulb.



T5-5-45



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF AXLE LOCK INDICATOR • Confirm that brake switch is at position other than OFF position. If brake switch is at OFF position, axle lock is released, so indicator does not go ON. Refer to SYSTEM/Control System group in the T/M (Operating Principle). • Check for loose harness connections beforehand.



Check if indicator goes ON when axle lock relay (R19) and right YES turn signal relay (R16) are exchanged.



Indicator does not go ON.



Check if voltage at axle lock relay (R19) terminals #1 and #3 is 24 V.



YES



Disconnect column box connector B (9P). Check if voltage at harness end terminal #3 is 24 V. NO



· Brake switch: Other than OFF position



NO



Check if indicator goes ON when fuses #28 and #29 are exchanged.



YES



Indicator goes ON even if brake switch is OFF position.



· Brake switch: OFF position



Check if indicator goes OFF when axle lock relay (R19) and right turn signal relay (R16) are exchanged.



YES



NO



Check if indicator goes OFF when connector B (9P) is disconnected from column box.



NO



T5-5-46



Disconnect brake switch connector. Check if continuity between brake switch end connector terminal #4 and #6.



TROUBLESHOOTING / Troubleshooting C Connector (Harness end connector terminals seen from the open end side) Column Box: Connector B (9P)



１



2



3



4



5



6



7



8



9



Brake Switch



1



2



3



4



5



6



Faulty axle lock relay (R19).



YES



NO YES



NO



Faulty logic circuit in column box.



Broken harness between axle lock relay (R19) and column box.



Faulty fuse #28.



Broken harness between fuse #28 and axle lock relay (R19).



Faulty axle lock relay (R19).



YES



NO



Broken harness between axle lock relay (R19) and brake switch.



Faulty brake switch.



Faulty column box.



T5-5-47



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF CLEARANCE LIGHT INDICATOR • If indicator goes ON when light switch is OFF and clearance light is OFF, column box can malfunction. If clearance lights on front and rear on right side as well as their indicators go ON when light switch is OFF, right clearance light relay (R12) can malfunction. • Check for loose harness connections beforehand.



Clearance lights at front and rear on left side as well as their indicators does not go ON.



YES Check if voltage at left clearance light relay (R28) terminals #1 and #3 is 24 V. NO



· Light switch: ON · Clearance lights at front/rear on right side: ON



Clearance light goes ON, but indicator does not go ON.



Disconnect column box connector B (9P). Check if voltage at harness end connector terminal #9 is 24 V.



· Light switch: ON



YES



NO



Connector (Harness end connector terminals seen from the open end side) Column Box: Connector B (9P)



１



2



3



4



5



6



7



8



9



T5-5-48



Faulty clearance left light relay (R28).



Faulty fuse #31, or faulty harness between fuse #31 and left clearance light relay (R28).



Faulty logic circuit in column box or blown bulb.



Broken harness between column box terminal #9 and right clearance light relay (R12).



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF HAZARD LIGHT INDICATOR • The hazard light indicator comes ON when lighting signal is inputted to the logic circuit in the column box from both left and right turn signals. Therefore, the hazard light indicator does not come ON when the signal is coming from only one side. If the hazard light indicator does not come ON even if both turn signals are lighting or blinking, blown bulb, broken wiring within column box, or failure in logic circuit may be suspected. If only one side of turn signal indicator comes ON/blinks, refer to Troubleshooting “Malfunction of Turn Signal Indicator”. • Check for loose harness connections beforehand.



T5-5-49



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF HIGH-BEAM INDICATOR • Check for loose harness connections beforehand.



Check if indicator goes ON when high-beam relay (R14) and parking YES brake relay (R11) are exchanged. High-beam indicator does not go ON even if light switch is at high-beam position.



Indicator goes ON even if light switch is not at high-beam position.



Check if voltage at high-beam relay (R14) terminals #1 and #3 is 24 V.



YES



Faulty high-beam relay (R14).



NO



Disconnect light switch connector A (6P). Check if voltage at harness end connector terminal #5 is 0 V.



NO



Faulty fuse #23, or broken harness between fuse #23 and high-beam relay (R14).



YES



Faulty high-beam relay (R14).



Check if indicator goes OFF when high-beam relay (R14) and parking brake relay (R11) are exchanged.



YES



NO



Check if indicator goes OFF when column box connector B (9P) is disconnected.



Reconnect disconnected connector. Check if indicator goes OFF when light switch connector A (6P) is disconnected.



Faulty column box. NO



T5-5-50



TROUBLESHOOTING / Troubleshooting C



Broken harness between high-beam relay (R14) and light switch.



YES



Check if there is continuity between light switch end connector NO terminals #2 and #5.



Reconnect disconnected connector. Disconnect column box connector B (9P). Check if voltage at YES harness end connector terminal #2 is 0 V.



YES



NO



Broken harness between high-beam relay (R14) and column box.



Faulty logic circuit in column box or blown bulb.



Faulty light switch. NO



YES



Faulty light switch.



NO



Short-circuited harness between high-beam relay (R14) and light switch.



Connector (Harness end connector terminals seen from the open end side) Column Box: Connector B (9P)



１



2



3



4



5



6



7



8



9



Light Switch: Connector A (6P)



1 3



T5-5-51



2



● 4



5



6



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF BUZZER IN COLUMN BOX NOTE: An example of travel motor indicator is described below.



• If buzzer in column box sounds, travel motor indicator, parking brake indicator or brake oil indicator must go ON at the same time. • If buzzer sounds even though each indicator is not ON, or if buzzer does not sound even though each indicator is ON, Check buzzer circuit and each indicator circuit. (Refer to “Malfunction of Indicator.) • Check for loose harness connections beforehand.



YES Disconnect column box connector H (buzzer). Check if voltage at harYES ness end connector terminal #1 is 0 V.



Travel motor light goes ON, but buzzer does not sound.



Disconnect column box connector I (9P). Check if voltage at column box connector terminal #1 is 0 V.



Check if there is continuity between column box connecNO tor terminals #1 and #2.



Check if voltage at diode (D15) terminal #2 is 0 V.



YES



NO



Check if voltage at diode (D20) terminal #2 is 0 V.



NO



Broken harness between diodes (D15) and (D20).



Broken harness between diode (D20) and travel motor alarm relay (R22).



Reconnect disconnected conYES nector. Check if buzzing stops Reconnect disconnected when diode (D15) is removed. connector. Check if buzzing stops when colYES umn box connector H (buzzer) is disconnected. Buzzer sounds even if travel motor indicator goes OFF.



Check if buzzing stops when column box connector I (9P) is disconnected.



NO



NO



T5-5-52



TROUBLESHOOTING / Troubleshooting C



Connector (Column box end connector terminals seen from the open end side)



Connector (Harness end connector terminals seen from the open end side)



Column Box: Connector H (Buzzer)



１



Column Box: Connector I (9P)



2



１



2



3



4



5



6



7



8



9



YES



Faulty logic circuit in column box.



NO



Broken harness between connector I terminal #1 and connector H (buzzer) terminal #1.



Broken harness between connector H (buzzer) terminal #2 and diode (D15).



YES



Faulty buzzer in column box. NO



Short-circuited harness between diodes (D15) and (D20).



YES



Short-circuited harness between column box buzzer and diode (D15).



NO



Short-circuited harness between column box terminals #I-1 and #H-1.



Faulty logic circuit in column box.



T5-5-53



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF BRAKE OIL PRESSURE GAUGE • Check for loose harness connections beforehand.



YES



Pressure gauge does not swing at all.



Disconnect pressure gauge connector. Check if voltage at harness end connector terminal #1 is 5 V.



· Key switch: ON



Check if gauge pointer swings toward upper limit when pressure sensor harness end connecter terminals #1 and #2 are connected.



· Key switch: ON · Connection is made using clip.



YES Reconnect disconnected connector. Disconnect column box connector B (9P). Check if voltage at harness end connector NO terminal #6 is 0.5 V or more.



NO



YES Pressure gauge pointer swings excessively.



Check if the pointer returns toward lower limit when pressure sensor connector is disconnected.



· Key switch: ON



NO



Faulty pressure sensor.



Disconnect column box connector B (9P), with pressure sensor connector disconnected. Check if there is continuity between harness end connector terminal #6 and body.



YES



Short-circuited harness between pressure sensor and column box.



Faulty column box. NO



Pressure gauge pointer fluctuates.



Disconnect pressure sensor connector. Check if pointer swings toward upper limit when harness end connector terminals #1 and #2 are connected.



Faulty pressure sensor.



YES



NO



Check if the pointer returns toward lower limiter when column box connector B (9P) is disconnected.



· Key switch: ON · Connection is made using clip.



Short-circuited harness YES between pressure sensor and column box.



Faulty column box. NO



T5-5-54



TROUBLESHOOTING / Troubleshooting C



Faulty pressure sensor.



YES



Faulty column box.



Broken harness between pressure sensor and column box.



NO



Broken harness between MC and pressure sensor.



Brake Oil Pressure Gauge



Connector (Harness end connector terminals seen from the open end side) Column Box: Connector B (9P) １



2



3



4



5



6



7



8



9



MCBB-01-006



Pressure and Voltage of Pressure Gauge Standard Pressure bar 0 90 160 200 (MPa) (0) (9) (16) (20) (kgf/cm2) (0) (92) (163) (204) Voltage (V) 0.5 1.23 1.81 2.13 Tolerance



±3.75



±7.5



－



±3.75



T5-5-55



Pressur Sensor (Brake Oil Pressure Sensor)



1



2



3



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF SPEED METER • Check for loose harness connections beforehand.



• If the malfunctioning occurs on the speed meter, it difficult to decide safely and surely whether the column box or the speed sensor is causing trouble. Therefore, determine the cause by replacing the speed sensor to the correctly functioning sensor. If the symptom disappears, the speed sensor is faulty. If the symptom still occurs, the column box is malfunctioning.



Speed meter pointer does not swing at all.



Using Dr. ZX, monitor travel motor speed. Check if it is within specifications.



YES



NO



Disconnect column box connector C (6P), both ring connector and brush connector of slip ring, and N sensor connector. Check if there is continuity among the following connections:



Faulty speed meter in column box.



· Refer to Performance Measurement. · Between N sensor terminal #1 and brush terminal #1 of slip ring · Between brush terminal #1 and ring terminal #1 of slip ring · Between ring terminal #1 of slip ring and connector C terminal #1 of column box



Speed meter pointer swings excessively.



Check if speed meter works normally when faulty N sensor is replaced with a sound one.



YES



Faulty N sensor.



Faulty column box. NO



Speed meter pointer fluctuates.



Disconnect ring connector and brush connector of slip ring. Check if there is continuity between brush terminal #1 and ring terminal #1 of slip ring, and between brush terminal #4 and ring terminal #4 of slip ring.



Reconnect disconnected connectors. Check if speed meter works normally when faulty N YES sensor is replaced with a sound one.



YES Faulty N sensor.



Faulty column box. NO Faulty slip ring. NO



T5-5-56



TROUBLESHOOTING / Troubleshooting C



YES



Check if speed meter works normally when faulty N sensor is replaced with a sound one.



YES



Faulty N sensor.



Faulty column box. NO Broken harness at connection without continuity.



NO



Connector (Harness end connector terminals seen from the open end side) Speed Meter



Column Box: Connector C (6P) １



2



3



4



5



6



Connector (Slip ring end connector terminals seen from the open end side) MCBB-01-006



Brush Side



T5-5-57



Ring Side



1



2



3



4



4



3



2



1



5



6



7



8



8



7



6



5



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF BRAKE OIL PRESSURE INDICATOR • Check for loose harness connections beforehand. NOTE: Operating conditions of brake remaining pressure switch: (Holding pressures of brake circuit between accumulator charging valve and brake valve) ON: 5.2 MPa or lower OFF: 5.2 to 6.4 MPa Disconnect column box connector B (9P). Check if voltage YES at column box connector terminal #7 is 24 V. Indicator does not go ON even though hydraulic pressure in brake circuit drops.



Faulty diode (D18), or broken harness between column box and diode (D18).



Faulty logic circuit in column box.



Check if buzzer sounds.



NO



Disconnect brake remaining pressure switch connector. Check if voltage at harness end NO terminal #2 is 24 V.



YES



Faulty brake remaining pressure switch.



NO



Broken harness between diode (D18) and brake remaining pressure switch.



YES



Disconnect brake remaining pressure switch connector. YES Check if voltage at harness end connector terminal #2 is 24 V. Indicator goes ON even in normal operation.



YES



Check if buzzer sounds.



NO YES



· Engine: Running NO



Check if indicator goes OFF when column box connector B (9P) is disconnected. NO



Faulty brake remaining pressure switch. Short-circuited harness between diode (D18) and brake remaining pressure switch. Short-circuited harness between connector B terminal #7 and diode (D18).



Faulty logic circuit in column box.



Connector (Harness end connector terminals seen from the open end side) Column Box: Connector B (9P)



１



2



3



4



5



6



7



8



9



Brake Remaining Pressure Switch



1



T5-5-58



2



3



TROUBLESHOOTING / Electrical System Inspection PRECAUTIONS FOR INSPECTION AND MAINTENANCE 1. Disconnect the power source. Be sure to remove the negative terminals from the batteries first when taking wire harnesses and connectors off for repair or replacement work. Failure to do so can result in damage to the wire harnesses, fuses, and fusible links and, in some cases, cause fire due to short circuiting. 2. Color coding of wire harnesses. The color codes of the wire harnesses in the electrical system are shown in the table on the right. In cases on the design sheet where two colors are indicated for one wire, the left initial stands for the base color, while the right initial stands for the marking color. NOTE: 1) Code BW indicates a black base wire with white fine-line marking. 2) Initials “O” and “Or” both stand for the color orange. 3) Wires with longitudinal stripes printed on them are not color coded. Be sure not to confuse them with color coded wires.



T5-6-1



Code R L Or



Color Red Blue Orange



Code W G Lg



Y Br Gr



Yellow Brown Gray



B P V



Color White Green Light green Black Pink Violet



TROUBLESHOOTING / Electrical System Inspection 3. Precautions for connecting and disconnecting terminal connectors. 1) When disconnecting harnesses, grasp them by their connectors. Do not pull on the wire itself. Be sure to release the lock first before attempting to separate connectors, if a lock is provided. (Refer to “Instructions for Disconnecting Connector” on page T5-6-3.) 2) Water-resistant connectors keep water out so that if water enters them, water will not easily drain from them. When checking water-resistant connectors, take extra care not to allow water to enter the connectors. In case water should enter the connectors, reconnect only after the connectors are thoroughly dried. 3) Before connecting terminal connectors, check that no terminals are bent or coming off. In addition, as most connectors are made of brass, check that no terminals are rusting. 4) When connecting terminal connectors provided with a lock, be sure to insert them together until the lock “clicks.” 5) Pull the harness near the connector to check if it is correctly connected. 4. Precaution for using a circuit tester. 1) Before using a circuit tester, refer to the instructions in the circuit tester manual. Then, set the circuit tester to meet the object to be measured, voltage range and current polarity. 2) Before starting the connector test, always check the connector terminal numbers, referring to the circuit diagram. When the connector size is very small, and the standard probe size is too large to be used for testing, wind a fine piece of sharpened wire or a pin around the probe to make the test easier.



T5-6-2



Right



Wrong



T107-07-06-001



Right Rust Wrong (Deformation) Wrong (Separation) T107-07-06-002



Wind a Piece of Wire



Tester Probe



Sharpen the end of the Wire T107-07-06-003



TROUBLESHOOTING / Electrical System Inspection INSTRUCTIONS CONNECTORS



FOR



DISCONNECTING



• Push to Unlock and Separate Type NOTE: Most of connectors are “Push to Unlock and Separate Type”. NOTE: Connectors will not be easily separated even if the lock is pushed while being pulled. Push the lock first before pulling the connectors. The lock is located on female side connector (harness end side).



T107-04-05-002



• Pull Up to Unlock and Separate Type Locations of This Type Connector Starter Relay



T107-04-05-003



• Pull to Separate Type IMPORTANT: Generally, the solenoid valve connector has a lock. Always pull to separate the connector only after unlocking using a tool such as a pair of needle nose pliers. Locations of This Type Connector



T107-04-05-004



Hydraulic Oil Temperature Sensor Dr. ZX



T5-6-3



TROUBLESHOOTING / Electrical System Inspection FUSE INSPECTION Cracks in a fuse are so fine that it is very difficult or impossible to find by visual inspection. Use a tester to correctly inspect fuse continuity by following the instructions described below. 1. Turn Key Switch ON When the key switch is turned ON, current from key switch terminal M activates the battery relay so that electric power is supplied to all circuits except the glow plug relay circuit. (Refer to the circuit diagram.) 2. Remove the fuse box cover. Set the tester voltage to meet the circuit specification to be measured. (Measurement Range: 0 to 30 V) 3. Ground the negative probe of the tester to the vehicle frame. Touch the terminals located away from the center of the fuse box with the positive probe of the tester one at a time. When normal continuity of a fuse is intact, the tester will indicate 20 to 25 V (battery voltage).



T5-6-4



NOTE: All terminals located along the lengthwise centerline of the fuse box are connected to the power source, while terminals located away from the center of the fuse box are connected to loads (accessories). Therefore, test all fuses in the same method except for the glow plug relay circuit fuse. Check the glow plug relay circuit fuse with the key switch turned to the ON position then follow the procedure in step 3.



TROUBLESHOOTING / Electrical System Inspection



10



20



30



40



9



19



29



39



8



18



7



17



6



16



5



15



4



14



3



13



2



12



1



11



28 27 26 25 24 23 22 21



38 37 36 35 34 33 32 31



M178-07-034



Fuse No. 1 2 3 4



M178-07-034



Fuse No. 21 22 23 24



Capacity



Connected to



5A 5A 10 A 10 A



Radio, Monitor, ICX (Backup Power) MC (Main Power) MC (EC Motor Power) MC (Solenoid Valve Power)



5 6



5A 5A



Monitor MC, ICX (Power ON Signal), Parking Brake Relay 3



25 26



15 A 10 A



7 8



5A 5A



Air Conditioner Unit Optional 1



27 28



10 A 10 A



9 10 11 12



10 A 5A 20 A 10 A



29 30 31 32



13 14 15 16 17 18 19 20



20 A 10 A 5A 10 A 5A 10 A 5A 10 A



Optional 2 Optional 3 Work Light Relays 1 and 2 Wiper Relays A, B-1, B-2 and B-3, Wiper Motor, Washer Relay Heater (Air Conditioner Unit) Horn Relay Radio Cigarette Lighter Room Lamp Auxiliary QOS Controller, Glow Plug Relay Parking Brake Relay 1, Travel Motor Alarm Relay, Parking Brake Alarm Relay, Transistor Units 1 and 2, Travel Forward/Reverse Pi Cut Relay, Auto-Acceleration Cancel Relay



33 34 35 36 37 38 39 40



T5-6-5



Capacity



Connected to



10 A 10 A 10 A 10 A



10 A 10 A 10 A 10 A



Right Clearance Light Relay Head Light Relay (Right-Lower) High-Beam Relay Flasher Relay, Turn Signal Relay (Left and Right) Stop Lamp Relay Reverse Light (Reverse Light is only available in Japanese domestic market.) Column Box (Power ON Signal) Starter Relay, Work Brake Indicator Relay, Neutral Signal Relay, Axle Lock Relay Blade/Stabilizer Circuit (Optional) Assist Circuit (Optional) Left Clearance Light Relay Head Light Relay (Left-Lower)



10 A 10 A 15 A 10 A 10 A 5A 5A 10 A



Heater Seat (Optional) Seat Compressor (Optional) Warning Lamp (Optional) Rear Cab Lamp (Optional) Front Cab Lamp (Optional) Quick Hitch (Optional) Auxiliary 2 Auxiliary 3



TROUBLESHOOTING / Electrical System Inspection FUSIBLE LINK INSPECTION



Battery Relay



Inspection 1. Remove the negative cable from the battery. 2. Loosen bolt M8 holding the cable routed in front of the fusible link box to move the cable out of the way of the front cover. 3. Visually inspect the fusible link.



Replacement 1. Check that the negative cable is removed from the battery. 2. Remove bolt M8 to take the fusible link off the battery relay. 3. Take out the fusible link to replace it. 4. Install the fusible link box and the cable to the battery relay. 5. Reconnect the negative cable to the battery.



Fusible Link



M178-07-049



Fusible Link



T1GL-05-06-001



T5-6-6



TROUBLESHOOTING / Electrical System Inspection BATTERY VOLTAGE CHECK 1. Turn the key switch OFF. Check voltage between the battery positive terminal and the vehicle frame. Normal Voltage: 24 V NOTE: If voltage is abnormal, recharge or replace the battery. 2. Start the engine. Check voltage between the battery positive terminal and the vehicle frame. Normal Voltage: 26 to 28 V NOTE: If voltage is abnormal, check the charging system.



V



T157-07-06-007



T5-6-7



TROUBLESHOOTING / Electrical System Inspection HOW TO TROUBLESHOOT ALTERNATOR MALFUNCTIONS In general, the alternator indicator remains off when the alternator is generating power. If the alternator indicator comes on while the engine is running, the alternator might be defective. How to check the circuit 1. Stop the engine. Turn the key switch to the ON position. Confirm that the alternator indicator comes on. 2. Measure the voltage between teminals B and E terminals of the alternator. If the measured voltage is around 24 V, the alternator circuit can be considered normal. If the measured voltage is low, a shortage in battery capacity or looseness of the wire connectors of the alternator circuit might be the cause of the malfunction. When the voltage is 0 V, the wiring between the fuse box and alternator might be loose or disconnected. Also, the alternator cannot generate electricity if the ground line is disconnected. 3. Next, start the engine and measure the voltage generated while the alternator is rotating. As described above, measure the voltage between terminals B and E on the side of the alternator. If the voltage is around 28 V, the alternator is operating normally. If the rated voltage is not being generated, there is some trouble with the alternator or the regulator.



T5-6-8



B



E



T157-07-06-003



TROUBLESHOOTING / Electrical System Inspection (Blank)



T5-6-9



TROUBLESHOOTING / Electrical System Inspection CONTINUITY CHECK Harness



Single-line continuity check Disconnect both end connectors of the harness and check continuity between both ends: If the ohm-meter reading is: 0 Ω = Continuity ∞ Ω = Discontinuity NOTE: When the one end connector is far apart from the other, connect one end of connector (A) to the machine chassis using a clip. Then, check continuity of the harness through the vehicle frame as illustrated.



A



Ω



Connect to the vehicle frame.



Connect to the vehicle frame.



If the ohm-meter reading is: 0 Ω = Continuity ∞ Ω = Discontinuity



a



Single-line short-circuit check Disconnect both end connectors of the harness and check continuity between one end connector of the harness and the vehicle frame: If the ohm-meter reading is: 0 Ω = Short circuit is present. ∞ Ω = No short circuit is present.



a



A



Ω



a



A ×



Ω



Short-circuit between the harness and the vehicle frame.



T107-07-05-003



T5-6-10



TROUBLESHOOTING / Electrical System Inspection Multi-line continuity check Disconnect both end connectors of the harness, and short-circuit two terminals, (A) and (B), at one end connector, as illustrated. Then, check continuity between terminals (a) and (b) at the other connector. If the ohm-meter reading is ∞ Ω, either line (A) - (a), or (B) - (b) is in discontinuity. To find out which line is discontinued, conduct the single line continuity check on both lines individually, or, after changing the short-circuit terminals from (A) - (B) to (A) - (C), check continuity once more between terminals (a) and (c).



First short-circuit



A B C



a b c



Second short-circuit



Ω



NOTE: By conducting the multi-line continuity check twice, it is possible to find out which line is discontinued. With terminals (A) and (C) short-circuited, check continuity between terminals (a) and (c). If the ohm-meter reading is: 0 Ω = Line (B) - (b) has discontinuity. ∞ Ω = Line (A) - (a) has discontinuity. Multi-line short-circuit check Disconnect both end connectors of the harness, and check continuity between terminals (A) and (B) or (C). If the ohm-meter reading is: 0 Ω = Short-circuit exists between the lines. ∞ Ω = No short-circuit exists between the lines.



T107-07-05-004



Short-circuit between harnesses. A B C



×



a b c



Ω



T107-07-05-005



T5-6-11



TROUBLESHOOTING / Electrical System Inspection (Blank)



T5-6-12



TROUBLESHOOTING / Electrical System Inspection VOLTAGE MENT



AND



CURRENT



MEASURE-



Turn key switch ON so that the specified voltage (current) is supplied to the location to be measured. Judge if the circuit is normal by evaluating whether the measured voltage (current) matches the specification. 24-Volt Circuit Start checking the circuit in order up to the location to be measured from either power source or actuator side. Thereby, the faulty location in the circuit will be found. Black Probe (Minus) of Tester : To ground to the vehicle frame Red Probe (Plus) of Tester : To touch the location to be measured



T5-6-13



TROUBLESHOOTING / Electrical System Inspection Engine Power Source Circuit



Key Switch



Location to be Measured



Specification



OFF OFF OFF OFF OFF OFF



Between (2) and (1): One Battery Between (3) and (2): One Battery Between (3) and (1): Two Batteries Between (4) and Ground: Battery Power Between (5) and Ground: Fusible Link Between (1) and Ground: Backup Current*



10 to 12.5 V 10 to 12.5 V 20 to 25 V 20 to 25 V 20 to 25 V 6 mA



ON or START ON or START



Between (6) and Ground: Key Switch Between (7) and Ground: Glow Plug



20 to 25 V 20 to 25 V



START START START START START START



Between (8) and Ground: Key Switch Between (9) and Ground: Battery Relay (Coil) Between (10) and Ground: Battery Relay (Switch) Between (11) and Ground: Starter (B) Between (12) and Ground: Starter (C) Between (13) and Ground: Starter Relay (S)



20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V



Fast Speed



ON



26 to 30 V



Fast Speed



ON



Fast Speed



ON



Fast Speed Fast Speed



ON ON



Between (14) and Ground: Alternator (B) / Generating Voltage Between (10) and Ground: Battery Relay / Generating Voltage Between (15) and Ground: Fuse Box / Starter Relay (R) / Generating Voltage Between (16) and Ground: Generating Voltage Between (17) and Ground: Monitor



ON ON ON ON



Between (14) and Ground: Alternator (B) Between (16) and Ground: Starter Relay (R) Between (18) and Ground: Load Damp Relay Between (10) and Ground: Battery Relay



26 to 30 V 13 to 30 V 26 to 30 V 26 to 30 V



ON ON ON ON ON ON



Between (19) and Ground: Auxiliary Between (20) and Ground: Room light Between (21) and Ground: Lighter Between (22) and Ground: Radio Between (23) and Ground: Horn Between (9) and Ground: Battery Relay



20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V



Stopped Stopped Stopped Stopped Stopped Stopped



Preheat Circuit Stopped Stopped



Starting Circuit Started Started Started Started Started Started



Charging Circuit 26 to 30 V 26 to 30 V 13 to 30 V 13 to 30 V



Surge Voltage Prevention Circuit Slow Idle Slow Idle Slow Idle Slow Idle



Accessory Circuit Stopped Stopped Stopped Stopped Stopped Stopped



NOTE: *Measure after disconnecting the negative cable from the battery.



T5-6-14



TROUBLESHOOTING / Electrical System Inspection



Key Switch



Battery



1



2



3



5



4



6



9



8



15



Battery Relay



Fuse Box



10



Starter



18



Load Damp Relay



11 12



23



22 21 20 19



13



Starter Relay



17



Monitor



16



Alternator Glow Plug Relay



14 7 Glow Plug T178-05-06-001



T5-6-15



TROUBLESHOOTING / Electrical System Inspection 5 Voltage Circuit



• Voltage between terminal #1 and the vehicle



Signal or Ground



Power Source 1



Two Polarities



frame (ground) With the key switch turned OFF, disconnect the sensor connector. Measure the voltage between terminal #1 on the machine harness side connector and the vehicle (ground) under the following conditions.



2



V



• Key switch position: ON • Tester black terminal (negative): Connected to the vehicle (ground)



• Tester red terminal (positive):



T107-07-05-006



Connected to terminal #1



Power Source Signal Ground 1 2 3



Three Polarities



Evaluation: If the measuring voltage is within 5±0.5 volts, the circuit up to terminal #1 is normal.



V



• Voltage between terminal #1 and the ground terminal With the key switch turned OFF, disconnect the sensor connector. Measure the voltage between terminal #1 on the machine harness side connector and the ground terminal (terminal #2 for two polarities, or terminal #3 for three polarities) under the following conditions.



T107-07-05-007



Two Polarities 1



2



V



• Key switch position: ON • Tester black terminal (negative): Connected to the ground terminal (terminal #2 or 3) • Tester red terminal (positive): Connected to terminal #1



T107-07-05-008



Three Polarities 1



Evaluation: If the measuring voltage is within 5±0.5 volts, the circuit up to terminal #1 or the ground terminal is normal.



2



3



V



T107-07-05-009



T5-6-16



TROUBLESHOOTING / Electrical System Inspection CHECK BY FALSE SIGNAL



Two Polarities



Turn the key switch OFF. After disconnecting the sensor connector, turn the key switch ON. Then, connect machine side harness end connector terminal #1 (power) to terminal #2 (signal). (Power voltage is used as a false signal.) Check the controller using Dr. ZX monitor function under this condition. When the maximum value is displayed, the MC and the circuit up to the machine side harness end connector are normal. When the pressure switch circuits are normal, Dr. ZX displays “ON”. IMPORTANT: Don’t connect terminal #1 or #2 to terminal #3 or to the vehicle frame (ground) when checking a three-polarity connector. NOTE: Some kinds of sensors can be monitored by the built-in diagnosing system. (Refer to the TROUBLESHOOTING / General group.)



(Hydraulic Oil Temperature Sensor) (Fuel Sensor) (N Sensor)



1



2



Connect



T107-07-05-010



Three Polarities (Pressure Sensor) (Pump Delivery Pressure Sensor) (Pump Control Pressure Sensor) (Travel Motor Drain Pressure Sensor) (Service Brake Pressure Sensor) (EC Sensor)



1



2



3



Connect



T107-07-05-011



T5-6-17



TROUBLESHOOTING / Electrical System Inspection TEST HARNESS With a test harness installed between connectors, the circuit condition is checked depending on whether the test harness lamp lights or extinguishes during operation. Parts Number 4283594 (ST 7126) Use to check a single-line (discontinuity and/or voltage). During Operation: Lamp is ON.



To Location to be Measured.



To Ground T107-07-05-012



Parts Number 4283594 (ST 7126)



Parts Number (ST 7226) Use to check the solenoid valve unit circuits. When the corresponding control lever or switch is operated: Lamp is ON. (Refer to T5-4-60, 74 and 96.)



4 3 1



50



150



2



50



50



2



1 T107-07-06-015



Parts Number (ST 7226)



Parts Number 4274589 (ST 7125) Use to check the EC motor circuit. (Refer to T5-4-42 and 46.)



5 6



• EC Motor Circuit When the engine control dial is rotated: Both lamps ON: Normal Only one lamp ON: Check for continuity of the circuit connected to the lamp OFF. Both lamps OFF: Check the harness together with the relay.



1



2



4



3



50



150



50 50



1



4



3



50



7 8



Parts Number 4274589 (ST 7125)



T5-6-18



2



T107-07-06-024



TROUBLESHOOTING / Electrical System Inspection Parts Number 4284347 (ST 7129) Use to measure the EC sensor circuit signal line voltage (between terminals #2 and #3). (Refer to T5-3-4.)



(Red)



(Black) V



Parts Number 4284347 (ST 7129)



Parts Number (ST 7227) Use to check the wiper circuit. (Refer to T5-4-98.)



T107-07-03-009



2 5



1



2 4



7



1



Parts Number (ST 7227)



T5-6-19



T178-05-06-003



TROUBLESHOOTING / Electrical System Inspection (Blank)



T5-6-20



TROUBLESHOOTING / ICX OUTLINE The ICX (information controller) stores signals from various kinds of sensors and switches provided on the machine as data. The various input signals are grouped into “Daily Report Data List”, “Frequency Distribution Data List”, “Cumulative Operation Hour List”, “Alarm List”, and “Trouble List” and are recorded in the ICX.



T5-7-1



TROUBLESHOOTING / ICX Daily Report Data List



1



Data Key Switch ON Time



Details Time when key switch is first turned ON during daily operation (Time is recorded by key switch ON signal.)



2



Key Switch OFF Time



Time when key switch is last turned OFF during daily operation (Time is recorded by key switch ON signal.)



3



Engine Start Time



Time when engine is first started during daily operation (Time is recorded by alternator output signal.)



4



Engine Stop Time



Time when engine is last stopped during daily operation (Time is recorded by alternator output signal.)



5



Hour Meter



Hour meter cumulative hours (Hours are recorded by hour meter signal from monitor.)



6



Fuel Level



The value of the final remained fuel during a day (Value is recorded by fuel sensor signal from monitor.)



7



Engine Operating Hours



Total engine operating hours during daily operation (Hours are recorded by alternator output signal.)



8



Swing Operating Hours



Total swing operating hours during daily operation (Hours are recorded by signals from swing pressure sensor.)



9



Travel Operating Hours



Total travel operating hours during daily operation (Hours are recorded by signals from travel pressure sensor.)



10



Front Attachment Operat- Total front attachment operating hours during daily operation ing Hours (Hours are recorded by signals from front attachment pressure sensor.)



11



Breaker Operating Hours



12



Auxiliary Attachment ExTotal auxiliary attachment except for breaker operating hours during daily cept for Breaker Operating operation Hours (Hours are recorded by signals from auxiliary pressure sensor and attachment mode switch.)



Total breaker operating hours during daily operation (Hours are recorded by signals from auxiliary pressure sensor and attachment mode switch.)



T5-7-2



TROUBLESHOOTING / ICX



13



14



Data *ML Operating Hours



Engine Operating Distribution



Details Total *ML crane operating hours during daily operation (Hours are recorded by signals from crane mode switch.) Hour Engine operating hour distribution during daily operation (Operating hours are recorded only when alternator output signal is continuously delivered for more than 10 minutes.)



NOTE: The daily operation in this table is equivalent to the hours between 0:00 and 23:59:59 counted by the ICX built-in clock. In case the engine is kept operated beyond 0:00, such data are recorded as those for the following day. NOTE: *ML specification is only available in Japanese domestic market.



Frequency Distribution Data List



1



Data Engine Speeds



Oil



Details Frequency distribution of engine speeds (Speeds are recorded by signals from N sensor.)



2



Hydraulic perature



Tem-



Frequency distribution of hydraulic oil temperature (Temperatures are recorded by signals from hydraulic oil temperature sensor.)



3



Coolant Temperature in Radiator



Frequency distribution of coolant temperature (Temperatures are recorded by signals from coolant temperature sensor.)



4



Average Pump Delivery Pressure



Frequency distribution of average delivery pressure from pumps 1 and 2 (Average pressures are recorded by signals from delivery pressure sensors of pumps 1 and 2.)



5



Average Pump Delivery Pressure in Digging Operation



Frequency distribution of average delivery pressure from pumps during digging operation (Average pressures are recorded by signals from arm roll-in pressure sensor.)



6



Average Pump Delivery Pressure in Travel Operation



Frequency distribution of average delivery pressure from pumps during travel operation (Average pressures are recorded by signals from travel pressure sensor.)



T5-7-3



TROUBLESHOOTING / ICX Cumulative Operation Hour List



1



Data Engine Operation Hour



Details Cumulative engine operation hours (Hours are recorded by alternator output signal.)



2



Swing Operation Hour



Cumulative swing operation hours (Hours are recorded by signals from swing pressure sensor.)



3



Travel Operation Hour



Cumulative travel operation hours (Hours are recorded by signals from travel pressure sensor.)



4



Front Hour



5



Breaker Operation Hour



6



Auxiliary Attachment Except for Cumulative attachment operation hours except for breaker operation Breaker Operation Hour hours (Hours are recorded by signals from auxiliary pressure sensor and auxiliary mode switch.)



7



*ML Operation Hour



Attachment



Operation Cumulative front attachment operation hours (Hours are recorded by signals from front attachment pressure sensor.) Cumulative breaker operation hours (Hours are recorded by signals from auxiliary pressure sensor and attachment mode switch.)



Cumulative *ML operation hours (Hours are recorded by signals from crane mode switch.)



NOTE: *ML specification is only available in Japanese domestic market.



T5-7-4



TROUBLESHOOTING / ICX Alarm List Code 86



Data Hydraulic Oil Filter



Details Date and time when hydraulic oil filter indicator lighted are recorded by signals from hydraulic oil filter restriction switch.



89



Overheat



Date and time when overheat indicator lighted are recorded by signals from overheat switch.



90



Engine Oil Pressure



Date and time when engine oil pressure indicator lighted are recorded by signals from engine oil pressure switch.



93



Air Filter Restriction



Date and time when air filter restriction indicator lighted are recorded by signals from air filter restriction switch.



94



Alternator Indicator



Date and time when alternator indicator lighted are recorded by signals from monitor controller.



NOTE: In case the above alarms are recorded, check individual item. If malfunction of the monitor is found, refer to troubleshooting C.



T5-7-5



TROUBLESHOOTING / ICX Trouble List Fault Code 01



Trouble



Details



Abnormal EEPROM



Occurrence time and date of fault code 01



02



Abnormal RAM



Occurrence time and date of fault code 02



03



Abnormal A/D Conversion



Occurrence time and date of fault code 03



04



Abnormal Sensor Voltage



Occurrence time and date of fault code 04



06



Abnormal EC Sensor



Occurrence time and date of fault code 06



07



Abnormal Engine Control Dial



Occurrence time and date of fault code 07



10



Abnormal Pump 1 Delivery Pressure



Occurrence time and date of fault code 10



11



Abnormal Pump 2 Delivery Pressure



Occurrence time and date of fault code 11



12



Abnormal Pump 1 Control Pressure



Occurrence time and date of fault code 12



13



Abnormal Pump 2 Control Pressure



Occurrence time and date of fault code 13



14



Abnormal Swing Pilot Pressure Sensor



Occurrence time and date of fault code 14



15



Abnormal Boom Raise Pilot Pressure Sensor



Occurrence time and date of fault code 15



16



Abnormal Arm Roll-In Pilot Pressure Sensor



Occurrence time and date of fault code 16



18



Abnormal Travel Pilot Pressure Sensor



Occurrence time and date of fault code 18



19



Abnormal Hydraulic Oil Temperature Sensor



Occurrence time and date of fault code 19



20



Abnormal Travel Motor Drain Pressure Sensor



Occurrence time and date of fault code 20



22



Abnormal Travel Motor



Occurrence time and date of fault code 22



23



Abnormal Travel Forward Pilot Pressure Sensor



Occurrence time and date of fault code 23



24



Abnormal Travel Reverse Pilot Pressure Sensor



Occurrence time and date of fault code 24



26



Travel Motor Over-rev.



Occurrence time and date of fault code 26



T5-7-6



TROUBLESHOOTING / ICX



Fault Code 64



Trouble



Details



MC Communication Error



Time and date when communication error between MC and ICX occurred.



65



Monitor Communication Error



Time and date when communication error between monitor and ICX occurred.



66



Satellite Terminal Communication Error



Time and date when communication error between satellite terminal and ICX occurred.



NOTE: In case the above fault codes are recorded, refer to troubleshooting A.



T5-7-7



TROUBLESHOOTING / ICX ICX FAULT CODE LIST Fault Code 1



Abnormal Internal RAM



In case of SAM error



2



Abnormal Flush Memory



In case of SAM error



3



Abnormal Exterior



In case of SAM error or read-write error



4



Abnormal EEPROM



In case of SAM error



6



Abnormal Time



In case RTC data was other than figures.



7



MC Communication Timeout (For ZAXIS)



In case MC communication didn’t last for more than 7 seconds.



8



Monitor Communication Timeout



In case monitor communication didn’t last for more than 24 seconds.



9*



MC Communication Timeout (For EX5)



In case MC communication didn’t last for more than 20 seconds.



10



Satellite Terminal Communication Timeout



In case satellite communication didn’t last for more than 1 minute.



Trouble



Remarks



NOTE * Fault code 9 may be displayed on only the machine (Type: EX5 with minor change), to which the ICX is installed later.



SATELLITE TERMINAL FAULT CODE LIST Fault Code 101



Satellite Terminal: Internal Error



Abnormal EEPROM



102



Satellite Terminal: Internal Error



Abnormal sent data



103



Satellite Terminal: Internal Error



In case reception is difficult.



104



Satellite Terminal: Communication Error



In case satellite communication cannot be accomplished.



105



Satellite Terminal: Internal Error



In case sending retry over occurred or local loop back test failed with power ON.



106



Satellite Terminal: Communication Error



In case sending retry over occurred.



107



Satellite Terminal: Abnormal Harness



In case reception data doesn’t match sending data.



Trouble



Remarks



T5-7-8



TROUBLESHOOTING / ICX FAULT CODE 1 TO 4 AND 6



*Faulty ICX.



YES Check if all data are normally cumulated.



Faulty ICX. NO



*Even if the fault code remains displayed after retrying, the machine can be operated as it is when data record is normally cumulated.



FAULT CODE 7 TO 10 Check for continuity between ICX and corresponding component while referring to the following table.



Fault code



YES



Faulty ICX.



NO



Broken harness between ICX and corresponding component.



ICX terminal #



Corresponding component terminal #



7



Connector C terminal #11



MC connector D terminal #10



8



Connector C terminal #12



Monitor connector B terminal #1



10



Connector B terminal #4



Satellite terminal DSUb9 pin terminal #2



T5-7-9



TROUBLESHOOTING / ICX SOME PARTS OF DATA IN DAILY REPORT, FREQUENCY DISTRIBUTION, CUMULATIVE OPERATION HOURS ARE NOT RECORDED • All necessary data signals may not be input into the ICX. Individual signals are utilized to record more than one data. While referring to the table below, check the corresponding system for any abnormality. Related Data



Input Signal Key switch



Key switch ON and OFF time



Engine start and stop time, Engine operating hours (Daily report and cumulative Alternator operation hour), Engine operating hour distribution Hour meter



Monitor controller



Coolant temperature distribution in radiator



Coolant temperature sensor Fuel level sensor



Remaining fuel level (detected at regular data sending time)



Travel operating hours (Daily report and cumulative operation hour), Average Travel pressure sensor pump delivery pressure distribution in travel operation Front attachment operating hours (Daily report and cumulative operation hour) Swing operating hours (Daily report and cumulative operation hour)



Front attachment pressure sensor Swing pressure sensor



Average pump delivery pressure distribution in digging operation



Arm roll-in pressure sensor Breaker operating hours (Daily report and cumulative operation hour), Auxiliary Auxiliary pressure sensor attachment except for breaker operating hours (Daily report and cumulative operation hour)



Distribution of average pump delivery pressure, average pump delivery pressure Pump 1 delivery pressure in digging operation and travel operation sensor Distribution of average pump delivery pressure, average pump delivery pressure Pump 2 delivery pressure in digging operation and travel operation sensor Engine speed distribution



N sensor



Breaker operating hours (Daily report and cumulative operation hour)



Attachment mode switch



Auxiliary attachment except for breaker operating hours (Daily report and cumula- Auxiliary mode switch tive operation hour) *ML operating hours (Daily report and cumulative operation hour) NOTE: *ML specification is available only in Japanese domestic market.



T5-7-10



Crane mode switch



TROUBLESHOOTING / ICX



Corrective Action Remarks Check harness between ICX terminal A5 and key In case engine doesn’t start, refer to troubleshooting B. switch terminal M. Check harness between ICX terminal A2 and alter- In case alternator indicator malfunctions, refer to trounator terminal L. bleshooting C. Check harness between ICX terminal B1 and monitor terminal B3. Check harness between ICX terminal B1 and monitor terminal B3. Check harness between ICX terminal C3 and monitor terminal C12. Check harness between ICX terminal C11 and MC terminal D10. Check harness terminal D10. Check harness terminal D10. Check harness terminal D10. Check harness terminal D10.



In case hour meter malfunctions, refer to troubleshooting C. In case coolant temperature gauge malfunctions, refer to troubleshooting C. In case fuel gauge malfunctions, refer to troubleshooting C. In case machine control system malfunctions, refer to troubleshooting B.



between ICX terminal C11 and MC In case machine control troubleshooting B. between ICX terminal C11 and MC In case machine control troubleshooting B. between ICX terminal C11 and MC In case machine control troubleshooting B. between ICX terminal C11 and MC In case machine control troubleshooting B.



system malfunctions, refer to system malfunctions, refer to system malfunctions, refer to system malfunctions, refer to



Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to terminal D10. troubleshooting B. Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to terminal D10. troubleshooting B. Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to terminal D10. troubleshooting B. Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to terminal D10. troubleshooting B. Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to terminal D10. troubleshooting B. Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to terminal D10. troubleshooting B.



T5-7-11



TROUBLESHOOTING / ICX (Blank)



T5-7-12



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Hitachi Construction Machinery Co. Ltd Attn: Publications, Marketing & Product Support Fax: 81-298-31-1162



Hitachi Ref. No.



SERVICE MANUAL REVISION REQUEST FORM NAME OF COMPANY:



MODEL: PUBLICATION NO.:



YOUR NAME: DATE: FAX:



(Located at the right top corner in the cover page)



PAGE NO.: (Located at the bottom center in the page. If two or more revisions are requested, use the comment column)



YOUR COMMENTS / SUGGESTIONS: Attach photo or sketch if required. If your need more space, please use another sheet.



REPLY:



(Copy this form for usage)



THE ATTACHED DIAGRAM LIST (The following diagrams are attached to this manual.) ZAXIS160W/210W ELECTRICAL CIRCUIT DIAGRAM (ALL) ZAXIS160W/210W ELECTRICAL CIRCUIT DIAGRAM (OVERLOAD ALARM) ZAXIS160W/210W ELECTRICAL CIRCUIT DIAGRAM (BLADE/STABILIZER) ZAXIS160W/210W CAB HARNESS ZAXIS160W ENGINE HARNESS ZAXIS160W/210W MONITOR HARNESS ZAXIS160W CHASSIS HARNESS ZAXIS160W/210W BLADE/STABILIZER HARNESS ZAXIS160W/210W OVERLOAD ALARM-1 HARNESS ZAXIS160W/210W OVERLOAD ALARM-2 HARNESS ZAXIS160W HYDRAULIC CIRCUIT DIAGRAM (STANDARD) ZAXIS160W HYDRAULIC CIRCUIT DIAGRAM (FULL OPTION)



Manual No. : KM-CBBE Vol. No. : WCBBE-00



160W



Wheeled Excavator Workshop Manual



Workshop Manual 160W Wheeled Excavator



Service Manual (Manual No. KM-CBBE) consists of the following three separate volumes; Technical Manual (Operational Principle) : Vol. No. TOCBBE Technical Manual (Troubleshooting) : Vol. No. TTCBBE Workshop Manual : Vol. No. WCBBE



PRINTED IN SINGAPORE (PS)



Zaxis160W Wheeled-Wsh



1



24/6/03, 3:51 PM



INTRODUCTION TO THE READER • This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine. • Be sure to thoroughly read this manual for correct product information and service procedures.



• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.): Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-298-32-7173 FAX: 81-298-31-1162



ADDITIONAL REFERENCES • Please refer to the materials listed below in addition to this manual. • The Operator’s Manual • The Parts Catalog



• Operation Manual of the Engine • Parts Catalog of the Engine • Hitachi Training Material



MANUAL COMPOSITION • This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual. • Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.



• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures. • Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/disassemble procedures.



PAGE NUMBER • Each page has a number, located on the center lower part of the page, and each number contains the following information: Example : T 1-3-5 Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual



W: Workshop Manual



IN-01



INTRODUCTION SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.



•



CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.



• IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.



•



NOTE: Indicates supplementary technical information or know-how.



UNITS USED • SI Units (International System of Units) are used in



Example : 24.5 MPa (250 kgf/cm2, 3560 psi)



this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units.



Quantity Length Volume



Weight Force Torque



To Convert From mm mm L L m3 kg N N N⋅m N⋅m



Into in ft US gal US qt yd3 lb kgf lbf kgf⋅m lbf⋅ft



A table for conversion from SI units to other system units is shown below for reference purposees.



Quantity



Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 1.0197 0.7375



Pressure Power Temperature Velocity Flow rate



IN-02



To Convert From MPa MPa kW kW °C km/h min-1 L/min mL/rev



Into kgf/cm2 psi PS HP °F mph rpm US gpm cc/rev



Multiply By 10.197 145.0 1.360 1.341 °C×1.8+32 0.6214 1.0 0.2642 1.0



SAFETY RECOGNIZE SAFETY INFORMATION • This is the SAFETY ALERT SYMBOL. • When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. • Follow recommended precautions and safe operating practices.



001-E01A-0688 SA-688



UNDERSTAND SIGNAL WORDS • On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol. • DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. • WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. • CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. • Some safety signs don’t use any of the designated signal words above after the safety alert symbol are occasionally used on this machine. • CAUTION also calls attention to safety messages in this manual. • To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine.



•



NOTE indicates an additional explanation for an element of information. 002-E01C-1223



SA-1



SA-1223



SAFETY FOLLOW SAFETY INSTRUCTIONS • Carefully read and follow all safety signs on the machine and all safety messages in this manual.



• Safety signs should be installed, maintained and



• • •



•



replaced when necessary. • If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering). Learn how to operate the machine and its controls correctly and safely. Allow only trained, qualified, authorized personnel to operate the machine. Keep your machine in proper working condition. • Unauthorized modifications of the machine may impair its function and/or safety and affect machine life. The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine. 003-E01B-0003



SA-2



SA-003



SAFETY PREPARE FOR EMERGENCIES • Be prepared if a fire starts or if an accident occurs. • Keep a first aid kit and fire extinguisher on hand. • Thoroughly read and understand the label attached on the fire extinguisher to use it properly.



• To ensure that a fire-extinguisher can be always used when necessary, check and service the fire-extinguisher at the recommended intervals as specified in the fire-extinguisher manual. • Establish emergency procedure guidelines to cope with fires and accidents. • Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone.



SA-437



004-E01A-0437



WEAR PROTECTIVE CLOTHING • Wear close fitting clothing and safety equipment appropriate to the job. You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances. • Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine. • Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine. 005-E01A-0438



SA-3



SA-438



SAFETY PROTECT AGAINST NOISE • Prolonged exposure to loud noise can cause impairment or loss of hearing. • Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.



006-E01A-0434 SA-434



INSPECT MACHINE • Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury. • In the walk-around inspection be sure to cover all points described in the “PRE-START INSPECTION” chapter in the operator’s manual.



S007-E01A-0435 SA-435



SA-4



SAFETY GENERAL PRECAUTIONS FOR CAB • Before entering the cab, thoroughly remove all



• •



• • • •



dirt and/or oil from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal accident. Don’t leave parts and/or tools lying around the operator’s seat. Store them in their specified locations. Avoid storing transparent bottles in the cab. Don’t attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire. Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine. Keep all flammable objects and/or explosives away from the machine. After using the ashtray, always cover it to extinguish the match and/or tobacco. Don’t leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode. 524-E01A-0000



SA-5



SAFETY USE HANDHOLDS AND STEPS • Falling is one of the major causes of personal injury. • When you mounting and dismounting the machine, always face the machine and maintain a three-point contact with the steps and handrails. • Do not use any controls as hand-holds. • Never jump on or off the machine. Never mount or dismount a moving machine. • Be careful of slippery conditions on platforms, steps, and handrails when mounting and dismounting the machine. SA-439 008-E01B-0439



ADJUST THE OPERATOR'S SEAT • A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations. • The seat should be adjusted whenever changing the operator for the machine. • The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back. • If not, move the seat forward or backward, and check again. SA-378 009-E01A-0378



SA-6



SAFETY FASTEN YOUR SEAT BELT • If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death. • Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine. • Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident. • We recommend that the seat belt be replaced every three years regardless of its apparent condition.



SA-237



010-E01A-0237



MOVE AND OPERATE MACHINE SAFELY • Bystanders can be run over. • Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine. • Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move. • Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine. 011-E01A-0426



SA-7



SA-083



SAFETY OPERATE SEAT



ONLY



FROM



OPERATOR'S



• Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. • Start the engine only when seated in the operator's seat. • NEVER start the engine while standing on the track or on ground. • Do not start engine by shorting across starter terminals. • Before starting the engine, confirm that all control levers are in neutral. SA-084 012-E01B-0444



JUMP STARTING • Battery gas can explode, resulting in serious injury. • If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chapter in the operator’s manual. • The operator must be in the operator’s seat so that the machine will be under control when the engine starts. Jump starting is a two-person operation. • Never use a frozen battery. • Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine. S013-E01A-0032



SA-8



SA-032



SAFETY KEEP RIDERS OFF MACHINE • Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine. • Only the operator should be on the machine. Keep riders off. • Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner. 014-E01B-0379 SA-091



PROVIDE SIGNALS FOR FOBS INVOLVING MULTIPLE NUMBERS OF MACHINES • For jobs involving multiple numbers of machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.



018-E01A-0481 SA-481



CONFIRM DIRECTION OF MACHINE TO BE DRIVEN • Incorrect steering wheel shift lever operation may result in serious injury death. • Before driving the machine, confirm the position of the undercarriage in relation to the operator’s position. If the travel motors are located in front of the cab, the machine will move in reverse when travel pedals/levers are operated to the front. 017-E01A-0491 SA-092



SA-9



SAFETY DRIVE MACHINE SAFELY (WORK SITE) • Before driving the machine, always confirm that the steering wheel/shift lever direction corresponds to the direction you wish to drive. • Be sure to detour around any obstructions.



• Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death. • When driving up or down a slope, keep the bucket facing the direction of travel, approximately 0.5 to 1.0 m (A) above the ground. • If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.



SA-090



SA-288



• Driving across the face of a slope or steering on a slope may cause the machine to skid or overturn. If the direction must be changed, move the machine to level ground, then, change the direction to ensure sage operation.



019-E05B-0090



SA-10



SAFETY AVOID INJURY ACCI-DENTS



FROM



ROLLAWAY



• Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways: • Select level ground when possible to park machine. • Do not park the machine on a grade. • Lower the bucket and/or other work tools to the ground. • Place the shift lever in neutral, and put the brake switch in the P (parking brake) position. • Turn the auto-idle switch and the H/P mode switch off. • Run the engine at slow idle speed without load for 5 minutes to cool down the engine. • Stop the engine and remove the key from the key switch. • Pull the pilot control shut-off lever to LOCK position. • Block both tires and lower the bucket to the ground. Thrust the bucket teeth into the ground if you must park on a grade. • Position the machine to prevent rolling. • Park a reasonable distance from other machines. 020-E01A-0270



SA-11



SA-278



SAFETY AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS • If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: • Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR. • Keep the travel alarm in working condition (if equipped). ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE. • USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. Use hand signals, which conform to your local regulations, when work conditions require a signal person. • No machine motions shall be made unless signals are clearly understood by both signalman and operator. • Learn the meanings of all flags, signs, and markings used on the job and confirm who has the responsibility for signaling. • Keep windows, mirrors, and lights clean and in good condition. • Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting. • Read and understand all operating instructions in the operator’s manual. S021-E01A-0494



SA-12



SA-383



SA-384



SAFETY AVOID TIPPING DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE---SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT



• The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death.



SA-012



To avoid tipping:



• Be extra careful before operating on a grade. • Prepare machine operating area flat. • Keep the bucket low to the ground and close to the machine.



• Reduce operating speeds to avoid tipping or slipping.



• Avoid changing direction when traveling on grades.



• NEVER attempt to travel across a grade steeper than 5 degrees if crossing the grade is unavoidable. • Reduce swing speed as necessary when swinging loads. • Be careful when working on frozen ground. • Temperature increases will cause the ground to become soft and make ground travel unstable. S025-E01B-0495



SA-13



SA-562



SAFETY AVOID POWER LINES • Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines. • When operating near an electric line, NEVER move any part of the machine or load closer than 3 m (10 ft) plus twice the line insulator length. • Check and comply with any local regulations that may apply. • Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site.



SA-089



029-E01A-0381



OBJECT HANDLING • If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death. • When using the machine for craning operations, be sure to comply with all local regulations. • Do not use damaged chains or frayed cables, sables, slings, or ropes. • Before craning, position the upperstructure with the travel motors at the rear. • Move the load slowly and carefully. Never move it suddenly. • Keep all persons well away from the load. • Never move a load over a person's head. • Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground. • Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall. 032-E01A-0014



SA-14



SA-014



SAFETY PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body, serious injury may result. • Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. • Keep bystanders away from the working area before striking any object. 031-E01A-0432 SA-432



PARK MACHINE SAFELY To avoid accidents: • Park machine on a firm, level surface. • Lower bucket to the ground. • Place the shift lever in neutral, and put the brake switch in the P (parking brake) position. • Turn auto-idle switch and auto-acceleration switch off. • Run engine at slow idle speed without load for 5 minutes. • Turn key switch to OFF to stop engine. • Remove the key from the key switch. • Pull up the pilot shut-off lever further to release the catch, so that the left console can be moved upward (“CONSOLE UP” position). • Close windows, roof vent, and cab door. • Lock all access doors and compartments. 033-E07B-0093



SA-15



SA-093



SAFETY HANDLE FLUIDS SAFELY－AVOID FIRES • Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death. • Do not refuel the machine while smoking or when near open flame or sparks. • Always stop the engine before refueling the machine. • Fill the fuel tank outdoors.



• All fuels, most lubricants, and some coolants are flammable. • Store flammable fluids well away from fire hazards. • Do not incinerate or puncture pressurized containers. • Do not store oily rags; they can ignite and burn spontaneously. • Securely tighten the fuel and oil filler cap.



SA-018



034-E01A-0496



SA-019



SA-16



SAFETY SAFETY TRANSPORTING • The



danger of tipping is present when loading/unloading the machine onto/from a truck or trailer bed. • Be sure to observe local regulations when transporting the machine on public roads. • Provide an appropriate truck or trailer for transporting the machine. Take the following precautions when loading/unloading the machine: 1. Select firm level ground. 2. Be sure to use a loading dock or ramp. 3. Be sure to have a signal person when loading/unloading the machine. 4. Always turn the auto-idle switch, auto-acceleration switch and the H/P mode switch OFF when loading or unloading the machine, to avoid unexpected speed increase due to unintentional operation of a control lever. 5. Always select the slow travel with the fast/slow travel switches. 6. Avoid steering while driving up or down the ramp as it is extremely dangerous. If steering is unavoidable, first move back to the ground or flatbed, modify traveling direction, and begin to drive again. 7. Do not operate any levers besides the travel levers when driving up or down the ramp. 8. The top end of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it. 9. Prevent possible injury from machine tipping while the upperstructure is rotating. 10.Keep the arm tucked under and rotate the upperstructure slowly for best stability. 11.Turn the brake switch to the parking (P) position. Place blocks in front of and behind the tires to secure the machine. 12.Securely fasten chain or cables to the machine frame. Refer to "transporting" chapter in the operator’s manual for details. 035-E06A-0395



SA-17



Less than 15° SA-094



Less than 15° SA-095



SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents:



• Understand service procedures before doing work.



• Keep work area clean and dry. • Do not spray water or steam inside cab. • Never lubricate or service the machine while it is moving.



• Keep hands, feet and clothing away from power-driven parts.



• Before servicing the machine: 1) 2) 3) 4) 5) 6) 7) 8) 9) 10)



Park the machine on a level surface. Lower the bucket to the ground. Turn the auto-idle / acceleration selecltor off. Run the engine at slow idle speed without load for 5 minutes. Turn the key switch to OFF to stop engine. Relieve the pressure in the hydraulic system by moving the control levers several times. Remove the key from the switch. Attach a “Do Not Operate” tag on the control lever. Pull the pilot control shut-off lever to the LOCK position. Allow the engine to cool.



SA-18



SAFETY • If a maintenance procedure must be performed •



• •



• • •



• • • •



• •



with the engine running, do not leave machine unattended. If the machine must be raised, maintain a 90 to 110 angle between the boom and arm. Securely support any machine elements that must be raised for service work. Never work under a machine raised by the boom. Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter in the operator’s manual. Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris. When cleaning parts, always use nonflammable detergent oil. Never use highly frammable oil such as fuel oil and gasoline to clean parts or surfaces. Disconnect battery ground cable (-) before making adjustments to electrical systems or before welding on the machine. Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure that the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil. Sufficiently illuminate the work site. Use a maintence work light when working under or inside the machine. Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil antifreeze fluid, or window washer fluid may catch fire.



SA-028



SA-527



S500-E02B-0497



SA-037



SA-19



SAFETY WARN OTHERS OF SERVICE WORK • Unexpected machine movement can cause serious injury. • Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever. This tag is available from your authorized dealer.



SS2045102



SUPPORT MACHINE PROPERLY • Never attempt to work on the machine without securing the machine first. • Always lower the attachment 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 tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.



SA-527



519-E01A-0527



STAY CLEAR OF MOVING PARTS • Entanglement in moving parts can cause serious injury. • To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts. 502-E01A-0026



SA-026



SA-20



SAFETY PREVENT PARTS FROM FLYING • Travel reduction gears are under pressure. • As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury. GEAR OIL is hot. • Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure. 503-E03A-0344



SA-344



STORE ATTACHMENTS SAFELY • Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death. • Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas.



504-E01A-0034



SA-034



SUPPORT MAINTENANCE PROPERLY • Explosive separation of a tire and rim parts can cause serious injury or death. • Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Have it done by your authorized dealer or a qualified repair service. • Always maintain the correct tire pressure. DO NOT inflate tire above the recommended pressure. • When inflating tires, use a chip-on chuck and extension hose long enough to allow you to stand to one side and not in front of or over the tire assembly. Use a safety cage it available. • Inspect tires and wheels daily. Do not operate with low pressure, cuts bubbles, damaged rims, or missing lug bolts and nuts. • Never cut or weld on an inflated tire or rim assembly. Heat from welding could cause an increase in pressure and may result in tire explosion. 521-E02A-0249



SA-21



SA-249



SAFETY PREVENT BURNS Hot spraying fluids:



• After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. • To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap. • The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.



SA-039



Hot fluids and surfaces:



• Engine oil, gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well. • Wait for the oil and components to cool before starting any maintenance or inspection work. 505-E01B-0498



SA-225



REPLACE RUBBER HOSES PERIODICALLY • Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone. • Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator’s manual.) • Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death. S506-E01A-0019



SA-22



SA-019



SAFETY AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death. • Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. • Tighten all connections before applying pressure. • Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection. • If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.



SA-031



SA-292



507-E03A-0499



SA-044



SA-23



SAFETY PREVENT FIRES Check for Oil Leaks:



• Fuel, hydraulic oil and lubricant leaks can lead to fires. • Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts. • Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts. • Do not bend or strike high-pressure lines. • Never install bent or damaged lines, pipes, or hoses. Check for Shorts:



• Short circuits can cause fires. • Clean and tighten all electrical connections. • Check before starting work for loose, kinked, hardened or frayed electrical cables and wires.



• Check before starting work for missing or damaged terminal caps.



• DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.. Clean up Flammables:



• Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires. • Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately.



SA-24



SA-019



SAFETY Check Key Switch:



• If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting. • Always check key switch function before operating the machine every day: 1) Start the engine and run it at slow idle. 2) Turn the key switch to the OFF position to confirm that the engine stops. • If any abnormalities are found, be sure to repair them before operating the machine. Check Heat Shields:



• Damaged or missing heat shields may lead to fires. • Damaged or missing heat shields must be repaired or machine.



replaced



before



operating



the



S508-E02B-0019



SA-25



SAFETY EVACUATING IN CASE OF FIRE • If a fire breaks out, evacuate the machine in the following way: • Stop the engine by turning the key switch to the OFF position if there is time. • Use a fire extinguisher if there is time. • Exit the machine.



• In an emergency, if the cab door and/or the front



SA-393



window cannot be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab. Refer to the explanation page on “EMERGENCY EXIT” in Operator’s Manual. 518-E02B-0393



SS-1510



BEWARE OF EXHAUST FUMES • Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. • If you must operate in a building, be sure 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. 509-E01A-0016 SA-016



SA-26



SAFETY PRECAUTIONS GRINDING



FOR



WELDING



AND



• Welding may generate gas and/or small fires. • Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding. • Only qualified personnel should perform welding. Never allow an unqualified person to perform welding. • Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding. • After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.



SA-818



523-E01A-0818



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 temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc..



AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS • Do not weld or flame cut pipes or tubes that contain flammable fluids. them thoroughly with nonflammable solvent before welding or flame cutting them.



• Clean



510-E01B-0030



SA-27



SA-030



SAFETY REMOVE PAINT BEFORE WELDING OR HEATING • Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness. • Avoid potentially toxic fumes and dust. • Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly.



• Remove paint before welding or heating: 1) If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. 2) If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.



SA-029



511-E01A-0029



PREVENT BATTERY EXPLOSIONS • Battery gas can explode. • Keep sparks, lighted matches, and flame away from the top of battery.



• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. • Do not charge a frozen battery; it may explode. Warm the battery to 16 °C ( 60 °F ) first. • Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result. • Loose terminals may produce sparks. Securely tighten all terminals. • Battery electrolyte is poisonous. If the battery should explode battery electrolyte may be splashed into eyes, possibly resulting in blindness. • Be sure to wear eye protection when checking electrolyte specific gravity. 512-E01C-0032



SA-28



SA-032



SAFETY SERVICE AIR CONDITIONING SYSTEM SAFELY • If spilled onto skin, refrigerant may cause a cold contact burn. • Refer to the freon container for proper use when servicing the air conditioning system. • Use a recovery and recycling system to avoid venting freon into the atmosphere. • Never let the freon stream make contact with the skin. 513-E01A-0405



SA-405



HANDLE CHEMICAL PRODUCTS SAFELY • Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives. • A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. • Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment. S515-E01A-0309



SA-29



SA-309



SAFETY DISPOSE OF WASTE PROPERLY • Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. • Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. • Do not pour waste onto the ground, down a drain, or into any water source. • Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants. • Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center.



SA-226



S516-E01A-0226



BEFORE RETURNING THE MACHINE TO THE CUSTOMER • After maintenance or repair work is complete, confirm that: • The machine is functioning properly, especially the safety systems. • Worn or damaged parts have been repaired or replaced



S517-E01A-0435



SA-30



SA-435



SECTION AND GROUP CONTENTS



SECTION 1 GENERAL INFORMATION Group 1 Precautions for disassembling and Assembling Group 2 Tightening Torque Group 3 Painting Group 4 Bleeding Air from Hydraulic Oil Tank



SECTION 2 UPPERSTRUCTURE WORKSHOP MANUAL



Group 1 Cab Group 2 Counterweight Group 3 Main Frame Group 4 Pump Device Group 5 Control Valve Group 6 Swing Device Group 7 Pilot Valve Group 8 Pilot Shut-Off Valve Group 9 Signal Control Valve Group 10 Travel Shockless Valve Group 11 Solenoid Valve Group 12 Pilot Relief Valve Group 13 Steering Valve Group 14 Brake Valve Group 15 Accumulator Charging Valve Group 16 Transmission Control Valve



SECTION 3 UNDERCARRIAGE



All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.



Group 1 Swing Bearing Group 2 Travel Motor Group 3 Center Joint Group 4 Transmission Group 5 Axle Group 6 Axle Lock Cylinder Group 7 Operate-Check Valve



SECTION 4 FRONT ATTACHMENT COPYRIGHT(C)2003 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved



Group 1 Front Attachment Group 2 Cylinder Group 3 Hose-Rupture Safety Valve Group 4 Operate-Check Valve



SECTION 5 ENGINE



TECHNICAL MANUAL (Operational Principle) SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION Group 1 Specifications Group 1 Pump Device Group 2 Component Layout Group 2 Swing Device Group 3 Component Specifications Group 3 Control Valve Group 4 Pilot Valve SECTION 2 SYSTEM Group 5 Travel Device Group 1 Control System Group 6 Signal Control Valve Group 2 Hydraulic System Group 7 Steering Valve Group 3 Electrical System Group 8 Brake Valve Group 9 Transmission Control Valve Group 10 Others (Upperstructure) Group 11 Others (Undercarriage)



TECHNICAL MANUAL (Troubleshooting) SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Excavator Test Group 5 Component Test Group 6 Adjustment



SECTION 5 TROUBLESHOOTING Group 1 General Group 2 Component Layout Group 3 Troubleshooting A Group 4 Troubleshooting B Group 5 Troubleshooting C Group 6 Electrical System Inspection Group 7 ICX



SECTION 1



GENERAL — CONTENTS — Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling.................................................W1-1-1 Maintenance Standard Terminology.......... W1-1-7



Group 2 Tightening Torque Tightening Torque Specification ..................W1-2-1 Torque Chart ................................................W1-2-2 Piping Joint ..................................................W1-2-5 Periodic Replacement of Parts .................. W1-2-9



Group 3 Painting Painting.................................................... W1-3-1



Group 4 Bleeding Air from Hydraulic Oil Tank Bleeding Air from Hydraulic Oil tank .......... W1-4-1



CBBW-1-1



(Blank)



CBBW-1-2



GENERAL / Precautions for Disassembling and Assembling PRECAUTIONS FOR AND ASSEMBLING



DISASSEMBLING



Precautions for Disassembling and Assembling



• Clean the Machine



• Precautions for Disassembling



Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work.



• Inspect the Machine Be sure to thoroughly understand all disassem-bling/assembling procedures beforehand, to help avoid incorrect disassembling of components as well as personal injury. Check and record the items listed below to prevent problems from occurring in the future. • The machine model, machine serial number, and hour meter reading. • Reason for disassembly (symptoms, failed parts, and causes). • Clogging of filters and oil, water or air leaks, if any. • Capacities and condition of lubricants. • Loose or damaged parts.



• Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work.



W1-1-1



• To prevent dirt from entering, cap or plug the removed pipes. • Before disassembling, clean the exterior of the components and place on a work bench. • Before disassembling, drain gear oil from the reduction gear. • Be sure to provide appropriate containers for draining fluids. • Use matching marks for easier reassembling. • Be sure to use the specified special tools, when instructed. • If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause(s), then take the appropriate measures to remove it. • Orderly arrange disassembled parts. Mark and tag them as necessary. • Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss. • Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage. • Measure and record the degree of wear and clearances.



GENERAL / Precautions for Disassembling and Assembling • Precautions for Assembling



Bleeding Air from Hydraulic System



• Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace part. • Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces. • Be sure to replace O-rings, backup rings, and oil seals with new ones once they are disassembled. Apply a film of grease before installing. • Be sure that liquid-gasket-applied surfaces are clean and dry. • If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent. • Utilize matching marks when assembling. • Be sure to use the designated tools to assemble bearings, bushings and oil seals. • Keep a record of the number of tools used for disassembly/assembly. After assembling is complete, count the number of tools, so as to make sure that no forgotten tools remain in the assembled machine.



When hydraulic oil is drained, the suction filter or the suction lines are replaced, or the removal and installation of the pump, swing motor, travel motor or cylinder is done, bleed air from the hydraulic system in the following procedures: IMPORTANT: If the engine is started with air trapped in the hydraulic pump housing, damage to the pump may result. If the hydraulic motor is operated with air trapped in the hydraulic motor housing, damage to the motor may result. If the cylinder is operated with air trapped in the cylinder tube, damage to the cylinder may result. Be sure to bleed air before starting the engine.



• Bleeding Air from Hydraulic Pump • Remove the air bleeding plug from the top of the pump and fill the pump housing with hydraulic oil. • After the pump housing is filled with hydraulic oil, temporarily tighten the plug. Then, start the engine and run at slow idle speed. • Slightly loosen the plug to bleed air from the pump housing until hydraulic oil oozes out. • After bleeding all the air, securely tighten the plug.



• Bleeding Air from Travel Motor / Swing Motor • With the drain plug / hose on travel motor / swing motor removed, fill the motor case with hydraulic oil.



W1-1-2



GENERAL / Precautions for Disassembling and Assembling • Bleeding Air from Hydraulic Circuit • After refilling hydraulic oil, start the engine. While operating each cylinder, swing motor and travel motor evenly, operate the machine under light loads for 10 to 15 minutes. Slowly start each operation (never fully stroke the cylinders during initial operation stage). As the pilot oil circuit has an air bleed device, air trapped in the pilot oil circuit will be bled while performing the above operation for approx. 5 minutes. • Reposition the front attachment to check hydraulic oil level. • Stop the engine. Recheck hydraulic oil level. Replenish oil as necessary.



W1-1-3



W1F3-01-04-001



GENERAL / Precautions for Disassembling and Assembling Floating Seal Precautions A



1. In general, replace the floating seal with a new one after disassembling. If the floating seal is to be reused, follow these procedures: (1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces. (2) Check the slide surface on seal ring (A) for scuffing, scoring, corrosion, deformation or uneven wear. (3) Check O-ring (B) for deformation or hardening.



tears,



B



W105-03-05-019



breaks,



2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble. (1) Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust or dirt. After cleaning, thoroughly dry parts with compressed air.



Correct



Incorrect



(2) Clean the floating seal and seal mounting bores. Check the bore surface for scuffing or scoring by touching the surface with touch. (3) Check that the O-ring is not twisted, and that it is installed correctly on the seal ring. (4) After installing the floating seal, check that seal ring surface (A) is parallel with seal mating face (C) by measuring the distances (A) and (C) at point (a) and (b), as illustrated. If these distances differ, correct the O-ring seating.



Correct



C



W105-03-05-020



Incorrect



a



a



A B



b



a=b



b



a≠b W110-03-05-004



W1-1-4



GENERAL / Precautions for Disassembling and Assembling Precautions for Using Nylon Sling 1. Follow the precautions below to use nylon slings safely. • Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from being damaged and the lifted load from slipping. • Lower the temperature of the lifted load to lower than 100 °C (212 °F). If unavoidably lifting a load with a temperature of 100 °C (212 °F) or more, reduce the load weight. • Do not lift acid or alkali chemicals. • Take care not to allow the sling to become wet. The load may slip. • When required to use more than one sling, use slings with the same width and length to keep the lifted load balanced. • When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load. (Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force. • Avoid using twisted, bound, connected, or hitched slings. • Do not place any object on twisted or bent slings. (Refer to the right illustration.) • When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions. • Avoid dragging slings on the ground, throwing slings or pushing slings with a metal object. • When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged. • Store the nylon slings indoors so they won’t deteriorate with heat, sun light, or chemicals.



Correct Eyehole Lifting Method



W102-04-02-016



Incorrect Eyehole Lifting Method



W105-04-01-008



Bent Sling



W1-1-5



W162-01-01-009



GENERAL / Precautions for Disassembling and Assembling CAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may result. Be sure to visually check the nylon sling for any damage before using.



Damaged Appearance



2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples shown to the right. If any damage is found, cut and discard the sling. Even if no damage is found, do not use slings older than 7-years.



Broken Sewing Thread



W162-01-01-002



Scuffing



W162-01-01-003



Fuzz Broken Sewing Thread



W162-01-01-004



Broken Sewing Thread



W162-01-01-005



Broken Sewing Thread



Scoring



Fuzz



Separation of Belt



Scuffing



W162-01-01-006



W162-01-01-007



Broken Warp



W162-01-01-008



W1-1-6



GENERAL / Precautions for Disassembling and Assembling MAINTENANCE STANDARD TERMINOLOGY “Standard” 1. Dimension for parts on a new machine. 2. Dimension of new components or assemblies adjusted to specification.



“Allowable Limit” 1. Normal machine performance cannot be accomplished after exceeding this limit. 2. Repair or adjustment is impossible after exceeding this limit. 3. Therefore, in consideration of operation efficiency and maintenance expense, proper maintenance shall be carried out before reaching the “Allowable Limit”.



W1-1-7



GENERAL / Precautions for Disassembling and Assembling (Blank)



W1-1-8



GENERAL / Tightening TIGHTENING TORQUE SPECIFICATION No.



Bolt Dia mm 14 16 10 10 16 16



Descriptions Engine cushion rubber mounting nut Engine cushion rubber mounting bolt Engine bracket mounting bolt Engine bracket mounting nut Hydraulic oil tank mounting bolt Fuel tank mounting bolt



1 2 3 4



5



ORS and metal face seal fittings for hydraulic hoses and piping



6 7 8 9



Pump mounting bolt Control valve mounting bolt Control valve bracket mounting bolt Swing device mounting bolt



10



Swing motor mounting bolt



11 12



14 15



Battery mounting nut Cab mounting nut Swing bearing mounting bolt to upperstructure Swing bearing mounting bolt to chassis * Center joint lock mounting bolts * Transmission mounting bolts



16



* Travel motor mounting bolts



17 19 20



* Propel shaft mounting nuts * Rear axle mounting bolts Wheel pin nuts



21



Cover mounting bolt



22



Flexible master coupling of piping



23



T-bolt clamp of low pressure piping



13



Q’ty 4 2 7 1 4 4



10 8 14 4 16 4 20 12 12 (Hex. 8 Wrench) 10 2 16 4 20 31 20 36 16 5 20 3 16 (Hex. 4 Wrench) 10 32 20 8 22 40 － 6 － 10 － 12 8 4 pairs －



* : Apply LOCTITE to the threads. NOTE: 1. Apply lubricant (e.g. white zinc B dissolved into spindle oil) to bolts and nuts to reduce friction coefficient of them. 2. Make sure bolt and nut threads are clean before installing.



W1-2-1



Wrench Size (mm) 22 24 17 17 24 24 17 19 22 27 32 36 41 17 22 24 30



Nm 140 235 50 50 210 210 24.5 30 40 95 140 175 210 50 140 210 500



Torque (kgf m) (14.0) (24) (5.1) (5.1) (21.5) (21.5) (2.5) (3.1) (4.1) (9.7) (14.3) (17.8) (21.5) (5.1) (14.0) (21.5) (51)



(lbf ft) (103) (175) (37) (37) (155) (155) (18) (22) (30) (70) (105) (130) (155) (37) (103) (155) (370)



10



90



(9.2)



(67)



17 24 30 30 24 30



50 210 510 490 270 550



(5.1) (21.5) (52) (50) (27.5) (56.0)



(37) (155) (375) (360) (200) (410)



14



270



(27.5)



(200)



14 30 30 10 17 19 13



76 550 600 10 50 90 10.3 to 12.4 6.0



(8) (56.0) (61) (1) (5.1) (9.2) (1.05 to 1.26) (0.6)



(60) (410) (440) (7.4) (37) (66) (7.59 to 9.11) (4.3)



11



GENERAL / Tightening TORQUE CHART CAUTION: Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools may slip, potentially causing personal injury.



Bolt Types Tighten nuts or bolts correctly to torque specifications. Four different types and grades of bolt are employed. Make sure to employ correct bolts and tighten them correctly when assembling the machine or components. Hexagon T Bolt



SA-040



Hexagon H Bolt



Hexagon M Bolt



Socket Bolt



W162-01-01-001



Specified Tightening Torque Chart T Bolt Bolt Wrench Hexagon Wrench Dia. Size N⋅m (kgf⋅m) Size



H Bolt, Socket bolt (lbf⋅ft)



N⋅m



M Bolt



(kgf⋅m)



(lbf⋅ft)



N⋅m



(kgf⋅m)



(lbf⋅ft)



M8



13



6



30



(3.1)



(22)



20



(2.0)



(15.0)



10



(1.0)



(7.4)



M10



17



8



65



(6.6)



(48)



50



(5.1)



(37)



20



(2.0)



(15.0)



M12



19



10



110



(11.0)



(81)



90



(9.2)



(66)



35



(3.6)



(26.0)



M14



22



12



180



(18.5)



(135)



140



(14.0)



(103)



55



(5.6)



(41)



M16



24



14



270



(27.5)



(200)



210



(21.5)



(155)



80



(8.2)



(59)



M18



27



14



400



(41.0)



(295)



300



(30.5)



(220)



120



(12.0)



(89)



M20



30



17



550



(56.0)



(410)



400



(41.0)



(295)



170



(17.0)



(125)



M22



32



17



750



(76.5)



(550)



550



(56.0)



(410)



220



(22.5)



(162)



M24



36



19



950



(97.0)



(700)



700



(71.5)



(520)



280



(28.5)



(205)



M27



41



19



1400



(143)



(1030)



1050



(107)



(770)



400



(41.0)



(295)



M30



46



22



1950



(200)



(1440)



1450



(148)



(1070)



550



(56.0)



(410)



M33



50



24



2600



(265)



(1920)



1950



(200)



(1440)



750



(76.5)



(550)



M36



55



27



3200



(325)



(2360)



2450



(250)



(1810)



950



(97.0)



(700)



W1-2-2



GENERAL / Tightening IMPORTANT: The following items are applied to both fine and coarse pitch threads. 1. Apply lubricant (i. e. white zinc B dissolved Into Spindle oil) to nuts and bolts to reduce their friction coefficients. The plated bolts require no lubricant. 2. Torque tolerance is ±10 %. 3. Be sure to use bolts of correct length. Bolts that are too long cannot be tightened, as the bolt tip comes into contact with the bottom of the bolt hole. Bolts that are too short cannot develop sufficient tightening force. 4. The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific application. 5. Make sure that nut and bolt threads are clean before installing. Remove dirt or corrosion, if any. Bolt Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening. Equally tighten upper and lower alter-



Tighten diagonally 1



1st to 4th



Tighten from center and diago12



9



4



1



6



7



14



13



8



5



2



3



10



11



3



6



5



4 2 2nd to 3rd



W105-01-01-003



W1-2-3



GENERAL / Tightening Service Recommendations for Split Flange IMPORTANT: 1. Be sure to clean and Inspect sealing surfaces. Scratches / roughness cause leaks and seal wear. Unevenness causes seal extrusion. If defects cannot be polished out, replace the component. 2. Be sure to use only specified O-rings. Inspect O-rings for any damage. Take care not to file O-ring surfaces. When installing an O-ring into a groove, use grease to hold it in place. 3. While lightly tightening split flange halves, check that split is centered and perpendicular to the port. Hand-tighten bolts to hold parts in place. Take care not to pinch the O-ring. 4. Tighten bolts alternately and diagonally, as shown, to ensure even tightening. 5. Do not use air wrenches. Using an air wrench often causes tightening of one bolt fully before tightening of the others, resulting in damage to O-rings or uneven tightening of bolts.



W105-01-01-015



WRONG



W105-01-01-016



W105-01-01-008



WRONG



RIGHT



Nut and Bolt Locking



Do not bend it round



Bend along edge sharply



RIGHT



WRONG



RIGHT



• Lock Plate IMPORTANT: Do not reuse lock plates. Do not try to bend the same point twice. • Cotter Pin IMPORTANT: Do not reuse cotter pins. Match the holes in the bolt and nut while tightening, not while loosening.



Bend along edge sharply



RIGHT



• Lock Wire IMPORTANT: Apply wire to bolts in the bolt-tightening direction, not in the bolt-loosening direction. RIGHT



RIGHT



WRONG



Loosen



W105-01-01-009



WRONG



Tighten



W105-01-01-010



W1-2-4



GENERAL / Tightening PIPING JOINT IMPORTANT: The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific application.



1



4



3



5



Union Joint



2



M202-07-051



Joint Body



Metal sealing surfaces (4) and (5) of adapter (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines. IMPORTANT: 1. Do not over-tighten nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adapter (1). Be sure to tighten nut (3) to specifications. 2. Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting/disconnecting.



Description 30°male



37°female



37° 30°



Male Union Joint



Female Union Joint W105-01-01-017



Wrench Size mm Union Nut 17 19 22 27 32 36 41 17 19 22 27 32 36 41



Wrench Size mm Hose Fittings 17 19 22 27 32 36 41 14 17 19 22 27 32 36



Tightening Torque N⋅m (kgf⋅m, lbf⋅ft) 24.5 (2.5,18) 29.5 (3.0, 21.5) 39 (4.0, 28.5) 78 (8.0, 58) 137 (14.0,101) 175 (18.0,129) 205 (21.0,151) 24.5 (2.5,18) 29.5 (3.0, 21.5) 39 (4.0, 28.5) 78 (8.0, 58) 137 (14.0,101) 175 (18.0,129) 205 (21.0,151)



NOTE: Tightening torque of 37°male coupling without union is similar to tightening torque of 37°female.



W1-2-5



GENERAL / Tightening O-ring Seal Joint



7



9



6



O-ring (6) seats against the end face of adapter (7) to seal pressure oil. IMPORTANT: 1. Be sue to replace O-ring (6) with a new one when reconnecting. 2. Before tightening nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (e). Tightening nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage. 3. Take care not to damage O-ring groove (e) or sealing surface (10). Damage to O-ring (6) will cause oil leakage. 4. If nut (9) is loose and oil is leaking, do not re-tighten nut (9). Replace O-ring (6) with a new one and check that O-ring (6) is correctly seated in place, tighten nut (9).



8



Wrench Size mm Union Nut 19 22 27 32 36 41 46



W1-2-6



Wrench Size mm Hose Fittings 17 19 22 27 30,32 36 41



1



Hose Fittings M104-07-033



Tightening Torque N⋅m (kgf⋅m, lbf⋅ft) 29.5 (3.0, 21.5) 69 (7.0, 51) 93 (9.5, 69) 137 (14.0,101) 175 (18.0,129) 205 (21.0,151) 205 (21.0,151)



GENERAL / Tightening Screw-In Connection PT



Depending on types of screw and sealing, different types of screw fittings are used. IMPORTANT: Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection.



30°



Male Tapered Thread



PF



Male Straight Thread



W105-01-01-018



Wrench Size mm Hose Fittings 19 22 27 36 41 50 60



Male Tapered Thread Tightening Torque N⋅m (kgf⋅m, lbf⋅ft) FC material SS material 14.5 (1.5,10.5) 34 (3.5, 25) 29.5 (3.0, 21.5) 49 (5.0, 36) 49 (5.0, 36) 93 (9.5, 69) 69 (7.0, 51) 157 (16,116) 108 (11, 80) 205 (21,151) 157 (16,116) 320 (33, 235) 195 (20,144)



Seal Tape Application Seal tape is used to seal clearances between male and female threads, so as to prevent any leaks between threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not overwrap.



Internal Thread



External Thread



Clearance



• Application Procedure



W105-01-01-019



Confirm that the thread surface is clean and, free of dirt or damage. Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads.



Leave one to two pitch threads uncovered



Low-Pressure-Hose Clamp Tightening Torque Low-pressure-hose clamp tightening torque differs depending on the type of clamp. T-Bolt Type Band Clamp: 4.4 N⋅m ( 0.45 kgf⋅m, 3.25 lbf⋅ft ) Worm Gear Type Band Clamp: 5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)



W1-2-7



M114-07-041



T-Bolt Type



Worm Gear Type



M114-07-043



M114-07-042



GENERAL / Tightening Connecting Hose RIGHT



WRONG CAUTION: When replacing hoses, be sure to use only genuine Hitachi service parts. Using hoses other than genuine Hitachi hoses may cause oil leaks, hose rupture or Separation of fitting, possibly resulting in a fire on the machine. Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leaks, hose rupture or separation of fitting. Utilize Print marks on hoses when installing to prevent hose from being kinked.



W105-01-01-011



RIGHT



WRONG Rubbing Against Each Other



If hoses rub against each other, wear to the hoses will result, leading to hose rupture. Take necessary measures to protect hoses from rubbing against each other. Take care so that hoses do not come into contact with moving parts or sharp objects.



W105-01-01-012



WRONG Clamp



RIGHT Clamp



Rubbing Against Each Other W105-01-01-013



WRONG



Rubbing Against Each Other



RIGHT



Clamp W105-01-01-014



W1-2-8



GENERAL / Tightening PERIODIC REPLACEMENT OF PARTS To ensure safe operation, be sure to conduct periodic inspection of the machine. In addition, the parts listed below, if defective, may pose serious safety/fire hazards. It is very difficult to gauge the extent of deterioration, fatigue, or weakening of the parts listed below simply by visual inspection alone. For this reason, replace these parts at the intervals shown in the table below. However, if any of these parts are found to be defective, replace before starting operation, regardless of the interval. Also, when replacing hoses, check the clamps for deformation, cracks, or other deterioration, and replace as necessary. Be sure to perform periodic inspection of all hoses, as shown below, and replace or retighten any defective parts found, as necessary. Consult your authorized dealer for correct replacement. Periodic Replacement Parts



Engine



Upperstructure Brakes Undercarriage Steering Mechanism



Base Machine Hydraulic System Front Attachment



Fuel hose (Fuel tank to filter) Fuel hose (Fuel tank to injection pump) Oil filter hose (Engine to oil filter) Heater hose (Heater to engine) Brake valve seals (Rubber parts) Brake hose Stop light switch Center joint seals (Rubber parts) Brake hose Steering hose Steering cylinder seals (Rubber parts) Steering valve seals (Rubber parts) Pump suction hose Pump delivery hose Swing hose Boom cylinder line hose Arm cylinder line hose Bucket cylinder line hose Pilot hose



NOTE: Be sure to replace seals, such as O-rings and gaskets, when replacing hoses.



W1-2-9



Replacement Intervals Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 1 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years



GENERAL / Tightening (Blank)



W1-2-10



GENERAL / Painting PAINTING Surfaces to Be Painted • Main surface of upperstructure Bed cover Tool box, Tool box cover Inner face • Front attachment • Chassis (undercarriage) • Floor plate • A part of rear left of cab



Painting Colour YR-01 [TAXI yellow] High-grade beige High-grade black Grey YR01 [TAXI yellow] N1.0 [Black] M/F cation colour YR-01 [TAXI yellow]



Final painted colour • Inside and outside surface of cab • Right window beam, U bolt • Suspension lifter (chair bottom) • Lever (lock, foot rest) • Torsion bar • Engine cover • Ladder rail on right side of upperstructure • Mirror stay (cab side and right side stay) • Head light bracket • Antislip cover



High-grade beige [KASAI PAINT LF-113-230B (Charcoal series black, semi glossy)] [N2.0 (Black) ] [N2.0 (Black) ] [N4.0 (Grey) ] High-grade black High-grade black High-grade black [N1.0 (Black) ] KASAI PAINT Amilack 1400 Deep Black.



W1F3-01-03-001



Tool Box Cover



350



900 Bed Cover



W1-3-1



GENERAL / Painting A



YR-01 (TAXI Yellow)



Out Surface of Hinge Swing Portion YR-01 (TAXI Yellow)



185



B



Door Catch Cover YR-01 (TAXI Yellow) 720



Section A



W178-01-03-003



5



Section B Mask Garnished Portion



Door



YR-01(TAXI Yellow)



Panel Behind the Door 10 Painting Area of the Door YR-01 (TAXI Yellow)



W178-01-03-005



W178-01-03-004



Front Attachment YR-01 (TAXI Yellow)



Antislip Cover KASAI PAINT Amilack 1400 Deep Black



W178-01-03-007



Upper Side of Frame



IMPORTANT: When cleaning arm, cylinder, etc. fitted with HN bushing, take care not to pour washing liquid directly on them. The ambient temperature should not exceed 70 °C when painting and drying.



W1-3-2



W1F3-01-03-002



GENERAL / Bleeding Air from Hydraulic Oil Tank BLEEDING AIR FROM HYDRAULIC OIL TANK CAUTION: Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Hydraulic oil may be hot just after operation, and may spurt, possibly causing severe burns. Be sure to wait for oil to cool before starting work. The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Loosen the hydraulic oil tank cap to release any remaining pressure. Preparation 1. Place the machine on a firm, level surface and lower the bucket to the ground. W1F3-01-04-001



2. Stop the engine. Push pressure release button (1) on the air breather to release any remaining pressure from hydraulic oil tank (3).



1



3. Remove cap (2) of hydraulic oil tank (3). : 5 mm



2



3



W1F3-01-04-002



Vacuum Pump



4. Connect a vacuum pump with the hole removed cap (2) to maintain negative pressure in the hydraulic oil tank (3). NOTE: Be sure to run the vacuum pump continuously while working.



Hose



Adapter



W562-02-03-008



W1-4-1



GENERAL / Bleeding Air from Hydraulic Oil Tank (Blank)



W1-4-2



MEMO ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... 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....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... 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....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... .......................................................................................................................................................................



MEMO ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... .......................................................................................................................................................................



SECTION 2



UPPERSTRUCTURE — CONTENTS — Group 1 Cab



Group 5 Control Valve



Remove and Install Cab .........................W2-1-1 Dimensions of the Cab Glass.................W2-1-7



Remove and Install Control Valve.......... W2-5-1 Disassemble Control Valve (4-Spool Section) ................................. W2-5-2 Disassemble Control Valve (5-Spool Section) ................................. W2-5-8 Disassemble and Assemble 4-Spool and 5-Spool Sections............ W2-5-14 Assemble Control Valve (4-Spool Section) ............................... W2-5-16 Assemble Control Valve (5-Spool Section) ............................... W2-5-24 Remove and Install Auxiliary Control Valve ....................... W2-5-33 Disassemble Auxiliary Control Valve ... W2-5-34 Assemble Auxiliary Control Valve ........ W2-5-36



Group 2 Counterweight Remove and Install Counterweight ........W2-2-1



Group 3 Main Frame Remove and Install Main Frame ............W2-3-1



Group 4 Pump Device Remove and Install Pump Device ..........W2-4-1 Disassemble Pump Device ....................W2-4-4 Assemble Pump Device .......................W2-4-12 Disassemble Regulator ........................W2-4-24 Assemble Regulator .............................W2-4-26 Disassemble Solenoid Valve ................W2-4-28 Assemble Solenoid Valve.....................W2-4-30 Disassemble and Assemble Pilot Pump ..........................................W2-4-32 Maintenance Standard .........................W2-4-34



Group 6 Swing Device



CBBW-2-1



Remove and Install Swing Device ......... W2-6-1 Disassemble Swing Reduction Gear ..... W2-6-4 Assemble Swing Reduction Gear ........ W2-6-10 Disassemble Swing Motor ................. W2-6-18 Assemble Swing Motor ........................ W2-6-22 Maintenance Standard ......................... W2-6-26



Group 7 Pilot Valve



Group 12 Pilot Relief Valve



Remove and Install Pilot Valve...............W2-7-1 Disassemble Front/Swing Pilot Valve.....W2-7-6 Assemble Front/Swing Pilot Valve........W2-7-10 Disassemble Travel, Positioning/Auxiliary Blade/Stabilizer Pilot Valve .................W2-7-14 Assemble Travel, Positioning/Auxiliary Blade/Stabilizer Pilot Valve .................W2-7-16



Remove and Install Pilot Relief Valve .. W2-12-1 Construction of Pilot Relief Valve......... W2-12-2



Group 13 Steering Valve Remove and Install Steering Valve ...... W2-13-1 Disassemble Steering Valve ................ W2-13-2 Assemble Steering Valve ..................... W2-13-6



Group 14 Brake Valve Remove and Install Brake Valve .......... W2-14-1 Disassemble Brake Valve .................... W2-14-2 Assemble Brake Valve ......................... W2-14-6



Group 8 Pilot Shut-Off Valve Remove and Install Pilot Shut-Off Valve...............................W2-8-1 Disassemble Pilot Shut-Off Valve...........W2-8-2 Assemble Pilot Shut-Off Valve ...............W2-8-4



Group 15 Accumulator Charging Valve Remove and Install Accumulator Charging Valve.............. W2-15-1 Construction of Accumulator Charging Valve.............. W2-15-2



Group 9 Signal Control Valve Remove and Install Signal Control Valve ........................................W2-9-1



Group 16 Transmission Control Valve



Group 10 Travel Shockless Valve Remove and Install Travel Shockless Valve.......................W2-10-1 Construction of Travel Shockless Valve.......................W2-10-2



Group 11 Solenoid Valve Remove and Install 4-Unit Solenoid Valve Unit ............................ W2-11-1 Disassemble Proportional Solenoid Valve .................................... W2-11-2 Assemble Proportional Solenoid Valve .................................... W2-11-4 Remove and Install 2-Unit Solenoid Valve (for Pump Control) .................... W2-11-6 Construction of 2-Unit Solenoid Valve (for Pump Control) .................... W2-11-7 Remove and Install 2-Unit Solenoid Valve (for Blade/Stabilizer) ................. W2-11-8 Construction of 2-Unit Solenoid Valve (for Blade/Stabilizer) ................. W2-11-9



CBBW-2-2



Remove and Install Transmission Control Valve ............. W2-16-1 Construction of Transmission Control Valve ............. W2-16-2



UPPERSTRUCTURE / Cab REMOVE AND INSTALL CAB Removal 1. Remove seat mounting nuts (2) (4 used) to remove seat (1). : 17 mm 2 1



W1F3-02-01-001



2. Remove bolts (4) (2 used) behind the cab to remove rear deck (3). : 17 mm



3 4 5



3. Raise duct (5) to remove it.



4. Remove air filter (6). Remove clips (7) (2 used) with a plier, then remove duct (8) from the cab.



W178-02-01-012



6



7



8



W1F3-02-01-002



W2-1-1



UPPERSTRUCTURE / Cab 5. Disconnect cable connectors (10, 11, 12, 13) on the right side in the cab and ground (9) at rear side in the cab. : 13 mm 9



10 11 12



13



6. Remove washer vinyl hose (14) at rear side in the cab.



W178-02-01-014



14



W178-02-01-015



16



7. Remove cap (15) from duct cover (17) with a screwdriver. Remove screw (16) with a screwdriver then remove duct cover (17).



17



15



W178-02-01-016



8. Remove screw (18) and bolt (21) then remove duct (19, 20). : 17 mm



18 Mating Surface



19



20



W2-1-2



21



W178-02-01-017



UPPERSTRUCTURE / Cab CAUTION: Cab weight: 290 kg (640 lb)



Lifting Point



9. Remove cab mounting bolts (23) and nut (24). : 17 mm : 24 mm : 8 mm



W178-02-01-018



23



24



W157-02-01-010



10. Lift the cab off.



W157-02-01-001



W2-1-3



UPPERSTRUCTURE / Cab Installation CAUTION: Cab weight: 290 kg (640 lb) 1. Lift the cab.



W157-02-01-001



23



2. Install cab mounting bolts (23) and nuts (24). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) : 24 mm : 205 N⋅m (21 kgf⋅m, 152 Ibf⋅ft) : 8 mm : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)



24



W157-02-01-010



6



3. Install duct (8) to the rear console of the cab with clips (7) (2 used). Install filter (6) into duct (8).



7



: 4.9 N⋅m (0.5 kgf⋅m, 3.6 Ibf⋅ft)



8



W1F3-02-01-002



4. Install harness connectors (10, 11, 12, 13) at the right side of the cab and install ground connector (9) at rear side in the cab. : 13 mm : 20 N⋅m (2.0 kgf⋅m, 15 Ibf⋅ft)



9



10 11 12



13



W178-02-01-014



W2-1-4



UPPERSTRUCTURE / Cab 5. Connect washer vinyl hose (14) at the rear of the cab inside.



14



6. While aligning the mounting hole for duct (5), press it to install the hose into the hole.



W178-02-01-015



3 4 5



7. Install rear beck (3) with bolt (4). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)



W178-02-01-012



8. Install duct (20) with bolt (21). Install duct (19) into duct (20) and secure them with bolts (18). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) 18



Mating Surface



19



20



W2-1-5



21



W178-02-01-017



UPPERSTRUCTURE / Cab 9. Install duct cover (17) with screws (16). Install caps (15) onto duct cover (17).



16 17



15



W178-02-01-016



10. Install seat (1) with nuts (2). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)



2 1



W1F3-02-01-001



W2-1-6



UPPERSTRUCTURE / Cab DIMENSIONS OF THE CAB GLASS Chamfer Here



A



Unit: mm



R2



67



Chamfer along the



303.5



11



Periphery unless Otherwise Specified



R35



R98 4-φ13 0 -1



Section A



R3018 W178-02-01-019



30



405



Chamfer Both Sides



375 612



51



238 R118 (5 mm)



148.5



343.5 196



100 50



R70



370.5



W178-02-01-006



Along the Periphery c1



Along the Periphery



B



W178-02-01-002



c1 14



733



R58 R58 R11508



Section B



W178-02-01-019



R1808



882.5



997



(4 mm)



R308



R1898 R258



100



150 943 W178-02-01-007



W2-1-7



UPPERSTRUCTURE / Cab Unit: mm Chamfer Here Chamfer Here



85.4 343.3



Charmfer Slightly unless the periphery Polish Chamfered



213



R105 R10



R72 R105



(4 mm) Chamfer Slightly unless the Periphery Polish Chamfered



C



39.5



733



733



R2465



2-φ12.2 +0.5-0



Section C and D



(4 mm)



D



6.754°



40



W178-02-01-019



Polish Chamfer Both Sides 289.5 50



3-R4



2-R4 50



86.9



50



556.3 50



W178-02-01-011



423 W178-02-01-008



366.1 R12



104.5



R95



(5 mm) 982.7



Chamfer along the Periphery



W178-02-01-004



R2002 872



R123



R5 for 3 Places



38.2 51



364.7 R2475



R14 470.6



(5 mm)



Chamfer along the Periphery



R115



888.58 W178-02-01-010



W2-1-8



W178-02-01-009



UPPERSTRUCTURE / Cab Remove Cab Glass Procedures to remove left-hand cab glass, lower glass of the door and upper front glass



Mounting Rubber Section



Mounting Rubber



CAUTION: When removing broken or cracked glass beware of the danger of glass shards that may cause serious injury. Before removing, gummed tape or something like should be used to paste the broken or cracked glass ready to reinforce them so as to prevent hurt from occurring. Be sure to remove glass pieces away. Take protective measures before removing. Reinforce broken or cracked glass with gummed tape to assist in safe removal.



Glass



Cab Seal Rubber



W178-02-01-022



W178-02-01-004



1. Insert bamboo spatula into position A in mounting rubber to pry the mounting rubber apart along all periphery. It is easier to remove glass when air is entered between cab and mounting rubber. 2. Tap glass from the side in cab by palm of the hand to take the glass off. Two men are required to do the work.



A



Mounting Rubber



IMPORTANT: Be sure to install the cab glass and mounting rubber using the special bonding agent. The cab glass may fall if the special bonding agent is not used. The cab glass assembly cannot be replaced individually. Be sure to change the cab glass as an assembly. The upper front glass is arched-fringed. If this glass needs to be replaced, contact with the nearest HITACHI dealers to replace it as an assembly.



W2-1-9



Glass



Cab Seal Rubber



W178-02-01-022



UPPERSTRUCTURE / Cab Procedure to Remove Right-Hand Cab Glass



Mounting Rubber Section Cab Inside



1. Insert a bamboo spatula into position A in mounting rubber to pry the mounting rubber apart along all periphery. It is easier to remove the glass when air is entered between cab and mounting rubber.



Glass



Mounting Rubber



A Cab



2. Tap glass from the side in cab by palm of the hand to take the glass off. Two men are required to do the work.



W216-02-01-005



W178-02-01-002



Mounting Rubber Section Mounting Rubber



Procedure to Remove Rear Side Cab Glass 1. Remove stopper (groove rubber) with a screwdriver.



Glass



Cab Inside A



2. Insert a bamboo spatula into position A in mounting rubber to pry the mounting rubber apart along all periphery.



Stopper (Groove Rubber) A



Cab W216-02-01-003



3. Tap glass from the side in cab by palm of the hand to take the glass off. Two men are required to do the work.



W178-02-01-005



W2-1-10



UPPERSTRUCTURE / Cab Left-Hand Cab Glass



Cab Glass Installation Procedure Procedure for installing left-hand cab glass, lower glass of the door and upper front glass



A CSE Braid



1. Install the seal rubber on the left-hand cab glass and lower glass of the door. Section A



Seal Rubber



Put Connect End in Center of Glass Edge and Then adhere It W178-02-01-021



Lower Glass Of Door 50 5



A



W178-02-01-023



CSE Braid



Seal Rubber 10



10



2. When the mounting rubber is already on the glass, pull and fasten the mounting rubber onto the mounting face of cab. IMPORTANT: Be sure to install the cab glass and mounting rubber using the special bonding agent. The cab glass may fall if the special bonding agent is not used. The cab glass assembly cannot be replaced individually. Be sure to change the cab glass as an assembly. The upper front glass is archedfringed. If this glass needs to be replaced, replaced it as an assembly.



W178-02-01-020



Mounting Rubber Section



Mounting Rubber



Glass



Cab Seal Rubber



W178-02-01-022



W178-02-01-004



W2-1-11



UPPERSTRUCTURE / Cab Procedure for Installing Right-Hand Cab Glass



Mounting Rubber Section



1. Install the mounting rubber into the surrounding of cab glass. Bond the connectors of mounting rubber with the bonding agent (Cemedine 366 Standard or equivalent).



Glass



Mounting Rubber



Cab



NOTE: Rubber aging will cause the contraction of rubber, be sure to leave a little extra, install by pressing with hands.



W216-02-01-005



2. Put and fasten the mounting rubber on the mounting face of cab after installing rubber.



W178-02-01-002



Procedure for Installing Rear Cab Glass



Mounting Rubber Section



1. Insert mounting rubber around the cab glass. Install the connectors or mounting rubber with the bonding agent (Cemedine 366 Standard or equivalent).



Mounting Rubber



Stopper



NOTE: Rubber aging will cause the contraction of rubber, be sure to leave a little extra, install by pressing with hands. 2. After installing the glass assembly on the cab, insert the stopper into rubber.



Glass



Cab W216-02-01-003



IMPORTANT: The rear side glass is arched-fringed. If this glass needs to be replaced, contact with the nearest HITACHI dealers to replace it as an assembly.



W178-02-01-005



W2-1-12



UPPERSTRUCTURE / Counterweight REMOVE WEIGHT



AND



INSTALL



COUNTER-



Removal FLENO LINKBOLT Mounting Holes



CAUTION: Counterweight Weight: 3770 kg (8320 lb)



1 2



1. Remove caps (1) from upper counterweight (2). Install FLENO LINKBOLTs to counterweight (2). NOTE: FLENO LINKBOLTs specification (B-36: M36, Pitch 4.0) 2. Lift and hold counterweight (2). 3. Remove counterweight mounting bolts (4) (4 used). : 50 mm IMPORTANT: The wire of combination lamp has been connected to back of counterweight (2). Before remove counterweight (2), disconnect the wire.



3 4



W1F3-02-02-001



CAUTION: When disconnecting wire take care not to get hands caught between counterweight (2) and frame. 2



4. Lift and dislocate counterweight (2) to backward approx. 200mm (7.9 in). Remove connectors of both side combination lamps. 3



5. Lift counterweight (2) off the frame.



4



W178-02-02-003



W2-2-1



UPPERSTRUCTURE / Counterweight Installation CAUTION: Counterweight Weight: 3770 kg (8320 lb) 1. Lift and place counterweight (2) on the frame leaving 200 mm (7.9 in) between frame backside and counterweight (2). 2. Connect connectors of both side combination lamps. 3. Lift and place counterweight (2) on mounting position.



2 4



3



W178-02-02-003



4. Temporarily tighten counterweight (2) onto the frame with washers (3) (4 used) and bolts (4) (4 used). 5. Tighten counterweight mounting bolts (4) (4 used) with a power wrench and toque wrench. : 50 mm : 2600 N⋅m (265 kgf⋅m, 1920 Ibf⋅ft) 6. Remove FLENO LINKBOLTs then install caps (1).



Toque Wrench Power Wrench



W178-02-02-004



1



W178-02-02-001



W2-2-2



UPPERSTRUCTURE / Main Frame REMOVE AND INSTALL MAIN FRAME CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.) Removal Counterweight



CAUTION: Counterweight weight: 3770 kg (8320 Ib) 1. Remove the counterweight. (Refer to “Remove and Install Counterweight” group.) : 50 mm CAUTION: Front attachment assembly weight: Monoblock boom: 2680 kg (5910 Ib) 2-Piece boom: 3220 kg (7100 Ib)



W178-02-02-003



Monoblock Boom



2. Remove the front attachment assembly. (Refer to “Remove and Install Front Attachment” group on page W4-1-2.) : 27 mm, 30 mm, 36 mm



W1F3-04-01-002



2-Piece Boom



W1F3-04-01-001



W2-3-1



UPPERSTRUCTURE / Main Frame Stopper



CAUTION: Center joint weight: 93 kg (210 Ib) 3. Remove the stopper and hoses. (Refer to “Remove and Install Center Joint” group.) : 24 mm, 36 mm



Center Joint



W1F3-03-03-003



CAUTION: Upperstructure weight: 4350 kg (9600 Ib) IMPORTANT: Make sure rear wire ropes not to touch engine. 4. Attach wire ropes to the rear (counterweight bracket) of the frame and boom bracket. NOTE: It is easy to adjust the wire ropes length and level the frame if a chain block is used.



5. Put mating marks on the upperstructure and the outer race of the swing bearing. Loosen the mounting bolt of the swing bearing and remove it. : 27 mm NOTE: Chain block shall be used to adjust and level the frame, then lift it slightly off the undercarriage.



Rear W105-02-03-004



Front W105-02-03-005



W1F3-03-01-002



Bolt



W2-3-2



UPPERSTRUCTURE / Main Frame Installation CAUTION: Upperstructure weight: 4350 kg (10980 Ib) 1. Fasten wire ropes to the main frame. Level the main frame by adjusting the chain block. Lift and install the main frame to the undercarriage. NOTE: As for lifting method, refer to Removal section. 2. Align the mating mark on the outer race of the upperstructure and the swing bearing. Install the mounting bolt to the swing bearing and tighten it temporarily. Remove wire ropes and tighten the mounting bolts to the swing bearing to specification. Upperstructure Side: : 27 mm : 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft) Undercarriage Side: : 30 mm : 500 N⋅m (51 kgf⋅m, 370 Ibf⋅ft) 3. Connect the hoses (15 used) to the center joint. : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft) : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft) : 22 mm : 39 N⋅m (4.0 kgf⋅m, 28.5 Ibf⋅ft) : 27 mm : 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft) 4. Apply LOCTITE#262 to the bolts (5 used). Install the stopper with them. : 24 mm : 265 N⋅m (27 kgf⋅m, 195 Ibf⋅ft) CAUTION: Counterweight weight: 3770 kg (8320 Ib)



W1F3-03-01-002



Bolt Bolt Stopper



Center Joint



W1F3-03-03-003



Counterweight



5. Install counterweight (6). (Refer to “Remove and Install Counterweight” group.) : 50 mm : 2600 N⋅m (265 kgf⋅m, 1920 Ibf⋅ft) W178-02-02-003



W2-3-3



UPPERSTRUCTURE / Main Frame CAUTION: Front attachment assembly weight: Monoblock boom: 2680 kg (5910 Ib) 2-Piece boom: 3220 kg (7100 Ib)



Monoblock Boom



6. Install front attachment assembly. Then, fill with hydraulic oil. (Refer to “Remove and Install Front Attachment” group on page W4-1-2.) : 27 mm : 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft) : 30 mm : 540 N⋅m (55 kgf⋅m, 400 Ibf⋅ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft)



W1F3-04-01-002



2-Piece Boom



7. Start the engine and set the front attachment in posture for checking hydraulic oil level in its tank. Inspect the hydraulic oil level and check if any oil leakage is available.



W1F3-04-01-001



W2-3-4



UPPERSTRUCTURE / Pump Device REMOVE AND INSTALL PUMP DEVICE CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.) Removal 1. Remove the cover, bracket and engine cover of the pump device upper side. 2. Disconnect all hoses, pipings and wire harness connectors from the pump device. Upper side • Hoses (5 used) • Regulator pilot hoses (4 used) Center side • Main hoses (2 used) • Pilot pump hose (3 used) • Wire Harness Connector (1 used) Lower side • Suction pipe (1 used) • Wire Harness Connectors (5 used) • Pilot hose (1 used) • Pilot pump hoses (2 used)



Steering Pump



Pilot Pump



Pilot Filter



CAUTION: Pump Device Weight: 95 kg (210 lb) 3. Attach a nylon sling to the pump device and hold it by crane. 4. Remove pump device mounting socket bolts (4 used). Hoist the pump device and remove it.



W2-4-1



Pump Device



Steering Filter



MCBB-07-026



UPPERSTRUCTURE / Pump Device Installation CAUTION: Pump Device Weight: 95 kg (210 lb) 1. Attach a nylon sling to the pump device and hoist it by crane. Install the pump device to the pump cover with socket bolts (4 used). : 14 mm : 200 to 270 N⋅m (20 to 27 kgf⋅m, 145 to 195 Ibf⋅ft)



Steering Pump



Pilot Pump



Pilot Filter



2. Connect all hoses and pipings. : 27 mm : 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft) : 36 mm : 175 N⋅m (18.0 kgf⋅m, 130 Ibf⋅ft)



Pump Device



Steering Filter



3. Connect wire harness connectors. IMPORTANT: Bleed the air from the pump. (Refer to W1-1-2) Be sure to check hydraulic oil level and any oil leaks after assembling. : 36 mm : 147 N⋅m (15 kgf⋅m, 108 Ibf⋅ft)



W2-4-2



MCBB-07-026



UPPERSTRUCTURE / Pump Device (Blank)



W2-4-3



UPPERSTRUCTURE / Pump Device DISASSEMBLE MAIN PUMP 18



15



14 11



12



16



19



20



21



22



17



13 23



10



24



9 7 4



5



8



6 25



3



39



2



26 37



1



38



36



27



35 34



41



33 30 28



29



31



40



42



32 45



44



43



46



53



52



51



47 50 48 63



49



54



62 61 60



64



55 56



59



65



57



66



58



67 68 69 71



70 W1F3-02-04-001



W2-4-4



UPPERSTRUCTURE / Pump Device



12345678910 11 12 13 14 15 16 17 18 -



Socket Bolt (2 Used) Steering Pump Cover O-Ring Retaining Ring (2 Used) Spacer (2 Used) Bearing (2 Used) Spacer (2 Used) Shaft Cover Nut (2 Used) Adjusting Screw (2 Used) Spring Pin (2 Used) Stopper (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Housing Tilt Pin (2 Used)



19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 -



Servo Piston (2 Used) O-Ring (2 Used) Backup Ring (2 Used) Stopper (2 Used) O-Ring (2 Used) Plug (2 Used) O-Ring (2 Used) Plug (8 Used) Socket Bolt (4 Used) Swash Plate (2 Used) Bushing (2 Used) Shoe Plate (2 Used) Plunger (18 Used) Retainer (2 Used) Spherical Bushing (2 Used) Spring (18 Used) Cylinder Block (2 Used) Valve Plate



37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 -



W2-4-5



Needle Bearing Gear O-Ring Socket Bolt (4 Used) Cover Oil Seal O-Ring Shaft Housing O-Ring (18 Used) O-Ring (2 Used) Valve Plate Needle Bearing Eye Bolt Nut (2 Used) Adjusting Screw (2 Used) Plug (8 Used) Valve Cover



55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 -



Spring Pin Pin O-Ring (2 Used) Plug (2 Used) O-Ring Spring Pin (2 Used) Pin Socket Bolt (4 Used) Cover Socket Bolt (2 Used) Cover O-Ring PTO Gear Case Socket Bolt (4 Used) O-Ring Pilot Pump Socket Bolt (2 Used)



UPPERSTRUCTURE / Pump Device



18



15



14 11



12



16



19



20



21



22



17



13 23



10



24



9 7 4



5



8



6 25



3



39



2



26 37



1



38



36



27



35 34



41



33 30 28



29



31



40



42



32 45



44



43



46



53



52



51



47 50 48 63



49



54



62 61 60



64



55 56



59



65



57



66



58



67 68 69 71



70 W1F3-02-04-001



W2-4-6



UPPERSTRUCTURE / Pump Device Disassemble Main Pump • Be sure to read “Precautions for Disassembly and Assembly Work” thoroughly on page W1-1-1 before starting the disassembly work. • For removal of the regulator, refer to “Remove Regulator”section. IMPORTANT: Do not disassemble nut (11), adjusting screw (12), nut (51) and adjusting screw (52) of main pump 1 and 2. The set flow rate may be changed. 1. Remove plugs (24) (2 used) and O-rings (23) (2 used) to drain hydraulic oil from the main pump. : 36 mm 2. Remove socket bolts (68) (4 used), remove the PTO gear case (67) assembly and o-ring (59) housing from valve cover (54). : 8 mm 3. Remove socket bolts (1) (2 used), remove steering pump (2), cover (3) and O-ring (4) from cover (10). : 8 mm



IMPORTANT: Take care that valve plate (36) and (48) may come off when parts separated. Do not remove needle bearings (37) and (49) unless necessary. In case they are removed, replace them with new ones. 6. Separate housing (17), valve cover (54) and the housing (45) assemblies. Be sure to remove O-rings (25) (2 used), (39), (43), (46) (18 used), spring pins (55) (2 used) and (60) (2 used) when separating these assemblies. 7. Remove valve plate (36) and pin (56) from valve cover (54). 8. Remove cylinder block (35) from housing (17) and the housing (45) assembly. Springs (34) (9 used), spherical bushing (33), retainer (32) and plungers (31) (9 used) will be removed together with cylinder block (35). NOTE: Slowly remove cylinder block (35) while turning it to left and right softly by both hands. 9. Remove retainer (32) from the cylinder block (35) assembly. Plungers (31) (9 used) will be removed together with retainer (32).



4. Remove eye bolt (50) from valve cover (54). CAUTION: Pump Device Weighet: 95 kg (210 lb) IMPORTANT: Take care not to dent or scratch the contact surface of regulator. After installing swash plate (28), check if it moves smoothly. 5. Attach a nylon sling to the main pump. Turn the main pump over with the regulator mounting side facing downward. Remove socket bolts (27) (4 used) and (62) (4 used). : 14 mm



10. Remove plungers (31) (9 used) from retainer (32). 11. Remove spherical bushing (33) from cylinder block (35), then remove springs (34) (9 used). 12. Tap cover (10) with a plastic hammer to remove it. Remove O-rings (46) (2 used) and spring pin (13) as well. 13. Remove swash plate (28) and shoe plate (30) from housing (17).



W2-4-7



UPPERSTRUCTURE / Pump Device



18



14



15



16



19



20



21



22



17



10 9 7 5



8



6



45



48 54



61



W1F3-02-04-001



W2-4-8



UPPERSTRUCTURE / Pump Device IMPORTANT: As LOCTITE (middle strength) has been applied on the contacting part between servo piston (19) and tilt pin (18), do not disassemble them unless required. When disassembling them, do not damage servo piston (19). 14. Remove stoppers (14), (22), backup rings (15), (21), O-rings (16) and (20) from housing (17) to remove servo piston (19) and tilt pin (18). 15. Tap the end of shaft (9) with a plastic hammer to remove it from cover (10). 16. Remove retaining ring (5) from shaft (9) to remove spacer (6). 17. Remove bearing (7) from shaft (9) with a press to remove spacer (8). 18. Remove valve plate (48) and pin (61) from valve cover (54). 19. Disassemble the housing (45) assembly according to the same procedure as 8 to 17.



W2-4-9



UPPERSTRUCTURE / Pump Device ASSEMBLE MAIN PUMP 33



63



45



52 51



28 30 29 39 46



22



21



20



17 18 19



14 16



15 10 11 12 13 4 3



40



44



1 5



43 42



9



41 27 62



47



32 31 34 35



36 56 55 37



38 54 49 61 47



60 48



8



25



7



6 T1F3-03-01-003



12345678910 11 12 13 14 15 16 17 18 -



Socket Bolt (2 Used) *Steering Pump Cover O-Ring Retaining Ring (2 Used) Spacer (2 Used) Bearing (2 Used) Spacer (2 Used) Shaft Cover Nut (2 Used) Adjusting Screw (2 Used) Spring Pin (2 Used) Stopper (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Housing Tilt Pin (2 Used)



19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 -



Servo Piston (2 Used) O-Ring (2 Used) Backup Ring (2 Used) Stopper (2 Used) *O-Ring (2 Used) *Plug (2 Used) O-Ring (2 Used) *Plug (8 Used) Socket Bolt (4 Used) Swash Plate (2 Used) Bushing (2 Used) Shoe Plate (2 Used) Plunger (18 Used) Retainer (2 Used) Spherical Bushing (2 Used) Spring (18 Used) Cylinder Block (2 Used) Valve Plate



37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 -



NOTE: As for the components with * mark, refer to W2-3-4.



W2-4-10



Needle Bearing Gear O-Ring Socket Bolt (4 Used) Cover Oil Seal O-Ring Shaft Housing O-Ring (18 Used) O-Ring (2 Used) Valve Plate Needle Bearing *Eye Bolt Nut (2 Used) Adjusting Screw (2 Used) Plug (8 Used) Valve Cover



55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 -



Spring Pin Pin *O-Ring (2 Used) *Plug (2 Used) *O-Ring Spring Pin (2 Used) Pin Socket Bolt (4 Used) Cover *Socket Bolt (2 Used) *Cover *O-Ring *PTO Gear Case *Socket Bolt (4 Used) *O-Ring *Pilot Pump *Socket Bolt (2 Used)



UPPERSTRUCTURE / Pump Device Assemble Main Pump IMPORTANT: Apply LOCTITE (middle strength) to the matching part between servo piston (19) and tilt pin (18). 1. Install tilt pin (18), servo piston (19), O-rings (16), (20), backup rings (15), (21), stopper (14) and (22) into both housing (17) and housing (45). 2. Install spring pin (13) and O-ring (25) onto covers (10) and (63). Install them onto housings (17) and (45). 3. Tap the covers (10) and (63) with a plastic hammer onto housings (17) and (45). IMPORTANT: Take care not to dent or scratch the contact surface of regulator. After installing swash plate (28), check if it moves smoothly. 4. Place housings (17) and (45) on a workbench with their regulator mounting side facing down. Install swash plate (28) with shoe plate (30) onto tilt pin (18). 5. Install spacer (8) onto shaft (9) and (44), then install bearing (7) with a press.



8. Install O-ring (43) and oil seal (42) onto cover (41). Install cover (41) onto cover (63) with socket bolts (40) (4 used). : 5 mm : 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft) 9. Install springs (34) (9 used) and spherical bushing (33) into cylinder block (35). 10. Install plungers (31) (9 used) into retainer (32), and install retainer (32) into cylinder block (35). 11. Aligning the splines, then install the cylinder block (35) assembly onto both shaft (9) and shaft (44). IMPORTANT: Apply grease to the back of valve plate (48) to prevent it from coming off. 12. Install pin (61), valve plate (48), O-rings (46) (6 used), O-ring (47) and spring pin (60) onto valve cover (54). Install valve cover (54) onto housing (17) with socket bolts (27) (4 used). Temporarily secure socket bolts (27) (4 used) so that shaft (44) can be turned by hand. : 14 mm



6. Install spacer (6) and retaining ring (5) onto each shaft (9) and shaft (44). Install each shaft (9) and (44) into covers (10) and (63) with a press. 7. Install O-rings (4) onto cover (3). Install cover (3) and steering pump (2) with socket bolts (1) (2 used). : 5 mm : 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft)



W2-4-11



UPPERSTRUCTURE / Pump Device



45



17 18



39 46



44



9



27 62



38 54 T1F3-03-01-003



NOTE: As for components (59), (67) and (68), refer to W2-3-4.



W2-4-12



UPPERSTRUCTURE / Pump Device 13. Install gear (38) into shaft (9). 14. Install O-rings (46) (3 used) and O-rings (39) onto valve cover (54). Connect the housing (17) assembly and the housing (45) assembly with socket bolts (62) (4 used). Temporarily tighten socket bolts (62) (4 used) and align the spline part with that of gear (38) while turning shaft (44) by hand to connect them. : 14 mm 15. Tighten socket bolts (27) (4 used) and (62) (4 used). : 14 mm : 240 N⋅m (24 kgf⋅m, 170 Ibf⋅ft) 16. Install O-ring (59) and the PTO gear case (67) assembly with socket bolts (68) (4 used) onto valve cover (54). : 8 mm : 33 N⋅m (3.5 kgf⋅m, 24.5 Ibf⋅ft) IMPORTANT: When installing regulator, be sure to insert the feedback lever of regulator into tilt pin (18).



W2-4-13



UPPERSTRUCTURE / Pump Device MAINTENANCE STANDARD 31



1. Clearance between plunger (31) diameter (d) and cylinder block (35) bore (D). D-d



35



Unit: mm (in) Standard 0.028 (0.017)



d



Allowable Limit 0.056 (0.002)



D



W117-02-02-009



34



2. Spring (34) free length (L). Unit: mm (in) Standard 31.3 (1.23)



Allowable Limit 30.2 (1.19)



L W117-02-02-010



3. Clearance between plunger (31) and shoe (e) and shoe thickness (t). e



31



Unit: mm (in) Standard 0 to 0.1 (0 to 0.004)



t



Allowable Limit Shoe



0.3(0.012) Unit: mm (in)



Standard 3.9 (0.154)



e



Allowable Limit 3.7 (0.146)



t



W117-02-02-011



Stand



4. Distance between retainer (32) bottom and spherical bushing (33) top. H-h



Unit: mm (in) Standard 19.0 (0.75)



32



33



h



Allowable Limit 18.2 (0.72)



H



W117-02-02-012



W2-4-14



UPPERSTRUCTURE / Pump Device (Blank)



W2-4-15



UPPERSTRUCTURE / Pump Device DISASSEMBLE REGULATOR (MAIN PUMP 2 SIDE) 12 11 10 9 8



7 6



B



5 2



D



21 22



F



4



3



1



19



14



16



24 25



20 A



26 31 30



G



18



15



23



C



17



E



29 28



13



27



32 34 33



47 46 35



43



42 39



45



36 37 44



48



41



49



40



38



D



50 E



67



51



66



52 65



59



64 A



53



54



58 B



C



57 63



56



62 61



W2-4-16



60



55 W1F3-02-04-006



UPPERSTRUCTURE / Pump Device



12345678910 11 12 13 14 15 16 17 18 -



Pin Sleeve O-Ring O-Ring Sleeve Compensating Piston Compensating Rod Spring Seat Spring Spring Stopper O-Ring Retaining Ring Spring Seat Spring Spring Retaining Ring Sleeve



19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 -



Spool Pin Lever Feedback Lever Pin Pin Lever Pin Pilot Piston Spring Seat Spring Stopper O-Ring Socket Bolt (4 Used) Cover Solenoid Valve O-Ring



36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 -



W2-4-17



O-Ring O-Ring (2 Used) Socket Bolt (2 Used) Socket Bolt (2 Used) O-Ring Adjusting Screw Adjusting Screw Nut O-Ring Cover Socket Bolt (4 Used) Nut Nut Adjusting Screw Housing Pin



52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 -



Supporting Plug O-Ring Retaining Ring Retaining Ring O-Ring Supporting Plug Pin Pin O-Ring O-Ring (7 Used) O-Ring (2 Used) O-Ring O-Ring Socket Bolt (2 Used) Socket Bolt (2 Used) Cover



UPPERSTRUCTURE / Pump Device 12 11 10 9 8



7 6



B



5 2



D



21 22



F



4



3



1



19



14



16



24 25



20 A



26 31 30



G



18



15



23



C



17



E



29 28



13



27



32 34 33



47 46 35



43



42 39



45



36 37 44



48



41



49



40



38



D



50 E



67



51



66 F



65



59



64 A



52 G



53



54



58 B



C



57 63



56



62 61



W2-4-18



60



55 W1F3-02-04-006



UPPERSTRUCTURE / Pump Device Disassemble Regulator (Main Pump 2 Side) • Be sure to read “Precautions for Disassembly and Assembly Work” thoroughly on page W1-1-1 before starting the disassembly work. 1. Remove socket bolts (38) (2 used) and (39) (2 used) to remove the regulator from the main pump. : 6 mm 2. Remove solenoid valve (34) from housing (50). : 32 mm IMPORTANT: Do not remove adjusting screws (41), (42), (49) and nuts (43), (47), (48). The flow rate setting of the pump will change after removing. 3. Remove socket bolts (32) (4 used) from cover (33), remove cover (33) from housing (50). : 5 mm 4. Remove O-ring (35), (36) and (37) (2 used) from cover (33). 5. Remove O-rings (60), (61) (7 used) and pin (59) from housing (50). 6. Remove socket bolts (65) (2 used) and (66) (2 used) from cover (67) to remove cover (67), spring (16) and O-ring (63), (64) and (62) (2 used). : 5 mm 7. Remove pin (1), sleeve (2), O-rings (3) and (4), sleeve (5) and compensating piston (6) from housing (50).



9. Remove socket bolts (46) (5 used) from cover (45) to remove cover (45), stopper (11), springs (10) and (9), spring seat (8), stopper (30), spring (29) and spring seat (28). : 5 mm IMPORTANT: Do not remove pin (58) from supporting plug (57). Make matching marks between support plugs (52), (57) and housing (50) to prevent them from confusion. 10. Remove retaining rings (54) and (55) from housing (50) to remove supporting plugs (52) and (57) using puller bolts (M6). IMPORTANT: Do not remove pin (26) from lever (25). 11. Remove lever (25) from housing (50) with a pairs or tweezers etc. to remove pilot piston (27). IMPORTANT: In case pin (23) cannot be removed, remove sleeve (18) first to remove pin (23) with making play for spool (19). 12. Insert a copper bar into the supporting plug (52) hole to remove pin (23) from feedback lever (22). After that, remove feedback lever (22), sleeve (18), retaining ring (17) and spool (19). IMPORTANT: Do not remove pins (20) and (51) from lever (21). 13. Remove lever (21) with a pairs of tweezers etc. from housing (50) to remove compensating rod (7).



8. Remove retaining ring (13) from housing (50) to remove spring seat (14) and spring (15).



W2-4-19



UPPERSTRUCTURE / Pump Device ASSEMBLE REGULATOR (MAIN PUMP 2 SIDE)



A B



52 53



54 51



55 56 57 A B



23 25



50 24



Section B-B



28 29 30 45



27



T1F3-03-01-006



46 48 49



60



38



63



58



22



26 39



31 T1F3-03-01-007



Section A-A 67



14 15 17



16 64



19



18 21



8



9



10



44



45 47



13



41



66



43



3



42



65



1



2



4



5



6



7



20



59 40



12



11 T1F3-03-01-008



W2-4-20



UPPERSTRUCTURE / Pump Device



12345678910 11 12 13 14 15 16 17 18 -



Pin Sleeve O-Ring O-Ring Sleeve Compensating Piston Compensating Rod Spring Seat Spring Spring Stopper O-Ring Retaining Ring Spring Seat Spring Spring Retaining Ring Sleeve



19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 -



Spool Pin Lever Feedback Lever Pin Pin Lever Pin Pilot Piston Spring Seat Spring Stopper O-Ring Socket Bolt (4 Used) Cover Solenoid Valve *O-Ring



36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 -



NOTE: As for parts with * mark, refer to W2-3-16.



W2-4-21



*O-Ring *O-Ring (3 Used) Socket Bolt (2 Used) Socket Bolt (2 Used) O-Ring Adjusting Screw Adjusting Screw Nut O-Ring Cover Socket Bolt (4 Used) Nut Nut Adjusting Screw Housing Pin



52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 -



Supporting Plug O-Ring Retaining Ring Retaining Ring O-Ring Supporting Plug Pin Pin O-Ring *O-Ring (7 Used) O-Ring (2 Used) O-Ring (7 Used) O-Ring Socket Bolt (2 Used) Socket Bolt (2 Used) Cover



UPPERSTRUCTURE / Pump Device ASSEMBLE REGULATOR (MAIN PUMP 2 SIDE)



A B



52 53



54 51



55 56 57 A B



23 25



50 24



Section B-B



28 29 30 45



27



T1F3-03-01-006



46 48 49



60



38



63



58



22



26 39



31 T1F3-03-01-007



Section A-A 67



14 15 17



16 64



19



18 21



8



9



10



44



45 47



13



41



66



43



3



42



65



1



2



4



5



6



7



20



59 40



12



11 T1F3-03-01-008



NOTE: As for parts (51) with * mark, refer to W2-3-16.



W2-4-22



UPPERSTRUCTURE / Pump Device Assemble Regulator (Main Pump 2 Side) 1. Insert compensating rod (7) and lever (21) into housing (50). 2. Align pin (51) of lever (21) with the pin hole in housing (50) inside. Align pin (20) with stepped joint portion of compensating rod (7) to install lever (21) into housing (50). 3. Install retaining ring (17) to sleeve (18) and insert sleeve (18) and spool (19) into housing (50). IMPORTANT: Check spool (19) if it should move smoothly before installing feedback lever (22). Be sure to install spool (19) and feedback lever (22) in the correct direction. Do not make any mistake while doing this procedure. 4. Align the pin hole in feedback lever (22) with the pin hole in spool (19), and tap pin (23) from the mounting hole of supporting plug (52) with a plastic hammer. 5. Insert pilot piston (27) and lever (25) into housing (50). IMPORTANT: Check pilot piston (27) if it should move smoothly before installing lever (25). 6. Align pin (26) of lever (25) with stepped joint portion of pilot piston (27) to install lever (25). 7. Install O-rings (53) and (56) to supporting plugs (52) and (57) respectively.



IMPORTANT: Supporting plug (57) and (52) can be installed in either hole. Be sure to install them according to the matching mark made when disassembling and never confuse them, otherwise the pump control will be out of order. 8. Align pin (58) of supporting plug (57) with the pin hole of lever (25) to insert pin (58) and install retaining ring (55). 9. Insert supporting plug (52) into housing (50) and install retaining ring (54). 10. Install O-ring (31) onto stopper (30). 11. Install spring seat (28), spring (29) and stopper (30) to housing (50). 12. Install O-ring (12) onto stopper (11). 13. Place O-ring (44) in housing (50). After that, insert spring seat (8), springs (9) and (10) and stopper (11) into housing (50). Install cover (45) to housing (50) with socket bolts (46) (4 used). : 5 mm : 12 N⋅m (1.2 kgf⋅m, 8.9 Ibf⋅ft) 14. Install spring (15), spring seat (14) and retaining ring (13) onto spool (19). 15. Place ring (4) to sleeve (5) and install sleeve (5), compensating piston (6), O-ring (3), sleeve (2) and pin (1) into housing (50).



W2-4-23



UPPERSTRUCTURE / Pump Device



A B



T1F3-03-01-006



50



Section B-B



63



38



60



39 T1F3-03-01-007



Section A-A 66



65



T1F3-03-01-008



NOTE: As for parts (62) and (61), refer to W2-3-16.



W2-4-24



UPPERSTRUCTURE / Pump Device 16. Install spring (16), O-rings (64), (63) and (62) (2 used) into housing (50) and install cover (67) to housing (50) with socket bolts (66) (2 used) and (65) (2 used). : 5 mm : 12 N⋅m (1.2 kgf⋅m, 8.9 Ibf⋅ft) 17. Install O-rings (60) and (61) (7 used) to housing (50). 18. Install the regulator onto the main pump with socket bolts (38) (2 used) and (39) (2 used). : 6 mm : 29 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)



W2-4-25



UPPERSTRUCTURE / Pump Device DISASSEMBLE REGULATOR (MAIN PUMP 1 SIDE)



12



11 10 9 8 7



6



1



2



3



21



D



B



5



22



F



4



23



24



25



20 19



26



A



13



14



15



16



30



G



18 17



C



E



31



29 28



27 32 33 34 58



44



42 43



41



40



39



57



38



37 50



52



53



56



35



36



54



55 60



51



59



49



45



46



47 48 61 D E



62 F



75 69 A



63 G



64



65



68 B



67



C



74



73



71 72



W2-4-26



70



66 W1F3-02-04-007



UPPERSTRUCTURE / Pump Device



12345678910 11 12 13 14 15 16 17 18 19 -



Pin Sleeve O-Ring O-Ring Sleeve Compensating Piston Compensating Rod Spring Seat Spring Spring Stopper O-Ring Retaining Ring Spring Seat Spring Spring Retaining Ring Sleeve Spool



20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 -



Pin Lever Feedback Lever Pin Pin Lever Pin Pilot Piston Spring Seat Spring Stopper O-Ring Block Socket Bolt (2 Used) Socket Bolt (2 Used) Stopper 1 Piston 1 Piston 2 O-Ring



39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 -



W2-4-27



Stopper 2 Adjusting Screw O-Ring Socket Bolt (2 Used) Cover Nut Socket Bolt (4 Used) Cover O-Ring (3 Used) O-Ring Socket Bolt (2 Used) Socket Bolt (2 Used) O-Ring Adjusting Screw Adjusting Screw Nut O-Ring Cover Socket Bolt (4 Used)



58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 -



Nut Nut Adjusting Screw Housing Pin Supporting Plug O-Ring Retaining Ring Retaining Ring O-Ring Supporting Plug Pin Pin O-Ring O-Ring (7 Used) O-Ring (2 Used) O-Ring O-Ring



UPPERSTRUCTURE / Pump Device 12



11 10 9 8 7 6



1



2



3



21



D



B



5



22



F



4



23



24



25



20 19



26



A



13



14



15



16



30



G



18 17



C



E



31



29 28



27 32 33 34 58



44



42 43



41



40



39



57



38



37 50



52



53



56



35



36



54



55 60



51



59



49



45



46



47 48 61 D E



62 F



75 69 A



63 G



64



65



68 B



67



C



74



73



71 72



W2-4-28



70



66 W1F3-02-04-007



UPPERSTRUCTURE / Pump Device Disassemble Regulator (Main Pump 1 Side) • Be sure to read “Precautions for Disassembly and Assembly Work” thoroughly on page W1-1-1 before starting the disassembly work. 1. Remove socket bolts (49) (2 used) and (50) (2 used) to remove the regulator from the main pump. : 6 mm IMPORTANT: Do not remove adjusting screws (52), (53), (60) and nuts (54), (58), (59). The flow rate setting of the pump will change after removing. 2. Remove socket bolts (45) (4 used) from cover (46) to remove covers (46). : 5 mm 3. Remove O-ring (47) (3 used) and (48) from cover (46). 4. Remove O-rings (71), (72) (7 used) and pin (70) from housing (61). 5. Remove socket bolts (34) (2 used) and (33) (2 used) from block (32) to remove block (32), spring (16) and O-ring (75), (74) and (73) (2 used). : 5 mm 6. Remove socket bolts (42) (2 used) to remove cover (43) from block (32). : 5 mm 7. Press piston 1 (36) from block (32) and compensating rods (7) side to remove the stopper 2 (39) assembly, piston (39) and stopper (35).



9. Remove pin (1), sleeve (2), O-rings (3) and (4), sleeve (5) and compensating piston (6) from housing (61). 10. Remove retaining ring (13) from housing (61) to remove spring seat (14) and spring (15). 11. Remove socket bolts (57) (4 used) from cover (56) to remove cover (56), stopper (11), springs (10) and (9), spring seat (8), stopper (30), spring (29) and spring seat (28). : 5 mm IMPORTANT: Do not remove pin (69) from supporting plug (68). Make matching marks between support plugs (63), (68) and housing (61) to prevent them from confusion. 12. Remove retaining rings (65) and (66) from housing (61) to remove supporting plugs (63) and (68) using forcing bolts (M6). IMPORTANT: Do not remove pin (26) from lever (25). 13. Remove lever (25) from housing (61) with a pairs of tweezers etc. to remove pilot piston (27). IMPORTANT: In case pin (23) cannot be removed, remove sleeve (18) first to remove pin (23) with making play for spool (19). 14. Insert a copper bar into the supporting plug (63) hole to remove pin (23) from feedback lever (22). After that, remove feedback lever (22), sleeve (18), retaining ring (17) and spool (19).



8. Remove O-ring (41) and O-ring (38) from stopper (39).



W2-4-29



UPPERSTRUCTURE / Pump Device



7 D



B



21



F



20 A G C



E



61 D E



62 F



A



B



G



C W1F3-02-04-007



W2-4-30



UPPERSTRUCTURE / Pump Device IMPORTANT: Do not remove pins (20) and (62) from lever (21). 15. Remove lever (21) with a pairs of tweezers etc. from housing (61) to remove compensating rod (7).



W2-4-31



UPPERSTRUCTURE / Pump Device ASSEMBLE REGULATOR (MAIN PUMP 1 SIDE)



A B



63 64



65



66 67 68 A B



41



Section B-B



38 32



35



23



24



61



27 28 29 30



25



T1F3-03-01-006



56 57



42



59 60



40 44



43



39



Section A-A



37 36 74



16



49



71



14 15



75



17



69



19



22 26



18



21



8



9



62



13



T1F3-03-01-004



31



50



10 55 51 56



58 52



3



54



34



53



33



1



2



4



5



6



7



W2-4-32



20



70



12



11



T1F3-03-01-005



UPPERSTRUCTURE / Pump Device



12345678910 11 12 13 14 15 16 17 18 19 -



Pin Sleeve O-Ring O-Ring Sleeve Compensating Piston Compensating Rod Spring Seat Spring Spring Stopper O-Ring Retaining Ring Spring Seat Spring Spring Retaining Ring Sleeve Spool



20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 -



Pin Lever Feedback Lever Pin Pin Lever Pin Pilot Piston Spring Seat Spring Stopper O-Ring Block Socket Bolt (2 Used) Socket Bolt (2 Used) Stopper 1 Piston 1 Piston 2 O-Ring



39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 -



NOTE: As for parts with * mark, refer to W2-3-26.



W2-4-33



Stopper 2 Adjusting Screw O-Ring Socket Bolt (2 Used) Cover Nut Socket Bolt (4 Used) Cover *O-Ring (3 Used) *O-Ring Socket Bolt (2 Used) Socket Bolt (2 Used) O-Ring Adjusting Screw Adjusting Screw Nut O-Ring Cover Socket Bolt (4 Used)



58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 -



Nut Nut Adjusting Screw Housing Pin Supporting Plug O-Ring Retaining Ring Retaining Ring O-Ring Supporting Plug Pin Pin O-Ring *O-Ring (7 Used) O-Ring (2 Used) O-Ring O-Ring



UPPERSTRUCTURE / Pump Device A B



63 64



65



66 67 68 A B



41



Section B-B



38 32



35



23



24



61



27 28 29 30



25



T1F3-03-01-006



56 57



42



59 60



40 44



43



39



Section A-A



37 36 74



16



49



71



14 15



75



17



69



19



22 26



18



21



8



T1F3-03-01-004



31



50



9



10 55 51 56



58



62



13



52



3



54



34



53



33



1



2



4



5



6



7



W2-4-34



20



70



12



11



T1F3-03-01-005



UPPERSTRUCTURE / Pump Device Assemble Regulator (Main Pump 1 Side) 1. Insert compensating rod (7) and lever (21) into housing (61). 2. Align pin (62) of lever (21) with the pin hole in the housing (61) inside. Align pin (20) with stepped joint portion of compensating rod (7) to install lever (21) into housing (61). 3. Install Assemble retaining ring (17) to sleeve (18) and insert sleeve (18) and spool (19) into housing (61). IMPORTANT: Check spool (19) if it should move smoothly before installing feedback lever (22). Be sure to install spool (19) and feedback lever (22) in the correct direction. Do not make any mistake while doing this procedure. 4. Align the pin hole in feedback lever (22) with the pin hole in spool (19), and tap pin (23) from the mounting hole of supporting plug (63) with a plastic hammer. 5. Insert pilot piston (27) and lever (25) into housing (61). IMPORTANT: Check pilot piston (27) if it should move smoothly before installing lever (25). 6. Align pin (26) of lever (25) with stepped joint portion of pilot piston (27) to install lever (25). 7. Install O-rings (64) and (67) to supporting plugs (63) and (68) respectively.



IMPORTANT: Supporting plugs (68) and (63) can be installed in either hole. Be sure to install them according to the matching mark made when disassembling and never confuse them, otherwise the pump control will be out of order. 8. Align pin (69) of supporting plug (68) with the pin (69) hole of lever (25) to insert the pin and install retaining ring (66). 9. Insert supporting plug (63) into housing (61) and install retaining ring (65). 10. Install O-ring (31) onto stopper (30). 11. Install spring seat (28), spring (29) and stopper (30) to housing (61). 12. Install O-ring (12) onto stopper (11). 13. Place O-ring (55) in housing (61). After that, insert spring seat (8), springs (9) and (10) and stopper (11) into housing (50). Install cover (56) to housing (61) with socket bolts (57) (5 used). : 5 mm : 12 N⋅m (1.2 kgf⋅m, 8.9 Ibf⋅ft) 14. Install spring (15), spring seat (14) and retaining ring (13) onto spool (19). 15. Install O-ring (4) to sleeve (5) and install sleeve (5), compensating piston (6), O-ring (3), sleeve (2) and pin (1) into housing (61).



W2-4-35



UPPERSTRUCTURE / Pump Device A B



A B



41



Section B-B



38 32



35



T1F3-03-01-006



61



42



43



Section A-A



39



37 36 74 16



49



71



69



T1F3-03-01-004



50



75



34



33



11



NOTE: As for parts (45), (46), (47), (48) and (72), refer to W2-3-26.



W2-4-36



T1F3-03-01-005



UPPERSTRUCTURE / Pump Device 16. Install O-rings (38), (41) and piston (37) to stopper 2 (39) 17. Install stopper 1 (35) and piston 1 (36) and the stopper (39) assembly to block (32) 18. Install cover (43) to block (32) with socket bolts (42) (2 used). : 5 mm : 12 N⋅m (1.2 kgf⋅m, 8.9 Ibf⋅ft) 19. Install spring (16), O-rings (75), (74) and (73) (2 used) into housing (61) and install block (32) with socket bolts (34) (2 used) and (33) (2 used). : 5 mm : 12 N⋅m (1.2 kgf⋅m, 8.9 Ibf⋅ft) 20. Install O-ring (48) and (47) (3 used) to cover (46) and install the cover (46) assembly onto housing (61) with socket bolts (45) (4 used). : 5 mm : 12 N⋅m (1.2 kgf⋅m, 8.9 Ibf⋅ft) 21. Install O-rings (71) and (72) (7 used) to housing (61). 22. Install the regulator onto the main pump with socket bolts (49) (2 used) and (50) (2 used). : 6 mm : 29 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)



W2-4-37



UPPERSTRUCTURE / Pump Device DISASSEMBLE PTO GEAR BOX 1 4 3 7



2 1



8



6 5



10 9



11 12 13 12



W1F3-02-04-002



14



1234-



Spacer (2 Used) Retaining Ring Bearing Gear



5678-



Retaining Ring Pin Pin (2 Used) Socket Bolt (4 Used)



9 - Plug 10 - O-Ring (1B P24) 11 - Gear Case



W2-4-38



12 - Bearing (2 Used) 13 - Gear 14 - Retaining Ring



UPPERSTRUCTURE / Pump Device Disassemble PTO Gear Box 1. Remove plug (9) from gear case (11). 2. Remove socket bolts (8) (4 used) to remove gear case (11) from pump casing. : 8 mm 3. Remove retaining ring (5) from gear case (11) to pull out pin (6). 4. Remove spacer (1) (2 used) and the gear (4) assembly from gear case (11). 5. Remove retaining ring (2) from gear (4) to remove bearing (3). 6. Remove retaining ring (14) from gear case (11) to remove bearing (12) (2 used) and gear (13). NOTE: Do not remove bearing (12) from gear (13). In case they are removed, replace them with new ones.



W2-4-39



UPPERSTRUCTURE / Pump Device ASSEMBLE PTO GEAR BOX



9



9



12



10



14 13



11



8



2



8



1 Gear Casing



6



7 4



3 5



4



5



W1F3-02-04-004



3



1234-



Spacer (2 Used) Retaining Ring Bearing Gear



5678-



Retaining Ring Pin Pin (2 Used) Socket Bolt (4 Used)



9 - Plug 10 - O-Ring (1B P24) 11 - Gear case



W2-4-40



W1F3-02-04-003



2



12 - Bearing (2 Used) 13 - Gear 14 - Retaining Ring



UPPERSTRUCTURE / Pump Device Assemble PTO Gear Box 1. Install the gear (13) assembly into gear case (11) to install retaining ring (14). 2. Install bearing (3) into gear (4). Lock bearing (3) with retaining ring (2) 3. Install the gear (4) assembly and spacer (1) (2 used). Install pin (6) onto gear case (11) to lock pin (6) with retaining ring (5). 4. Install O-ring (10) and plug (9) into gear case (11). 5. Install the gear case (11) assembly to the pump casing with socket bolts (8) (4 used). : 8 mm : 33 N⋅m (3.5 kgf⋅m, 24.5 Ibf⋅ft)



W2-4-41



UPPERSTRUCTURE / Pump Device DISASSEMBLE AND ASSEMBLE PILOT PUMP AND STEERING PUMP



27 13 26



10



10 12



1 9



6



26 14



27 6 9 2 3



5



16 15 7 12 W137-02-04-034



W2-4-42



UPPERSTRUCTURE / Pump Device



No.



Part Name



Q’ty



1



Housing



1



2



Flange



1



3



Oil Seal



1



5



Retaining Ring



1



Wrench Size mm



Tightening Torque (kgf⋅m) N⋅m (Ibf·ft)



Remarks



Apply grease to the lip of seal when assembling



6



Seal



2



7



Cover



1



Apply grease when assembling



9



Backup Ring



2



10



Key



2



12



O-Ring



2



13



Gear



1



14



Gear



1



15



Washer



2



16



Bolt



2



26



Bushing



4



Apply a film of hydraulic oil when installing



27



Bushing



4



Apply a film of hydraulic oil when installing



Apply grease when assembling Apply grease when assembling



: 17



39 to44



W2-4-43



(4 to 4.5) (29 to 32.5)



UPPERSTRUCTURE / Pump Device (Blank)



W2-4-44



UPPERSTRUCTURE / Control Valve REMOVE AND INSTALL CONTROL VALVE CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.)



2



Removal IMPORTANT: Attach identification tags to disconnected hoses for re-assembly. 1. Disconnect all hoses and pipes from signal control valve (2) (Refer to W2-9-1.) Cap open ends. : 17 mm : 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft) : 19 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)



3



1



4



2. Disconnect all hoses and pipes from 4-unit solenoid valve unit and pilot relief valve. (Refer to W2-11-1 and W2-12-1.) 3. Remove bolts (4) (3 used) then remove signal control valve (2) with bracket (3) from control valve (1). : 22 mm : 140 N⋅m (14.3 kgf⋅m, 103 Ibf⋅ft) IMPORTANT: Attach identification tags to disconnected hoses for re-assembly. 4. Disconnect all hoses, pipes and connectors from the control valve. Cap open ends. : 17 mm : 9.8 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft) : 19 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft) : 27 mm : 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft) : 6 mm : 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft) : 8 mm : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)



W1F3-02-05-004



Swing Arm 1 Boom 2 Arm 2 Boom 1 Bucket Travel



Auxiliary



Positioning



Front Side T176-03-03-038



W2-5-1



UPPERSTRUCTURE / Control Valve CAUTION: Control valve weight: 136 kg (300 lb)



Pilot Relief Valve



5. Remove control valve mounting bolts (5) (4 used). Install eyebolts (M14, Pitch 2.0 mm) (2 used) into bolt hole (6) on the top of control valve (1). Lift control valve (1) off. : 22 mm : 140 N⋅m (14.3 kgf⋅m, 103 Ibf⋅ft)



1



Installation NOTE: Refer to “Removal” section above for wrench sizes and tightening torques. 5



CAUTION: Control valve weight: 130 kg (290 lb)



W1F3-02-05-001



1. Lift control valve (1) and install control valve (1) with bolts (5) (4 used). 2. Connect all hoses, pipes and connectors to control valve (1). 3. Install signal control valve (2) with bracket (3) to control valve (1) with bolts (4) (3 used).



6



4. Connect all hoses and pipes to the 4-unit solenoid valve unit, pilot relief valve and signal control valve (2). (Refer to W2-9-1, W2-11-1 and W2-12-1) 6



IMPORTANT: After completing installation, check hydraulic oil level. Add oil as necessary. Run the engine. Check the component for any oil leaks.



W1F1-02-05-003



W2-5-2



UPPERSTRUCTURE / Control Valve (Blank)



W2-5-3



UPPERSTRUCTURE / Control Valve DISASSEMBLE VALVE



4-SPOOL



CONTROL 41



X



1 2



42



3



Boom AntiDrift Valve



29



23



4 5 6 7 8 9



30 24



Arm Regenerative Valve (Switch 10 Valve)



26



11



36 27



43



47



44



48



31 45



25



49



32 46



33



50 51



34



12 13 14 15 16



28 37



52



38



17



Check Valve (Main Relief Circuit)



35



39



18



40 W



62 63 64 65



60 61



58



W



66



59



67



72



X 12345678910 11 12 13 14 15 -



O-Ring Screw Backup Ring O-Ring O-Ring O-Ring Backup Ring Backup Ring O-Ring Sleeve Spool Washer Spring Backup Ring O-Ring



16 17 18 23 24 25 26 27 28 29 30 31 32 33 34 -



W1F1-02-05-004



Plug Spring Poppet O-Ring Bolt Spring Seat Spring Spring Seat Main Spool O-Ring Screw O-Ring Bolt Spring Seat Spring



35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 -



W2-5-4



Spring Seat Main Spool Poppet Spring O-Ring Plug O-Ring Bolt Spring Seat Spring Spring Seat Main Spool O-Ring Bolt Spring Seat



50 51 52 58 59 60 61 62 63 64 65 66 67 72 -



Spring Spring Seat Main Spool Cap Nut Plug O-Ring Cap Retaining Ring Shim Nut Pilot housing Socket bolt Housing



UPPERSTRUCTURE / Control Valve Disassemble 4-Spool Control Valve Upper Section • Be sure to read “Precautions for Disassembly and Assembly” thoroughly on page W1-1-1 before starting the disassembly work. • Attach identification tags to the spool and mounting positions in the housing in order to avoid misassembling. 1. Remove socket bolts (67) (11 used) from housing (72), and then remove pilot housing (66). : 8 mm 2. Remove boom anti-drift valve assembly (5 to 16), O-ring (4) and backup ring (3) from pilot housing (66). NOTE: Pry the boom anti-drift valve assembly by hand and remove it from pilot housing (66).



IMPORTANT: Put mating marks on main spools (28, 36, 46, 52) and housing (72) in order to avoid confusion during reassembling. 7. Clamp main spools (28, 36, 46, 52) in a vise with padded wooden pieces, then remove bolts (24, 32, 42, 48), spring seats (25, 33, 43, 49), springs (26, 34, 44, 50) and spring seats (27, 35, 45 and 51). : 17 mm 8. Remove plug (40), O-ring (39), spring (38) and poppet (37) from spool (36). : 17 mm 10. Remove spring (17) and poppet (18) from housing (72).



3. Remove plug (16), O-ring (15), backup ring (14), spring (13), washer (12) and spool (11) from sleeve (10). 4. Remove O-rings (5, 6, 9) and backup rings (7, 8) from sleeve (10). 5. Remove cap (62), retaining ring (63), shim (64) and nut (65) from pilot housing (66). Remove screw (30) from the pilot housing, then O-ring (29) from screw (30). : 17 mm : 4 mm 5. Remove cap (58) and nut (59) from pilot housing (66). Remove screw (2) from pilot housing (66), then O-ring (1) from screw (2). : 17 mm : 4 mm IMPORTANT: Remove main spool assemblies (28, 36, 46, 52) while carefully moving them. If they stick, even a little, try it again instead of pulling roughly. 6. Remove main spool assemblies (28, 36, 46, 52) and O-rings (23, 31, 41, 47) from housing (72).



W2-5-5



UPPERSTRUCTURE / Control Valve



X



Arm Regenerative Valve (Switch Valve)



Boom AntiDrift Valve



19 20 21



53



22



54 55 56



Check Valve (Main Relief Circuit)



57



W



69



68



70 71



W



72



X 19 20 21 22 -



Spring Washer O-Ring Spool



53 54 55 56 -



W1F1-02-05-004



Plug Backup Ring O-Ring Spring



57 - Poppet 68 - Overload Relief Valve 69 - Overload Relief Valve



W2-5-6



70 - Backup Ring 71 - O-Ring 72 - Housing



UPPERSTRUCTURE / Control Valve 11. Remove spring (19), washer (20), O-ring (21) and spool (22) from housing (72). 12. Remove plug (53), backup ring (54), O-ring (55), spring (56) and poppet (57) from housing (72). : 14 mm IMPORTANT: Never turn the lock nut. If turned, the set pressure may be changed. 13. Turn the cartridges of overload relief valves (68, 69). Remove overload relief valves (68, 69) from housing (72). : 27 mm Lock Nut Cartridge



W176-02-06-017



14. Remove backup ring (70) and O-ring (71) from housing (72).



W2-5-7



UPPERSTRUCTURE / Control Valve



72



Bypass Shut-Out Valve



79 78 77 76



74



81 Check Valve 80 75 Orifice (Arm 1 Load Check Parallel Circuit)



73



82



83



(Arm 2 Tandem Circuit)



84



85



86



87



95



90 89 88 108



99 107



91



92



96



97



98



94 93 Bucket Flow Rate Control Valve (Poppet Valve)



109



Bucket Flow Rate Control Valve (Switch Valve)



102 100 101



103



104 105 W176-02-05-012



106 72 73 74 75 76 77 78 79 80 81 -



Housing Plug O-Ring Plug O-Ring Spring Seat Spool Plug Spring



82 83 84 85 86 87 88 89 90 91 -



Poppet Bushing O-Ring Backup Ring Spring Poppet O-Ring Backup Ring Bushing Backup Ring



92 - O-Ring 93 - Spring 94 - Plug 95 - O-Ring 96 - Spring 97 - Poppet 98 - Valve Seat 99 - Pilot Plate 100 -Socket Bolt



W2-5-8



101 -Socket Bolt 102 -Spool 103 -Washer 104 -Spring 105 -O-Ring 106 -Plug 107 -O-Ring 108 -O-Ring 109 -Backup Ring



UPPERSTRUCTURE / Control Valve Disassemble 4-Spool Control Valve Side Section 15. Remove plug (106), then spring (104), washer (103), spool (102) and O-ring (105). : 36 mm 16. Loosen socket bolts (100) (7 used) and (101) (3 used). Remove pilot plate (99), O-ring (107, 108) and backup ring (109). : 6 mm, 8 mm 17. Remove bushing (90) from pilot plate (99), then O-rings (88, 92), backup ring (89, 91) and spring (93) from bushing (90). 18. Remove plug (94) from housing (72). Clamp the step portion of plug (94) with wooden pieces and secure it in a vise. Then remove valve seat (98), poppet (97), spring (96) and O-ring (95) from plug (94). 19. Remove O-ring (84), backup ring (85), spring (86) and poppet (87) from housing (72). (2 places). 20. Remove plug (80), spring (81), poppet (82) and bushing (83) from housing (72). 21. Remove plug (75), O-ring (76), spring (77), seat (78) and spool (79) from housing (72).



W2-5-9



UPPERSTRUCTURE / Control Valve



72



115 110 111 112



119



116 117 118 Check Valve (Flow



113 Combiner Circuit)



120



114 Auxiliary Flow Rate Control Valve



121



122 W1F1-02-05-005



72- Housing 110 -Poppet 111 -Spring 112 -O-Ring



113 -Backup Ring 114 -Plug 115 -Poppet 116 -Spring



117 -O-Ring 118 -Plug 119 -Overload Relief Valve



W2-5-10



120 -O-Ring 121 -Pilot Housing 122 -Socket Bolt



UPPERSTRUCTURE / Control Valve Disassemble 4-Spool Control Valve Lower Section IMPORTANT: Never turn the lock nut. If turned, the set pressure may be changed. 22. Turn the cartridge of overload relief valve (119) and remove it from housing (72). : 27 mm Lock Nut Cartridge



W176-02-06-017



23. Remove socket bolts (122) (5 used) from housing (72), then remove pilot housing (121) and O-ring (120). : 8 mm 24. Remove plug (118), O-ring (117), spring (116) and poppet (115) from housing (72). : 14 mm 25. Remove plug (114), backup ring (113), O-ring (112), spring (111) and poppet (110) from housing (72). : 14 mm



W2-5-11



UPPERSTRUCTURE / Control Valve DISASSEMBLE VALVE



5-SPOOL



CONTROL 184 183



185



123 124 125 126



149



127 128 150



144



Arm Anti-Drift Valve



134 135 136 137 138



133 143



186



157



129 130 131 132



155 156



145 146



151



158 159



152 153



160



141



139 140



171 166



147 148



165



167



172



168



173



169



174



179



175



180



154 161



142



162 163 164



177



178



170 181 176 182



187



W176-02-05-011



W2-5-12



UPPERSTRUCTURE / Control Valve



123 -Backup Ring 124 -O-Ring 125 -Plug 126 -O-Ring 127 -O-Ring 128 -O-Ring 129 -Backup Ring 130 -Backup Ring 131 -O-Ring 132 -Sleeve 133 -Spool 134 -Washer 135 -Spring 136 -Backup Ring 137 -O-Ring 138 -Plug 139 -Spring



140 -Poppet 141 -Backup Ring 142 -O-Ring 143 -Overload Relief Valve 144 -Plug 145 -O-Ring 146 -Backup Ring 147 -O-Ring 148 -Main Relief Valve 149 -O-Ring 150 -Bolt 151 -Spring Seat 152 -Spring 153 -Spring Seat 154 -Main Spool 155 -O-Ring 156 -Bolt



157 -Spring Seat 158 -Spring 159 -Spring Seat 160 -Main Spool 161 -Poppet 162 -Spring 163 -O-Ring 164 -Plug 165 -O-Ring 166 -Bolt 167 -Spring Seat 168 -Spring 169 -Spring Seat 170 -Main Spool 171 -O-Ring 172 -Bolt 173 -Spring Seat



W2-5-13



174 -Spring 175 -Spring Seat 176 -Main Spool 177 -O-Ring 178 -Bolt 179 -Spring Seat 180 -Spring 181 -Spring Seat 182 -Main Spool 183 -Socket Bolt 184 -Plug 185 -O-Ring 186 -Pilot Housing 187 -Housing



UPPERSTRUCTURE / Control Valve



183 123 124 125 126



149



127 128



134 135 136 137 138



186



157



129 130 131



Arm Anti-Drift Valve



155 156



150 151



158 159



152



132 133



153



165 171 166



160



172



168



173



169



174



143 141 148



154



139 140



161 142



162 163 164



177



167



178



175



179 180



170 181 176 182



187



W176-02-05-011



W2-5-14



UPPERSTRUCTURE / Control Valve Disassemble 5-Spool Control Valve Upper Section 1. Remove socket bolts (183) (10 used) from housing (187) to remove pilot housing (186). : 8 mm 2. Remove arm anti-drift valve assembly (125 to 138) and O-ring (124), backup ring (123) from pilot housing (186). NOTE: Pry out the arm anti-drift valve assembly by hand while removing pilot housing (186). 3. Remove plug (138), O-ring (137), backup ring (136), spring (135), washer (134) and spool (133) from sleeve (132).



7. Remove plug (164), O-ring (163), spring (162) and poppet (161) from main spool (160). : 17 mm 8. Remove spring (139), poppet (140), backup ring (141), and O-ring (142) from housing (187). IMPORTANT: Never turn the lock nut. If turned, the set pressure may be changed. 9. Turn the cartridges of overload relief valve (143) and main relief valve (148) to remove them from housing (187). : 27 mm Lock Nut



4. Remove plug (125), O-rings (126, 127, 128, 131) and backup rings (129, 130) from sleeve (132). 5. Remove the main spool (154, 160, 170, 176, 182) assemblies and O-rings (149, 155, 165, 171, 177) from housing (187). IMPORTANT: Put mating marks on main spools (154, 160, 170, 176, 182) and housing (187) in order to avoid confusion during reassembling. 6. Clamp the main spool (154, 160, 170, 176, 182) assemblies in a vise, then remove bolts (150, 156, 166, 172, 178), spring seats (151, 157, 167, 173, 179), springs (152, 158, 168, 174, 180), and spring seats (153, 159, 169, 175, 181). : 17 mm



W2-5-15



Cartridge



W176-02-06-017



UPPERSTRUCTURE / Control Valve



Aux. Flow Rate Control Valve (Poppet Valve)



197 198



Load Check Valve (Travel Parallel Cir192 cuit)



191



Load Check Valve (Arm 1 Parallel Circuit)



199



200



214 215



208 209 201



193 194



Load Check Valve (Arm 2 Parallel Circuit)



213



216 210



202



203



211 212



204 205



195 196



206 207



188 189 190



187



223



224 222



Aux. Flow Rate Control Valve (Switch Valve)



225 226 221



217



218



220 219 W176-02-05-013



W2-5-16



UPPERSTRUCTURE / Control Valve



187 -Housing 188 -Socket Bolt 189 -Cover 190 -O-Ring 191 -Socket Bolt 192 -Pilot Plate 193 -O-Ring 194 -Backup Ring 195 -Spring 196 -Poppet



197 -O-Ring 198 -Backup Ring 199 -Bushing 200 -Backup Ring 201 -O-Ring 202 -Spring 203 -Plug 204 -O-Ring 205 -Spring 206 -Poppet



207 -Valve Seat 208 -O-Ring 209 -Backup Ring 210 -Plug 211 -Spring 212 -Poppet 213 -O-Ring 214 -Backup Ring 215 -Spring 216 -Poppet



W2-5-17



217 -Plug 218 -O-Ring 219 -Spring 220 -Washer 221 -Spool 222 -Socket Bolt 223 -Socket Bolt 224 -Pilot Plate 225 -O-Ring 226 -O-Ring



UPPERSTRUCTURE / Control Valve



Aux. Flow Rate Control Valve (Poppet Valve)



197 198



Load Check Valve (Travel Parallel Cir192 cuit)



191



Load Check Valve (Arm 1 Parallel Circuit)



199 200 201 193



194



Load Check Valve (Arm 2 Parallel Circuit)



213 214 215



208 209



216 210



202



203



211 212



204 205



195 196



206 207



187



223



224 222



Aux. Flow Rate Control Valve (Switch Valve)



225 226 221



217



218



220 219 W176-02-05-013



W2-5-18



UPPERSTRUCTURE / Control Valve Disassemble 5-Spool Control Valve Side Section 10. Remove plug (217), then remove O-ring (218), spring (219), washer (220) and spool (221). : 36 mm 11. Remove socket bolts (222, 223), then remove pilot plate (224), O-rings (225, 226). : 6 mm, 8 mm 12. Remove bushing (199) from pilot plate (224), then remove O-rings (197, 201), backup rings (198, 200) and spring (202) from bushing (199). 13. Remove plug (203) from pilot plate (224) mounting surface of housing (187). Clamp the stepped portion of plug (203) with wood pieces in a vise, then remove valve seat (207), poppet (206), spring (205) and O-ring (204). 14. Remove O-ring (193), backup ring (194), spring (195) and poppet (196) from the pilot plate (224) mounting surface of housing (187). 15. Remove O-ring (213), backup ring (214), spring (215) and poppet (216) from the pilot plate (224) mounting surface of housing (187). (3 places) 16. Remove socket bolts (191) (6 used) from housing (187), then remove pilot plate (192). : 6 mm 17. Remove O-ring (208), backup ring (209), plug (210), spring (211) and poppet (212) from the pilot plate (192) mounting surface of housing (187). (2 places) 18. Remove O-ring (213), backup ring (214), spring (215) and poppet (216) from the pilot plate (192) mounting surface of housing (187).



W2-5-19



UPPERSTRUCTURE / Control Valve



187



227 228



235 236



243



244 245 246



237 247



229 238 230 248



239 231



254



232 233 234 Auxiliary Flow Combiner Valve



249 250 251



252 253



W1F3-02-05-007



187 - Housing 227 - Plug 228 - Spring 229 - Poppet 230 - Spool 231 - O-Ring 232 - Washer



233 234 235 236 237 238 239 -



Spring Bolt Plug Spring Poppet Spool O-Ring



243 244 245 246 247 248 -



W2-5-20



Overload Relief Valve O-Ring Backup Ring O-Ring Plug O-Ring



249 250 251 252 253 254 -



Socket Bolt O-Ring Plug O-Ring Plug Pilot Housing



UPPERSTRUCTURE / Control Valve Disassemble 5-Spool Control Valve Lower Section IMPORTANT: Never turn the lock nut. If turned, the set pressure may be changed. 19. Turn the cartridge of overload relief valve (243) to remove it from housing (187). : 27 mm Lock Nut Cartridge



W176-02-06-017



20. Remove socket bolts (249) (9 used) from housing (187), then remove pilot housing (254) and O-ring (248) (5 used). : 8 mm 21. Remove O-rings (231, 239), flow combiner valve assembly (235 to 242), and auxiliary flow combiner valve assembly (227 to 234) from housing (187). IMPORTANT: Do not remove plug (227), spring (228), poppet (229) from spool (230). When replacing these parts, replace them as an assembly. 22. Clamp spool (230) with wood pieces in a vise, then remove bolt (234), spring (233) and washer (232). : 17 mm NOTE: Do not remove plug (235), spring (236), poppet (237) and spool (238).



W2-5-21



UPPERSTRUCTURE / Control Valve SEPARATE AND COMBINE 4-SPOOL AND 5-SPOOL CONTROL VALVES



187 262 261



256



257 259 258



72



260 263 264



255



265 266



267 268 269 270



271 272 273



277 274



275



276 W176-02-05-015



72 - Housing 187 -Housing 255 -Socket Bolt 256 -O-Ring 257 -O-Ring 258 -O-Ring 259 -Backup Ring



260 -O-Ring 261 -O-Ring 262 -Backup Ring 263 -O-Ring 264 -Backup Ring 265 -O-Ring



266 -O-Ring 267 -Backup Ring 268 -O-Ring 269 -O-Ring 270 -O-Ring 271 -O-Ring



W2-5-22



272 -O-Ring 273 -Backup Ring 274 -O-Ring 275 -Backup Ring 276 -O-Ring 277 -Backup Ring



UPPERSTRUCTURE / Control Valve Combine 1. Install O-rings (256 to 258, 260, 261, 263, 265, 266, 268 to 272, 274, 276) and backup rings (259, 262, 264, 267, 273, 275, 277) into housing (187).



Separate CAUTION: Housing (72) weight: 45 kg (100 Ib) Housing (187) weight: 50 kg (110 Ib) 1. Remove socket bolts (255) (9 used), then separate housing (72) and housing (187). : 12 mm 2. Remove O-rings (256 to 258, 260, 261, 263, 265, 266, 268 to 272, 274, 276) and backup rings (259, 262, 264, 267, 273, 275, 277) from housing (187).



CAUTION: Housing (72) weight: 45 kg (100 Ib) Housing (187) weight: 50 kg (110 Ib) 2. Connect housing (72) and housing (187) with socket bolt (255). : 12 mm : 108+9.8 N⋅m (11+1 kgf⋅m, 80+7 lbf⋅ft)



W2-5-23



UPPERSTRUCTURE / Control Valve ASSEMBLE 4-SPOOL CONTROL VALVE



Main Spool (28, 46, 52)



A



61 60 31



23



41



47



Main Spool (36)



43, 25, 49



33



19



44, 26, 50



20



42, 24, 48



32



45, 27, 51



35



46, 28, 52



36



21 53 54, 55 56 57



22



34



72



37 38 52 28



36



46



Boom Anti-Drift Valve



Boom 1



Section A



66



39 40



W1F1-02-05-007



63, 64 62 65 29



10 11



6 7 8



30



58 59



W176-02-05-024



5



14



1 2



15 16



Boom Anti-Drift Valve



9 12 13 17 18 W176-02-05-025



3



4



W176-02-05-022



W2-5-24



UPPERSTRUCTURE / Control Valve



12345678910 11 12 13 14 15 16 17 18 -



O-Ring Screw Backup Ring O-Ring O-Ring O-Ring Backup Ring Backup Ring O-Ring Sleeve Spool Washer Spring Backup Ring O-Ring Plug Spring Poppet



19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 -



Spring Washer O-Ring Spool O-Ring Bolt Spring Seat Spring Spring Seat Main Spool O-Ring Screw O-Ring Bolt Spring Seat Spring Spring Seat Main Spool



37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 -



Poppet Spring O-Ring Plug O-Ring Bolt Spring Seat Spring Spring Seat Main Spool O-Ring Bolt Spring Seat Spring Spring Seat Main Spool Plug Backup Ring



NOTE: As for mark *, refer to W2-5-4, W-2-5-6.



W2-5-25



55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 -



O-Ring Spring Poppet Cap Nut Plug O-Ring Cap Retaining Ring Shim Nut Pilot Housing *Socket Bolt *Overload Relief Valve *Overload Relief Valve *Backup Ring *O-Ring Housing



UPPERSTRUCTURE / Control Valve



Main Spool (28, 46, 52)



A



31



23



41



Main Spool (36)



43, 25, 49



47



33



44, 26, 50



19 20 21 53 54, 55 56 57



22



72



34



42, 24, 48



32



45, 27, 51



35



46, 28, 52



36



37 38 39 40



52 28



36



46



W1F1-02-05-007



Boom Anti-Drift Valve



Boom 1



Section A



66



63, 64 62 65 29



10 11



30



58 59



W176-02-05-024



5



14



1 2



15 16



Boom Anti-Drift Valve



6 7 8 9 12 13 17 18 W176-02-05-025



3



4



W176-02-05-022



W2-5-26



UPPERSTRUCTURE / Control Valve Assemble 4-Spool Control Valve Upper Section 1. Clamp main spool (36) with wood pieces in a vise, then install poppet (37), spring (38), O-ring (39) and plug (40). : 17 mm : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) 2. Install spring seats (27, 35, 45, 51), springs (26, 34, 44, 50), spring seats (25, 33, 43, 49) and bolts (24, 32, 42, 48) onto spools (28, 36, 46, 52) respectively. : 17 mm : 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft) 3. Install screw (30) and O-ring (29) onto pilot housing (66), then install nut (65), shim (64), retaining ring (63) and cap (62) into screw (30). : 4 mm : 17 mm : 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) 4. Install screw (2) and O-ring (1) onto pilot housing (66), then install nut (59) and cap (58) onto screw (2). : 4 mm : 17 mm : 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) 5. Install backup rings (7, 8) and O-rings (5, 6, 9) onto sleeve (10). NOTE: Check the assembling location of backup rings (7, 8) and O-rings (6, 9). 9



8



7



IMPORTANT: When replacing sleeve (10) or spool (11), replace them together. 6. Assemble O-ring (15), backup ring (14), spring (13), washer (12), and spool (11) onto plug (16), then install them onto sleeve (10). NOTE: When assembling washer (12), the chamfer side shall be facing to the spring side. 7. Install boom anti-drift valve assembly (5 to 16) onto pilot housing (66). IMPORTANT: When replacing housing (72) or poppet (18), tap poppet (18) with a steel bar. 8. Install poppet (18) and spring (17) into housing (72). 9. Install spool (22), O-ring (21), washer (20) and spring (19) into housing (72). NOTE: When assembling washer (20), the chamfer side shall be facing to the spring side. 10. Install poppet (57), spring (56), O-ring (55), backup ring (54) and plug (53) into housing (72). : 14 mm : 120+20 N⋅m (12+2 kgf⋅m, 87+14.5 lbf⋅ft) 11. Install main spool assemblies (28, 36, 46, 52), O-rings (4, 23, 31, 41, 47, 71) and backup rings (3, 70) into housing (72) respectively.



6



W176-02-05-023



W2-5-27



UPPERSTRUCTURE / Control Valve



A



66



B



C



Section B



72



Arm 2



Arm 1



69 Load Check Valve (Arm 2 Tandem Circuit)



69 68



86 87



99



67 Section D 106



D



101



72



100 105 104



T176-03-03-038



103



102 80



Bucket Flow Rate Control Valve (Switch Valve)



T176-03-03-006



94 93



88 89



Section C



90



95



91 92



96



Boom 1 Boom 2



97



98



Section A



81 82 83



Check Valve Orifice (Arm 1 Parallel Circuit)



Bucket Flow Rate Control Valve (Poppet Valve) W176-02-05-026



Swing



84, 85



75 74 73



86 87 Load Check Valve (Boom 1 Parallel Circuit)



T176-03-03-005



76 77 78 79



Bypass Shut-Out Valve



T176-03-03-007



W2-5-28



UPPERSTRUCTURE / Control Valve



66 67 68 69 72 73 74 75 76 77 78 -



Pilot Housing Socket Bolt Overload Relief Valve Overload Relief Valve Housing Plug O-Ring Plug O-Ring Spring Seat



79 80 81 82 83 84 85 86 87 88 89 -



Spool Plug Spring Poppet Bushing O-Ring Backup Ring Spring Poppet O-Ring Backup Ring



90 - Bushing 91 - Backup Ring 92 - O-Ring 93 - Spring 94 - Plug 95 - O-Ring 96 - Spring 97 - Poppet 98 - Valve Seat 99 - Pilot Plate 100- Socket Bolt



NOTE: As for mark *, refer to W2-5-8, W2-5-16.



W2-5-29



101- Socket Bolt 102- Spool 103- Washer 104- Spring 105- O-Ring 106- Plug 107- *O-Ring 108- *O-Ring 109- *Backup Ring 217- *Plug



UPPERSTRUCTURE / Control Valve A



66



B



Section B



C



Arm 2



Arm 1



69 72



Load Check Valve (Arm 2 Tandem Circuit)



69



86 87



68



99



67



Section D 106



D



101



72



100



T176-03-03-038



80 105 104



103



Bucket Flow Rate Control Valve (Switch Valve)



Section C



88



93



89 90



95



91 92



96



T176-03-03-006



Boom 1 Boom 2



97



98



Section A



81 82 83



Check Valve Orifice (Arm 1 Parallel Circuit)



102



Bucket Flow Rate Control Valve (Poppet Valve) W176-02-05-026



Swing



84, 85



86 87 75



Load Check Valve (Boom 1 Parallel Circuit)



T176-03-03-005



76 77 78 79



Bypass Shut-Out Valve



T176-03-03-007



W2-5-30



UPPERSTRUCTURE / Control Valve IMPORTANT: Never turn the lock nut. If turned, the set pressure may be changed. 12. Install pilot housing (66) onto housing (72) with socket bolts (67) (11 used). Turn the cartridges of overload relief valves (68, 69) to install them into housing (72). : 8 mm : 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft) : 27 mm : 78+3 N⋅m (8+0.3 kgf⋅m, 58+2.2 Ibf⋅ft) Lock Nut Cartridge



W176-02-06-017



NOTE: Apply grease onto O-rings of overload relief valves (68, 69). (In order to protect O-rings from breakage).



19. Install O-rings (107, 108) and backup ring (109) into housing (72). Install pilot plate (99) with socket bolts (100) (7 used) and (101) (3 used). : 6 mm : 25 N⋅m (2.5 kgf･m, 18 Ibf⋅ft) : 8 mm : 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft) 20. Tighten plug (106) which has been temporarily tightened in step 13. : 36 mm : 200 N⋅m (20 kgf⋅m, 145 Ibf⋅ft) 21. Install spool (79), seat (78), spring (77), O-ring (76) and plug (75) into housing (72). : 27 mm : 180+3 N⋅m (18+0.3 kgf⋅m, 130.2+2.2 Ibf⋅ft) NOTE: Install seat (78) with the chamfered side facing the spring.



Assemble 4-Spool Valve Side Section 13. Install spool (102), washer (103), spring (104) and O-ring (105) onto pilot plate (99), then install plug (106) (Temporarily tighten it). : 36 mm NOTE: Tighten plug (106), after installation of pilot plate (99) to housing (72). Check the plugs identification because plug (106) and plug (217) have different length of screw thread. 14. Install poppet (97), spring (96), O-ring (95) and plug (94) onto valve seat (98). 15. Install O-rings (88, 92) and backup rings (89, 91) onto bushing (90). 16. Install valve seat (98) assembly, spring (93) and bushing (90) into housing (72). 17. Install poppet (87), spring (86), O-ring (84) and backup ring (85) into housing (72). (2 places) 18. Install bushing (83), poppet (82), spring (81) and plug (80) into housing (72).



W2-5-31



UPPERSTRUCTURE / Control Valve Section A



72 A



121 122



119



B



T176-03-03-036



120



120



120



120



Section B



115 110 111 112, 113 117 114 118



116



T1F3-03-03-013



Aux. Flow Rate Control Valve 72 - Housing 110 -Poppet 111 -Spring 112 -O-Ring



113 -Backup Ring 114 -Plug 115 -Poppet 116 -Spring



117 -O-Ring 118 -Plug 119 -Overload Relief Valve



W2-5-32



120 -O-Ring 121 -Pilot Housing 122 -Socket Bolt



W176-02-05-020



UPPERSTRUCTURE / Control Valve Assemble 4-Spool Control Valve Lower Section 22. Install O-ring (120) onto housing (72), then install pilot housing (121) with socket bolts (122) (5 used). : 8 mm : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) 23. Install poppet (115), spring (116), O-ring (117) and plug (118) into housing (72). : 14 mm : 120+20 N⋅m (12+2 kgf⋅m, 87+14.5 lbf⋅ft) 24. Install poppet (110), spring (111), O-ring (112), backup ring (113) and plug (114) into housing (72). : 14 mm : 120+20 N⋅m (12+2 kgf⋅m, 87+14.5 lbf⋅ft) IMPORTANT: Never turn the lock nut. If turned, the set pressure may be changed. 25. Turn the cartridge of overload relief valve (119) to install it into housing (72). : 27 mm : 78+3 N⋅m (8+0.3 kgf⋅m, 57.9+2.2 lbf⋅ft) Lock Nut Cartridge



W176-02-06-017



NOTE: Apply grease to O-ring of the overload relief valve. (In order to protect O-ring from breakage.)



W2-5-33



UPPERSTRUCTURE / Control Valve ASSEMBLE 5-SPOOL CONTROL VALVE 177 Section A



171



165



155



Main Spool (154, 170, 176, 182)



149



Main Spool (160)



151, 167, 173, 179



157 158



152, 168, 174, 180



156



150, 166, 172, 178



159



153, 169, 175, 181 160 154, 170, 176, 182



161 182



176 170



160



154



162 163



W176-02-05-021



Arm Anti-Drift Valve A



B



164



184 185 Arm Anti-Drift Valve



143 Section B



132 126



186 183



133



148



W176-02-05-024



125 127 128 129 130



187



131 136 137



134 135



138 139 140



T176-03-03-038



W2-5-34



W176-02-05-027



UPPERSTRUCTURE / Control Valve



123 -*Backup Ring 124 -*O-Ring 125 -Plug 126 -O-Ring 127 -O-Ring 128 -O-Ring 129 -Backup Ring 130 -Backup Ring 131 -O-Ring 132 -Sleeve 133 -Spool 134 -Washer 135 -Spring 136 -Backup Ring 137 -O-Ring 138 -Plug 139 -Spring



140 -Poppet 141 -*Backup Ring 142 -*O-Ring 143 -Overload Relief Valve 144 -*Plug 145 -*O-Ring 146 -*Backup Ring 147 -*O-Ring 148 -Main Relief Valve 149 -O-Ring 150 -Bolt 151 -Spring Seat 152 -Spring 153 -Spring Seat 154 -Main Spool 155 -O-Ring 156 -Bolt



157 -Spring Seat 158 -Spring 159 -Spring Seat 160 -Main Spool 161 -Poppet 162 -Spring 163 -O-Ring 164 -Plug 165 -O-Ring 166 -Bolt 167 -Spring Seat 168 -Spring 169 -Spring Seat 170 -Main Spool 171 -O-Ring 172 -Bolt 173 -Spring Seat



NOTE: As for mark *, refer to W2-5-12



W2-5-35



174 -Spring 175 -Spring Seat 176 -Main Spool 177 -O-Ring 178 -Bolt 179 -Spring Seat 180 -Spring 181 -Spring Seat 182 -Main Spool 183 -Socket Bolt 184 -Plug 185 -O-Ring 186 -Pilot Housing 187 -Housing



UPPERSTRUCTURE / Control Valve Main Spool (154, 170, 176, 182)



177 Section A



171



165



155



Main Spool (160)



149 151, 167, 173, 179



157 158



152, 168, 174, 180



156



150, 166, 172, 178



159



153, 169, 175, 181 160 154, 170, 176, 182



182 Arm Anti-Drift Valve A



176 170 B



160



161 162



154



163



W176-02-05-021



164 143



Arm Anti-Drift Valve



Section B



132 126



186 183



133



148



W176-02-05-024



125 127 128 129 130



187



131 136 137



134 135



138 139 140 T176-03-03-038



W2-5-36



W176-02-05-027



UPPERSTRUCTURE / Control Valve Assemble 5-Spool Control Valve Upper Section 1. Clamp main spool (160) with wood pieces in a vise. Install poppet (161), spring (162), O-ring (163) and plug (164). : 17 mm : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) 2. Install spring seats (153, 159, 169, 175, 181), springs (152, 158, 168, 174, 180), spring seats (151, 157, 167, 173, 179), and bolts (150, 156, 166, 172, 178) onto main spools (154, 160, 170, 176, 182) respectively. : 17 mm : 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft) 3. Install backup rings (129, 130) and O-rings (126, 127, 128, 131) and plug (125) onto sleeve (132). NOTE: Check the mounting location of backup rings (129, 130) and O-rings (128, 131). 131



130



129



128



5. Install arm anti-drift valve assembly (125 to 138) onto pilot housing (186). IMPORTANT: Tap poppet (140) with a steel bar when replacing housing (187) or poppet (140). 6. Install poppet (140) and spring (139), O-ring (142) and backup ring (141) onto housing (187). 7. Install main spool assemblies (154, 160, 170, 176, 182), O-rings (124, 149, 155, 165, 171, 177) and backup ring (123) into housing (187). IMPORTANT: Never turn the lock nut. If turned, the set pressure may be changed. 8. Install pilot housing (186) onto housing (187) with socket bolts (183) (10 used). Turn the cartridges of overload relief valve (143) and main relief valve (148) to install them into housing (187). : 8 mm : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 27 mm : 78+3 N⋅m (8+0.3 kgf⋅m, 58+2.2 lbf⋅ft) Lock Nut Cartridge



W176-02-05-023



IMPORTANT: When replacing sleeve (132) or spool (133), replace them together. 4. Install O-ring (137), backup ring (136), spring (135), washer (134) and spool (133) into plug (138), then install them on sleeve (132). NOTE: Assemble washer (134) with the chamfered side facing the spring.



W2-5-37



W176-02-06-017



UPPERSTRUCTURE / Control Valve 191



Boom 2



Section B Positioning



192



Section C



187



223 222 224



Load Check Valve (Positioning Tandem Circuit) F D



E



216



C



215



216 215 213, 214



B



Aux. Flow Rate Control Valve



A



Section Ｆ



217



218 219



220



221



203 202



198



195 196 Load Check Valve (Positioning Parallel Circuit)



Section D



199



204 205 206 Aux. Flow Rate Control Valve (Poppet Valve)



Load Check Valve (Arm 1 Parallel Circuit)



W176-02-05-026



Section A



216 215



216 215



W176-02-05-029



Swing



Arm 1



200 201 207



T176-03-03-036



Aux. Flow Rate Control Valve (Switch Valve)



197



Load Check Valve (Boom 2 Parallel Circuit) 2



193, 194



213, 214 Check Valve (Main Circuit)



208, 209 210



Section E



Load Check Valve (Swing Circuit)



216 215 213, 214



210



211 212



208, 209



Load Check Valve (Arm 1 Tandem Circuit)



W176-02-05-028



W2-5-38



W176-02-05-030



UPPERSTRUCTURE / Control Valve



187 -Housing 188 -*Socket Bolt 189 -*Cover 190 -*O-Ring 191 -Socket Bolt 192 -Pilot Plate 193 -*O-Ring 194 -*Backup Ring 195 -*Spring 196 -*Poppet



197 -O-Ring 198 -Backup Ring 199 -Bushing 200 -Backup Ring 201 -O-Ring 202 -Spring 203 -Plug 204 -O-Ring 205 -Spring 206 -Poppet



207 -Valve seat 208 -O-Ring 209 -Backup Ring 210 -Plug 211 -Spring 212 -Poppet 213 -O-Ring 214 -Backup Ring 215 -Spring 216 -Poppet



NOTE: As for mark *, refer to W2-5-16.



W2-5-39



217 -Plug 218 -O-Ring 219 -Spring 220 -Washer 221 -Spool 222 -Socket Bolt 223 -Socket Bolt 224 -Pilot Plate 225 -*O-Ring 226 -*O-Ring



UPPERSTRUCTURE / Control Valve 191



192



187



Boom 2



Section B Positioning



Section C



223 222 Load Check Valve (Positioning Tandem Circuit)



224



E



F



D



216



C



215



B



216 215 213, 214



A Aux. Flow Rate Control Valve



Section Ｆ



217



T176-03-03-036



218 219



220



Aux. Flow Rate Control Valve (Switch Valve)



197 198 199



204



200 201



205



207



195 196



221



Load Check Valve (Positioning Parallel Circuit)



Section D



203 202



Load Check Valve (Arm 1 Parallel Circuit)



206



W176-02-05-026



W176-02-05-029



Swing



Arm 1



Aux. Flow Rate Control Valve (Poppet Valve)



Section A



Load Check Valve (Boom 2 Parallel Circuit) 2



193, 194



216 215



216 215 213, 214



208, 209 210



Section E



Load Check Valve (Swing Circuit)



216 215 213, 214



210



Check Valve (Main Circuit)



211 212



208, 209



Load Check Valve (Arm 1 Tandem Circuit) W176-02-05-030



W176-02-05-028



W2-5-40



UPPERSTRUCTURE / Control Valve Assemble 5-Spool Control Valve Side Section 9. Install spool (221), washer (220), spring (219) and O-ring (218) into pilot plate (224), then install plug (217) (temporarily). : 36 mm NOTE: Tighten plug (217) after installing pilot plate (224) on housing (187). Check the length of the threaded portion because the thread length of plug (217) and plug (106) is different. 10. Install poppet (206), spring (205), O-ring (204) and plug (203) onto valve seat (207). 11. Install O-rings (197, 201) and backup rings (198, 200) onto bushing (199). 12. Install valve seat (207) assembly, spring (202) and bushing (199) into housing (187). 13. Install poppet (216), spring (215), O-ring (213), and backup ring (214) into housing (187). (3 places) 14. Install poppet (196), spring (195), backup ring (194), and O-ring (193) into housing (187). 15. Install O-rings (225, 226) onto housing (187). Install pilot plate (224) into housing (187) with socket bolts (222, 223). : 6 mm : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 8 mm : 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 16. Tighten plug (217) which is temporarily tightened in step 9. : 36 mm : 200 N⋅m (20 kgf⋅m, 145 lbf⋅ft) 17. Install poppet (212), spring (211), plug (210), backup ring (209) and O-ring (208) into housing (187) (2 places). 18. Install poppet (216), spring (215), backup ring (214) and O-ring (213) into housing (187). 19. Install pilot plate (192) onto housing (187) with socket bolts (191) (6 used). : 6 mm : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)



W2-5-41



UPPERSTRUCTURE / Control Valve Section B 187



247 B



249 254 A



243 T176-03-03-036



248



Section A



248



248



248



248



227



235 236



228



237



229 Aux. Flow



238



230



239, 240



Combiner Valve



231, 232 233 234 W1F3-02-05-002



187 227 228 229 230 231 232 -



Housing Plug Spring Poppet Spool O-Ring Washer



233 234 235 236 237 238 239 -



Spring Bolt Plug Spring Poppet Spool O-Ring



243 244 245 246 247 248 -



NOTE: As for mark *, refer to W2-5-20.



W2-5-42



Overload Relief Valve *O-Ring *Backup Ring *O-Ring *Plug O-Ring



249 250 251 252 253 254 -



Socket Bolt *O-Ring *Plug *O-Ring *Plug Pilot Housing



W176-02-05-021



UPPERSTRUCTURE / Control Valve Assemble 5-Spool Control Valve Lower Section IMPORTANT: Overall dimensions of spool (230) have been determined. When disassembling or replacing poppet (229), spring (228), plug (227), replace them as an assembly. 20. Clamp spool (230) with wood pieces in a vise, then install washer (232), spring (233) and bolt (234). : 17 mm : 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft) NOTE: Assemble washer (232) with the chamfered side facing the spring.



IMPORTANT: Never turn the lock nut. If turned, the set pressure may be changed. 24. Turn the cartridge of overload relief valve (243) to install it into housing (187). : 27 mm : 78+3 N⋅m (8+0.3 kgf⋅m, 57.9+2.2 lbf⋅ft)



IMPORTANT: Overall dimensions of spool (238) have been determined. When disassembling or replacing poppet (237), spring (236), plug (235), replace them as an assembly. 21. Clamp spool (238) with wood pieces in a vise, then install washer (240), spring (241) and bolt (242). : 17 mm : 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft) NOTE: Assemble washer (240) with the chamfered side facing the spring. 22. Install O-rings (231, 239), flow combiner valve assembly (235 to 242) and auxiliary flow combiner valve assembly (227 to 234) onto housing (187). 23. Install O-rings (248) (5 used) onto housing (187). Then install pilot housing (254) with socket bolts (249) (9 used). : 8 mm : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)



W2-5-43



Lock Nut Cartridge



W176-02-06-017



NOTE: Apply grease on the O-ring of overload relief valve (243). (In order to protect the O-ring from breakage.)



UPPERSTRUCTURE / Control Valve (Blank)



W2-5-44



UPPERSTRUCTURE / Control Valve REMOVE AND INSTALL CONTROL VALVE



AUXILIARY



CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.)



Cab Side



2



1 3



Removal IMPORTANT: Attach identification tags to disconnected hoses for re-assembly. 1. Disconnect hoses (4) (6 used) from valve (3). Cap open ends. : 19 mm, 27 mm 2. Remove bolts (1) (3 used) and remove valve (3) from bracket (2). : 17 mm



W1F3-02-05-005



Installation



4



1. Install valve (3) on bracket (2) with bolts (1) (3 used). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 2. Connect hoses (4) (6 used) to valve (3). : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) : 27 mm : 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft) IMPORTANT: After installation, check the hydraulic oil level. Run the engine and check for oil leaks.



W2-5-45



UPPERSTRUCTURE / Control Valve DISASSEMBLE AUXILIARY CONTROL VALVE 7



6



2



1



9



24



5



4



3



8



10



27



28



26



23



22



21



20



19



25



37



15



14 12



16



17



34



33



32



31



30



29



35



41



13



36



42 43 44



11



51



38 39 18 40



52



53



54



55



56



45 46 47



48



62 61 60



50 49 58



59



57 W198-02-05-001



12345678910 11 12 13 14 15 16 -



Nut Bolt O-Ring Spring Valve Sleeve Backup Ring O-Ring O-Ring Spring Spring Pin Valve O-Ring Backup Ring Valve



17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -



Sleeve O-Ring Nut Bolt O-Ring Spring Valve Sleeve Backup Ring O-Ring O-Ring Spring Spring Pin Valve O-Ring



33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 -



W2-5-46



Backup Ring Valve Sleeve O-Ring Seat O-Ring Valve Spring Sleeve O-Ring Spring Poppet Socket Bolt (2 Used) Cover O-Ring



48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 -



Socket Bolt Socket Bolt Cover End Spool Seat Spring Spring Seat O-Ring Spool O-Ring Plug Drive Screw Plate Housing



UPPERSTRUCTURE / Control Valve Disassemble Auxiliary Control Valve • Be sure to read “Precautions for Disassembly and Assembly” thoroughly on page W1-1-1 before starting any repair work. 1. Loosen socket bolts (45) (2 used), (48), and (49) to remove covers (46, 50) and O-rings (47, 56). : 6 mm IMPORTANT: Remove the spool (57) assembly (51 to 59) while carefully moving them. If they stick, even a little, try it again instead of pulling roughly. 2. Remove spool (57) assembly (51 to 59) from housing (62). 3. Secure spool (57) with wooden pieces in a vice. Remove end spool (51), seat (52), springs (53, 54) and seat (55). : 8 mm IMPORTANT: As the set pressure may be changed, be sure not to disassemble overload relief valve assemblies (1 to 18) and (19 to 36). 4. Remove overload relief valve assembly (1 to 18) and (19 to 36) from housing (62). : 32 mm NOTE: As each set pressure is different, be sure to install overload relief valve assemblies (1 to 18) and (19 to 36) correctly. 5. Remove sleeve (41) assembly (37 to 42) from housing (62). : 36 mm 6. Pull out spring (43) and poppet (44) from housing (62). 7. Secure seat (37) in a vice. Remove sleeve (41), spring (40), valve (39), and O-rings (38, 42). : 36 mm NOTE: As plate (61) is installed with drive screw (60), be sure not to disassemble the plate.



W2-5-47



UPPERSTRUCTURE / Control Valve ASSEMBLE AUXILIARY CONTROL VALVE Cross Section X-X



37



39 40



38 41 43 42



A1



44



A1



1 to 18



B1



62 19 to 36



B1



X



X



W198-02-05-002



W198-02-05-003



57



Cross Section W-W



48



45



W



52



54



53 55 56 62



47



50 51



W



W198-02-05-004



49



57 59 58 46 W198-02-05-005



12345678910 11 12 13 14 15 16 -



Nut Bolt O-Ring Spring Valve Sleeve Backup Ring O-Ring O-Ring Spring Spring Pin Valve O-Ring Backup Ring Valve



17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -



Sleeve O-Ring Nut Bolt O-Ring Spring Valve Sleeve Backup Ring O-Ring O-Ring Spring Spring Pin Valve O-Ring



33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 -



W2-5-48



Backup Ring Valve Sleeve O-Ring Seat O-Ring Valve Spring Sleeve O-Ring Spring Poppet Socket Bolt (2 Used) Poppet O-Ring



48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 -



Socket Bolt Socket Bolt Cover End Spool Seat Spring Spring Seat O-Ring Spool O-Ring Plug Drive Screw Plate Housing



UPPERSTRUCTURE / Control Valve Assemble Auxiliary Control Valve 1. Secure seat (37) in a vice. Install O-ring (38), valve (39), spring (40), sleeve (41) and O-ring (42). : 36 mm : 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft) 2. Install poppet (44) and spring (43) into housing (62). 3. Install sleeve (41) assembly (37 to 42) to housing (62). : 36 mm : 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft) IMPORTANT: As each set pressure is different, be sure to install overload relief valve assemblies (1 to 18) and (19 to 36) correctly. 4. Install overload relief valve assembly (1 to 18) and (19 to 36) to housing (62). : 32 mm : 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft) 5. Secure spool (57) with wooden pieces in a vice. Install O-ring (58) to plug (59). Install plug (59) to spool (57). Install seat (55), springs (53, 54), seat (52), and end spool (51) to spool (57). : 5 mm : 9.8 N⋅m (1 kgf⋅m, 7.4 lbf⋅ft) : 8 mm : 18.6 N⋅m (1.9 kgf⋅m, 13.7 lbf⋅ft) IMPORTANT: After installing spool (57) assembly (51 to 59) into housing (62), push them by hand to confirm smoothness. 6. Insert spool (57) assembly (51 to 59) to housing (62) through port A1 side. NOTE: When installing the spool assembly, be sure to install it straight to prevent it from damaging spool (57) inside housing (62). 7. Install O-ring (56) to cover (50) and O-ring (47) to cover (46). Install them to housing (62) with socket bolts (45) (2 used), (48), and (49). : 6 mm : 25.5 N⋅m (2.6 kgf⋅m, 18.8 lbf⋅ft)



W2-5-49



UPPERSTRUCTURE / Control Valve (Blank)



W2-5-50



UPPERSTRUCTURE / Swing Device REMOVE AND INSTALL SWING DEVICE CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.)



1



2



3



4



5



6



Removal IMPORTANT: Attach identification tags to disconnected hoses for re-assembly. 1. Disconnect the harness (1) connector and hoses (2 to 6). Cap the disconnected hose ends. • Main hose: 2 used • Makeup hose: 1 used • Drain hose: 1 used • Pilot hose: 1 used : 17 mm, 19 mm, 36 mm : 8 mm IMPORTANT: As for the handling of floating seal, refer to the “Handling of Floating Seal” on page W1-1-5. 2. Lift swing motor (8) off. Nylon sling (eye-type at both ends): 2 pieces



8



M178-07-014



7 Front



Nylon Sling



CAUTION: Swing device weight: 220 kg (485 lb) 3. Remove bolts (7) (12 used). Lift the swing device off the main frame. : 30 mm NOTE: When lifting the swing device, the machine may float together with it. Therefore, remove plugs (9) (2 places) to lift the swing device off the main frame with pulling bolt (M20, Pitch 2.5 mm). The number of hoses around the swing device is different according to the specification of front attachment. Be sure not to damage the hoses when removing and installing the swing device.



8



9



9



W176-02-06-002



W2-6-1



UPPERSTRUCTURE / Swing Device Installation CAUTION: Swing device weight: 220 kg (485 lb)



1



2



3



4



5



6



1. Install the swing device with bolts (7) (12 used). : 30 mm : 500 N·m (50 kgf·m, 360 Ibf⋅ft) IMPORTANT: Apply liquid packing to both mounting surfaces on the swing device and frame. 2. Connect hoses (2 to 6) and the harness (1) connector. : 36 mm : 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft) : 17 mm : 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft) : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft) : 8 mm : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) IMPORTANT: Be sure to fill the swing motor with hydraulic oil after installing it. After completing installation, check hydraulic oil level. Add oil as necessary. Run the engine and check the component for any oil leaks.



W2-6-2



8



7 Front



M178-07-014



UPPERSTRUCTURE / Swing Device (Blank)



W2-6-3



UPPERSTRUCTURE / Swing Device DISASSEMBLE GEAR



SWING



REDUCTION



22 23



1



24



2 3



32



21



25



4



31



5 20



6



26



7 19



8



27 9



18 28



10 17



29



11



16



12



15



30



13



14



W178-02-06-004



12345678-



Motor 1st Stage Sun Gear Thrust Plate Pin (3 Used) Spring Pin (3 Used) Needle Bearing (3 Used) Planetary Gear (3 Used) Thrust Plate (3 Used)



910 11 12 13 14 15 16 -



Pin (3 Used) Spring Pin (3 Used) Thrust Plate (6 Used) Needle Bearing (6 Used) Planetary Gear (3 Used) Roller Bearing Bearing Nut Lock Plate



17 18 19 20 21 22 23 24 -



W2-6-4



Bolt (2 Used) 2nd Stage Carrier Thrust Plate 2nd Stage Sun Gear 1st Stage Carrier Socket Bolt (8 Used) Socket Bolt (12 Used) Ring Gear



25 26 27 28 29 30 31 32 -



Housing Roller Bearing Oil Seal Sleeve O-Ring Shaft Drain Plug Pipe



UPPERSTRUCTURE / Swing Device Disassemble Swing Reduction Gear



3. Remove drain plug (31), then drain the oil. : 8 mm



CAUTION: Swing device weight: 215 kg (480 lb) CAUTION: When hoisting the swing device, do not string the rope suddenly. 1. Secure the swing device body with nylon slings, then hoist it by crane.



4. Remove pipe (32) from housing (25). : 18 mm 5. Put alignment marks at the jointed portion between motor (1) and ring gear (24), between ring gear (24) and housing (25).



Nylon Sling



CAUTION: Swing motor weight: 45 kg (105 lb) 6. Remove bolts (22) (8 used). Remove motor (1) from ring gear (24). : 10 mm NOTE: THREEBOND has been applied on the joint faces. Insert a screw driver into the gap between the swing motor and the ring gear, then pry it up for easy removing. 7. Remove first stage sun gear (2) from first stage carrier (21). 8. Remove first stage carrier (21) assembly from ring gear (24).



W176-02-06-002



2. Install the swing device on the bracket (ST 5097). Secure it with bolts (M20) (2 used). Insert the stopper located at the bottom of the bracket into the middle of two teeth of the pinion gear. Secure the bracket on a working bench. : 30 mm Swing Device



Stopper



ST 5097



9. Remove the ring gear (24) mounting bolt (23) (12 used). : 14 mm CAUTION: Ring gear weight: 23 kg (50 lb) 10. Install eyebolts (M12) (2 used) to the hole for the motor (1) mounting bolt on ring gear (24). Lift the ring gear off housing (25). NOTE: THREEBOND has been applied on the joint surface. Insert a screwdriver into the gap between the ring gear and housing. Then pry it up for easy removing. 11. Remove 2nd stage sun gear (20) from 2nd carrier (18). 12. Remove the 2nd stage carrier (18) assembly from shaft (30).



W178-02-06-012



W2-6-5



UPPERSTRUCTURE / Swing Device



23



3



25



21



4 5 6 7 8



18



10 17 16 30



11 12



15



W178-02-06-004



W2-6-6



UPPERSTRUCTURE / Swing Device IMPORTANT: The hole for the spring pin located on the 1st stage carrier is not a through one. Take care to the tapping-in distance when tapping the spring pin in. 13. Tap spring pin (5) on the 1st stage carrier (21) assembly into pin (4) using special tool (ST 1462). Stop tapping when the spring pin is driven to the middle of the pin hole. Do not try to tap spring pin (5) to the end.



CAUTION: Housing (25) assembly weight: 122 kg (270 lb) 21. Install eyebolt (M16) into bolt (23) hole in housing (25). Lift housing (25). Remove bracket (ST 5097), which has been installed at the pinion gear side. : 30 mm CAUTION: Before pressing shaft (30), provide a protection cover (outer diameter: 380 mm (15”), inner diameter: 110 mm (4.3”), thickness: 25 to 30 mm (0.98” to 1.18”)). Then, use the press to remove the shaft while covering housing (25) and roller bearing (14) with the protection cover may result in personal injury due to metal fragments flying off if the housing and/or bearing is broken. Use a press of capacity less than 30 tons (66000 lb). Be sure to degrease the housing inside before heating the bearing. Failure to degrease may cause a fire.



14. Remove pin (4), planetary gear (7), needle bearing (6), thrust plate (8) from 1st stage carrier (21). 15. Remove remaining two sets of pin (4), planetary gear (7), needle bearing (6), thrust plate (8) from 1st stage carrier (21) according to the removing procedure in step 13 and step 14. 16. Remove thrust plate (3) from 1st stage carrier (21). IMPORTANT: The surface of the pin except for both ends is a rotating surface for the needle bearing. Take care not to damage it. 17. Clamp the pin (4) with a vise. Push the spring pin out using special removing tool (ST 1462). (3 places) 18. Disassemble the 2nd stage carrier (18) assembly according to the removing procedure for the 1st stage carrier (21) assembly. However 6 needle bearings (12) and 6 thrust plates (11) are used on the 2nd stage carrier (18) assembly. Moreover, use ST 1463 as the extractor for spring pin (10) .



22. Install the protection cover on housing (25). Push the upper end of shaft (30) with a press and remove it from housing (25). The inner race of roller bearing (26) and sleeve (28) are removed with the shaft. 25



Protection Cover



30



14



Press



Protection Cover



19. Remove bolt (17) to remove lock plate (16). : 17 mm 20. Remove bearing nut (15) from shaft (30) using special nut removing tool (ST 2926). ST 2926



15



W178-02-06-008



W2-6-7



W1F3-02-06-001



UPPERSTRUCTURE / Swing Device



25



26



27



28



29



30 14



W178-02-06-004



W2-6-8



UPPERSTRUCTURE / Swing Device 23. Attach the shaft (30) assembly to the special tool bearing removal set. NOTE: Use the following parts as the special tool set for removing roller bearing (26). Part Size Remarks Shaft Length: 200 mm 8 used. All should be or Bolt (8 in) identical in length with no Diameter: 19 mm wear and deformation on both ends. (3/4 in) Material: S35C (JIS), 1035 (AISI) Hose Standard DiameClamp ter: 8-1/2” (Applicable Diameter: 185 to 215 mm) Guide



IMPORTANT: Push the shaft of the special tool into the gully side of the pinion. Secure the shaft with the hose clamp in order not to loosen and separate CAUTION: Shaft weight: 40 kg (90 lb) CAUTION: Be sure to use the guide when pushing shaft (30) with a press Press



2 used. Roller Bearing (26) Inner Race



Shaft (30)



Sleeve (28)



Height: 160 mm (6.3 in) Outer Diameter: 260 mm (10.24 in) Inner Diameter: 240 mm (9.45 in)



Guide



W157-02-06-014



24. Push the spline side of shaft (30) with a press. The inner race of roller bearing (26) and sleeve (28) are removed from the shaft.



Bearing Removal Tool Hose Clamp



Shaft



25. Remove O-ring (29) from sleeve (28). 26. Insert a round bar into the oil passage in housing (25). Tap the outer race of roller bearing (26) out.



Outer Race



Oil Passage



W157-02-06-012



Shaft (30) Roller Bearing (26) Inner Race W178-02-06-001



Sleeve (28)



Shaft Guide



W157-02-06-013



W2-6-9



UPPERSTRUCTURE / Swing Device CAUTION: Housing (25) weight: 60 kg (130 lb) 27. Secure housing (25) body with nylon sling, hoist it by crane. Turn the up side of the housing down. 28. Insert a screwdriver into the notch on housing (25) where oil seal (27) is mounted. Remove the oil seal. NOTE: THREEBOND has been applied on the periphery of oil seal. Thus, it can not be reused. 29. Insert a bar at the back side of the outer race of roller bearing (14). Remove the outer race from housing (25) while tapping with a bar and hammer.



W2-6-10



UPPERSTRUCTURE / Swing Device (Blank)



W2-6-11



UPPERSTRUCTURE / Swing Device ASSEMBLE SWING REDUCTION GEAR



1 2



4



3



5 22



21



6



20



7



18 24



8



19



10 11



23



13 12 11



17



9



16 32



15 14 26



29



31



25



27 28 30 W178-02-06-003



12345678-



Motor 1st Stage Sun Gear Thrust Plate Pin (3 Used) Spring Pin (3 Used) Needle Bearing (3 Used) Planetary Gear (3 Used) Thrust Plate (3 Used)



910 11 12 13 14 15 16 -



Pin (3 Used) Spring Pin (3 Used) Thrust Plate (6 Used) Needle Bearing (6 Used) Planetary Gear (3 Used) Roller Bearing Bearing Nut Lock Plate



17 18 19 20 21 22 23 24 -



Bolt (2 Used) 2nd Stage Carrier Thrust Plate 2nd Stage Gear 1st Stage Carrier Socket Bolt (8 Used) Socket Bolt (12 Used) Ring Gear



W2-6-12



25 26 27 28 29 30 31 32 -



Housing Roller Bearing Oil Seal Sleeve O-Ring Shaft Drain Plug Pipe



UPPERSTRUCTURE / Swing Device Assemble Swing Reduction Gear 1. Install O-ring (29) onto sleeve (28). CAUTION: Shaft + sleeve + outer race weight: 36 kg (80 lb) 2. Install sleeve (28) and the inner race of roller bearing (26) into shaft (30). Press sleeve and inner race using bearing mounting tool (ST 2923). NOTE: Press-in distance of the bearing inner race can be assured by using the bearing mounting tool.



5. Apply THREEBOND #1215 on the outer surface of oil seal (27). Put oil seal (27) flat on housing (25) and push oil seal (27) in gently. Then place seal mounting tool (ST 2925) on oil seal (27) and tap the seal mounting tool in by hammering directly. NOTE: If special tool (ST 2925) is used to replace the seal, no need to remove the sleeve.



ST 2925



27 25



Press



ST 2923 W178-02-06-007



26



6. Apply grease to the inner surface of oil seal (27) all around. Apply grease to the outer surface of sleeve (28) on shaft (30). NOTE: Apply grease carefully when installing the shaft to avoid accidental curling of the seal lip from the shaft.



28 30



W178-02-06-013



CAUTION: Housing + outer race weight: 63 kg (140 lb)



CAUTION: Housing weight: 60 kg (130 lb) 3. Secure housing (25) body with a nylon sling, and then lift housing (25). Place sleeve (28) with the mounting side up. 4. Tap the outer race of roller bearing (26) evenly by using a bar and hammer while installing the outer race into housing (25). Tap the bearing and listen to ring to confirm if installation is completed.



7. Secure housing (25) body with a nylon sling and lift housing (25) off. Place ring gear (24) with the mounting side up. 8. Tap the outer race of roller bearing (14) evenly using a bar and hammer while installing the outer race into housing (25). Tap the bearing and listen to ring to confirm if installation is completed.



W2-6-13



UPPERSTRUCTURE / Swing Device



24 23



15 14



25 27



30 W178-02-06-003



W2-6-14



UPPERSTRUCTURE / Swing Device CAUTION: Housing + outer races (2 used) weight: 65 kg (140 lb) 9. Install eyebolt (M16) into the ring gear mounting bolt (23) hole in housing (25). Then lift and place housing (25) on shaft (30). Check and align carefully to protect the oil seal (27) lip from curling. 10. Tap the inner race of roller bearing (14) into shaft (30) with a bar and hammer. Tap the inner race until two threads of shaft bearing nut (15) appear. NOTE: The fitting between the inner race and shaft is tight.



15. Lift and place the housing (25) assembly on bracket (ST 5097). Secure the housing (25) assembly with 2 bolts (M20) while the stopper at the bottom of bracket is located at the middle of two teeth of the pinion gear. Secure the bracket on a workbench. : 30 mm 25



Stopper



11. Screw-in bearing nut (15) to shaft (30). Tighten as much as possible by hand. NOTE: Prevent shaft (30) from falling down when lifting housing (25). CAUTION: Housing + shaft + bearing weight: 122 kg (270 lb) 12. Install eyebolt (M16) into the ring gear mounting bolt (23) hole in housing (25). Lift and place housing (25) on a press. 13. Remove bearing nut (15) from shaft (30). 14. Place mounting tool (ST 2924) onto the inner race of roller bearing (14). Push the inner race down using a press. NOTE: Press-in distance of the inner race can be assured by using the mounting tool. ST 2924



14



W178-02-06-011



W2-6-15



ST 5097



W178-02-06-012



UPPERSTRUCTURE / Swing Device



4 5



3



22 21



6 7



18 8 10 11 13 12 11



17



9



16 15



30 W178-02-06-003



W2-6-16



UPPERSTRUCTURE / Swing Device IMPORTANT: Take care to the direction of the bearing nut. Grease must be applied for keeping correct tightening torque. 16. Apply a film of grease on the threaded surface of bearing nut (15), then install bearing nut (15) on shaft (30) with the stepped side of bearing nut facing roller bearing (14). Tighten the bearing nut using mounting tool (ST 2926). : 350 N⋅m (36 kgf⋅m, 260 Ibf⋅ft) NOTE: Grease must be applied for keeping correct tightening torque. ST 2926



IMPORTANT: Pay attention to the mounting direction of spring pin (10) and thrust plate (19). 18. Assemble second stage carrier (18) according to following steps. Install needle bearing (12) (2 used) into planetary gear (13). Clamp planetary gear (13) with two pieces of thrust plate (11), then install them together into second stage carrier (18). When mounting needle bearings (12) (2 used), the spring pin hole (in mounting pin (9)) should be facing out. Align the spring pin hole in second stage carrier (18) with that of pin (9).



15



Tap spring pin (10) into second stage carrier (18) using the special tool (ST 1463). At this time, the slit of the spring pin should face the end of pin (19). 10 9



W178-02-06-008



Slit



17. Install lock plate (16) onto bearing nut (15) with bolt (17). In case the spline of lock plate and that of shaft (30) are not aligned, tighten the bearing nut in tightening direction until both splines are aligned. : 17 mm : 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)



W178-02-06-002



Install thrust plate (19) into second stage carrier (18), while the oil groove of thrust plate (19) is facing upward. Install needle bearings (12) (4 used), thrust plates (11) (4 used), pins (9) (2 used) and spring pins (10) (2 used) into two remaining holes of the second stage carrier according to the same procedure mentioned above. IMPORTANT: Take care to the mounting location of thrust plate (8). 19. Assemble the following parts to form the 1st stage carrier (21) assembly according to the same procedures 18 to 22 for 2nd stage carrier assembly: planetary gears (7) (3 used), needle bearings (6) (3 used), thrust plates (8) (3 used), pins (4) (3 used), spring pins (5) (3 used) and thrust plate (3). Thrust plate (8) is installed under needle bearing (6). Special tool (ST 1462) should be used as the extractor for the spring pin.



W2-6-17



UPPERSTRUCTURE / Swing Device



1 2 22 21 20 18 24



23



16 32



25



31



30 W178-02-06-003



W2-6-18



UPPERSTRUCTURE / Swing Device IMPORTANT: Take care to the mounting direction of the 2nd stage carrier. 20. Install the 2nd stage carrier (18) assembly onto the spline of shaft (30), while the concave part of the boss in bottom side of the carrier comes in contact with lock plate (16). Concave Part



18



28. Fill gear oil into ring gear (24) until the middle part of the 1st stage sun gear (2) is submerged. (Approx. 6.2 L (1.64 US gal.)) 29. Clean off the old THREEBOND, then apply new THREEBOND #1212 onto the motor (1) mounting surface of ring gear (24).



16



CAUTION: Motor weight: 47 kg (100 lb)



30



30. Install eyebolt (M10) to motor (1) and lift motor (1) off. Align the mating marks, and then fasten the swing motor and ring gear (24) with bolts (22) (8 used). : 10 mm : 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft) W178-02-06-014



21. Install 2nd stage sun gear (20) into the 2nd stage carrier (18) assembly with the small diameter part of the 2nd stage sun gear facing up.



Eyebolt Mounting Position



22. Clean off old THREEBOND and apply new THREEBOND #1215 onto the mounting surface of ring gear (24) inside of housing (25). W178-02-06-005



CAUTION: Ring gear weight: 23 kg (51 lb) 23. Install eyebolt (M12) to the motor mounting threaded hole on ring gear (24). Lift the ring gear off, install the ring gear on housing (25) with socket bolts (23) (12 used) while aligning the mating marks. : 14 mm : 205 N⋅m (21 kgf⋅m, 150 Ibf⋅ft) 24. Install the 1st stage carrier (21) assembly onto the spline of 2nd stage sun gear (20). IMPORTANT: Take care to the mounting direction of the sun gear. 25. Install 1st stage sun gear (2) into the 1st stage carrier (21) assembly with the stepped side of the sun gear facing down. 26. Install pipe (32) into housing (25) with seal tape wound on the threaded part of the pipe. : 18 mm 27. Wind seal tape on drain plug (31), then install drain plug (31) into pipe (32). : 8 mm : 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)



W2-6-19



UPPERSTRUCTURE / Swing Device DISASSEMBLE SWING MOTOR 11 9 8 7 6 5 4



10



3 2



24



25



1



26



29 27



15



14



27



17



Casing Oil Seal Bearing Shaft Shoe Plate Plunger (9 Used) Plate Retainer



910 11 12 13 14 15 16 -



26



25



24



12



16



12345678-



31



28



23



13



30



Rotor Plate (4 Used) Friction Plate (3 Used) O-Ring Piston Spring Ball Plug (2 Used)



17 18 19 20 21 22 23 24 -



18



19



20



O-Ring O-Ring Brake Piston Spring (24 Used) Valve Plate Bearing O-Ring Plug (2 Used)



W2-6-20



21



22



32 W178-02-06-015



25 26 27 28 29 30 31 32 -



O-Ring (2 Used) Spring (2 Used) Poppet (2 Used) Valve Casing Socket Bolt (4 Used) O-Ring (2 Used) Plug (2 Used) Relief Valve (2 Used)



UPPERSTRUCTURE / Swing Device Disassemble Swing Motor CAUTION: Another method is to float fload brake piston (19) by blowing air from port B. However, piston (13) may fly out when blowing air. Do not use this method.



• Be sure to read “Precautions for Disassembly and Assembly” thoroughly on page W1-1-1 before starting the disassembly work. CAUTION: Swing motor assembly weight: 47 kg (105 Ib)



7. Install tool (ST 1468) into notch A of brake piston (19), then pull brake piston (19) out from casing (1).



IMPORTANT: Do not disassemble relief valve (32). 1. Remove relief valves (32) (2 used) from valve casing (28). : 41 mm



Notch A



2. Remove plugs (24) (2 used) from valve casing (28). : 14 mm



19



3. Remove springs (26) (2 used) and poppets (27) (2 used) from valve casing (28).



13 1



Port B



4. Make mating marks at the joint surface between valve casing (28) and casing (1). Then loosen socket bolts (29) (4 used). At this moment, there is a clearance between valve casing (28) and casing (1). Take this clearance down. : 17 mm T178-03-02-003



5. Remove valve casing (28) from casing (1). NOTE: At this moment, valve casing (28) may be with valve plate (21) attached. Take care do not drop valve plate (21).



8. Remove O-rings (17, 18) from casing (1).



IMPORTANT: Be sure not to damage the mating surface when separating valve plate (21) from valve casing (28) or rotor (9) with a screwdriver. (Be sure not to mismatch the surfaces of the valve plate when installing.) 6. If valve plate (21) is still on rotor (9) in step 5, remove the valve plate from the rotor. Remove springs (20) (24 used).



W2-6-21



UPPERSTRUCTURE / Swing Device



11 9 8 7 6 5 4



10



3 2 1



15



14



13



W178-02-06-015



W2-6-22



UPPERSTRUCTURE / Swing Device IMPORTANT: Take care not to damage the slide surface of rotor (9) and plunger (6). 9. Place casing (1) horizontally. Remove rotor (9), retainer (8), plate (7) and plungers (6) (9 used) from shaft (4). 10. Remove plates (10) (4 used), friction plates (11) (3 used) from housing (1). IMPORTANT: Take care not to damage the slide surface of shoe plate (5). 11. Remove shoe plate (5) from casing (1). 12. Tap shaft (4) with a plastic hammer lightly and remove shaft (4) from casing (1). 13. Push out oil seal (2) from casing (1). 14. Remove the outer race of bearing (3) from casing (1) with a guide bar. 15. Remove the inner race of roller bearing (3) from shaft (4) with a press. IMPORTANT: Filter and orifice are mounted inside of piston (13). Do not disassemble them unless they are clogged or deformed. Disassemble them only when absolutely needed. If the inner parts need to be replaced, replace them as an assembly. 16. Remove piston (13) from casing (1) with pliers. 17. Remove spring (14) and ball (15) from casing (1).



W2-6-23



UPPERSTRUCTURE / Swing Device ASSEMBLE SWING MOTOR 27



26



25



24



12 13 14



15 16 29



T178-03-02-004



T178-03-02-003



30



31



31 30 28



32 21 20



22 23



19



18



10



17



6



11 9 7 5



8 3



1 2



4 12345678-



Casing Oil Seal Bearing Shaft Shoe Plate Plunger (9 Used) Plate Retainer



T178-03-02-002



910 11 12 13 14 15 16 -



Rotor Plate (4 Used) Friction Plate (3 Used) O-Ring Piston Spring Ball Plug (2 Used)



17 18 19 20 21 22 23 24 -



O-Ring O-Ring Brake Piston Spring (24 Used) Valve Plate Bearing O-Ring Plug (2 Used)



W2-6-24



25 26 27 28 29 30 31 32 -



O-Ring (2 Used) Spring (2 Used) Poppet (2 Used) Valve Casing Socket Bolt (4 Used) O-Ring (2 Used) Plug (2 Used) Relief Valve (2 Used)



UPPERSTRUCTURE / Swing Device Assemble Swing Motor IMPORTANT: Be sure to install the inner race of bearing (3) with the flange facing the stepped side of shaft (4). 1. Push the inner races of bearings (3, 22) into shaft (4) with a press. IMPORTANT: Push oil seal (2) in, with its lip facing up. 2. Push oil seal (2) into casing (1) with a guide plate.



11. Install brake piston (19) into casing (1) while aligning the mating mark. NOTE: If it is not easy to install O-rings (17, 18) into brake piston (19) due to the resistant force from the O-rings, tap them evenly with a plastic hammer to force them in. 12. Install springs (20) (24 used) onto brake piston (19).



3. Install the outer race of bearing (3) into casing (1) with a guide bar. IMPORTANT: Wind tape on the spline at the end of shaft (4) to prevent damaging oil seal (2) from being damaged. 4. Place casing (1) horizontally. Install shaft (4) into casing (1). 5. Place casing (1) vertically with the valve casing (28) mounting surface up. Then install shoe plate (5) with its chamfered inner side facing inside. IMPORTANT: When installing retainer (8) into plunger (6), be sure to place the notch side of the retainer facing shoe plate (5). 6. Assemble plate (7) and retainer (8) with the notch matched. Then install plungers (6) (9 used). IMPORTANT: Apply hydraulic oil into the plunger hole in rotor (9), then install plunger (6). 7. Insert the plunger (6) assembly into rotor (9). 8. Place casing (1) horizontally. Install the rotor (9) assembly onto shaft (4). IMPORTANT: 4 notchs are on the outer side of plate (10). And 4 notchs are on the spline teeth side of friction plate (11). Be sure to align each notch at the same place when installing. 9. Place casing (1) vertically. Alternately install plates (10) (4 used), friction plates (11) (3 used) into casing (1). 10. Install O-ring (17) and (18) onto casing (1).



W2-6-25



UPPERSTRUCTURE / Swing Device Drain Port



27



26



25



24



13 14



15



29



T178-03-02-004



T178-03-02-003



28



32



22



21



23



9



1



4



T178-03-02-002



W2-6-26



UPPERSTRUCTURE / Swing Device IMPORTANT: If the inner parts of piston (13) need to be replaced, replace the piston as an assembly. Be sure to align the end face of the piston with that of casing (1). 13. Install ball (15), spring (14) and piston (13) into housing (1).



21. Fill hydraulic oil through the drain port. NOTE: Amount of Hydraulic oil: 0.8 L (0.211US gal)



IMPORTANT: Tap the bearing type indicated surface with a plastic hammer while installing roller bearing (22). 14. Tap the outer race of bearing (22) with a plastic hammer while installing it into valve casing (28). IMPORTANT: Take care to the surfaces of valve plate (21). (Install the valve plate with the notch in the port facing rotor (9).) 15. Install O-ring (23) onto valve casing (28). Then install valve plate (21). NOTE: Apply grease onto valve plate (21) to avoid valve plate (21) coming off from valve casing (28). 16. Apply grease to the needle part on bearing (22). NOTE: It is easy to install shaft (4) into bearing (22) by pushing the needle with grease. 17. Align the mating marks in valve casing (28) and casing (1), while placing valve casing (28) onto casing (1). Be sure to confirm that the clearance between valve casing (28) and casing (1) is same to that before disassembling. If the clearance is larger than that before disassembling, reinstallation shall be carried out from step 5. 18. Install valve casing (28) onto casing (1) with socket bolts (29) (4 used). : 17 mm : 430 N⋅m (44 kgf⋅m, 320 Ibf⋅ft) 19. Install poppets (27) (2 used) and springs (26) ( 2 used) into valve casing (28). Tighten plug (24) with O-ring (25) attached. : 14 mm : 330 N⋅m (34 kgf⋅m, 245 Ibf⋅ft) 20. Install relief valves (32) (2 used) into valve casing (28). : 41 mm : 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)



W2-6-27



UPPERSTRUCTURE / Swing Device MAINTENANCE STANDARD Swing Motor 1. Clearance between the out diameter of plunger and the inner bore of cylinder D-d



d



Unit: mm (in) Standard



Allowable Limit



0.027 (0.0011)



0.052 (0.0020) W107-02-06-138



D



D



W107-02-06-139



2. Clearance between plunger and shoe at the crimped position Unit: mm (in) Standard



Allowable Limit



0 (0)



0.3 mm (0.0118 in) δ



W107-02-06-140



W2-6-28



UPPERSTRUCTURE / Swing Device 3. Thickness of shoe Unit: mm (in) Standard



Allowable Limit



5.5 (0.22)



5.3 (0.21) ｔ



W107-02-06-142



4. Thickness of friction plate Unit: mm (in) Standard



Allowable Limit



2.0 (0.08)



1.8 (0.07)



W107-02-06-143



W2-6-29



UPPERSTRUCTURE / Swing Device (Blank)



W2-6-30



UPPERSTRUCTURE / Pilot Valve REMOVE AND INSTALL PILOT VALVE The following is explained on the lever stand in the left. As for that in the right, perform the same procedure. CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.) Removal of Front/Swing Pilot Valve 1, 2



1. Remove screws (3) (5 used) from the lever stand then remove covers (1, 2). 3



2. Remove the clip band and disconnect the plug receptacle. 3. Lower boots (8). Loosen lock nut (7) then remove lever (5) and grip (6). : 22 mm



3



4. Raise boots (8). Remove screws (9) (4 used) then remove cover (10) and boots (8). IMPORTANT: Attach identification tags to disconnected hoses for re-assembly. 5. Disconnect hoses (12) (6 used) from pilot valve (11). Cap all open ends. : 19 mm



W1F3-02-07-003



6 7 8 5



9



10



11



4



IMPORTANT: Put mating marks on pilot valve (11) and lever stand to aid in reassembly. 6. Remove bolts (4) (4 used) then remove pilot valve (11) from the lever stand. : 13 mm 12



W1F3-02-07-004



W2-7-1



UPPERSTRUCTURE / Pilot Valve Installation of Front/Swing Pilot Valve 1. Insert pilot valve (11) into the lever stand and align the mating marks made when disassembling.



6 7 8



2. Install pilot valve (11) to the lever stand with bolts (4) (4 used). : 13 mm : 20 N⋅m (2.1 kgf⋅m, 15 lbf⋅ft)



5



9



10



11



4



3. Connect hoses (12) (6 used) to pilot valve (11). : 19 mm : 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft) 4. Insert lever (5) (with grip (6)) into boots (8). Install lever (5) into pilot valve (11).



12



5. Secure lever (5) to pilot valve (11) with lock nut (7). : 22 mm : 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft) W1F3-02-07-004



6. Connect the plug receptacle and Install the clip band. 7. Install boots (8) with cover (10) and screws (9) (4 used). 9. Install covers (1, 2) on the lever stand with screws (3) (5 used). IMPORTANT: After installation, check the hydraulic oil level. Run the engine and check for oil leaks.



1, 2 3



3



W2-7-2



W1F3-02-07-003



UPPERSTRUCTURE / Pilot Valve CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.)



1, 2, 3



Removal of Travel Pilot Valve 1. Remove rubber (1) from forward/reverse travel pedal (2). 2. Remove socket bolts (3) (2 used) from pilot valve (6) then remove forward/reverse travel pedal (2). : 6 mm



Brake Pedal



IMPORTANT: Attach identification tags to disconnected hoses for re-assembly. 3. Disconnect hoses (5) (4 used) from pilot valve (6). Cap all open ends. : 19 mm



Attachment Pedal



W1F3-02-14-002



4



4. Remove bolts (4) (2 used) then remove pilot valve (6). : 17 mm



Installation of Travel Pilot Valve 1. Install pilot valve (6) with bolts (4) (2 used). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 2. Connect hoses (5) (4 used) to pilot valve (6). : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)



6



W1F3-02-14-001



5



3. Install forward/reverse travel pedal (2) on pilot valve (6) with socket bolts (3) (2 used). : 6 mm : 20 N⋅m (2.1 kgf⋅m, 15 lbf⋅ft) 4. Install rubber (1) on forward/reverse travel pedal (2). IMPORTANT: After installation, check the hydraulic oil level. Run the engine and check for oil leaks.



W2-7-3



UPPERSTRUCTURE / Pilot Valve CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.) 3



Removal of Blade/Stabilizer Pilot Valve



4



2



1. Remove the under cover. : 17 mm



1



2. Remove socket bolts (2) (2 used) and remove the bracket (1) assembly from pilot valve (4). : 6 mm IMPORTANT: Attach identification tags to disconnected hoses for re-assembly. 3. Disconnect hoses (5) (4 used) from pilot valve (4). Cap all open ends. : 19 mm, 22 mm W1F3-02-07-006



4. Remove bolts (6) (2 used) and remove pilot valve (4) from bracket (3). : 17 mm



5 3



5



Installation of Blade/Stabilizer Pilot Valve 1. Install pilot valve (4) on bracket (3) with bolts (6) (2 used). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 2. Connect hoses (5) (4 used) to pilot valve (4). : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) : 22 mm : 39 N⋅m (4.0 kgf⋅m, 28.5 lbf⋅ft) 3. Install the bracket (1) assembly to pilot valve (4) with socket bolts (2) (2 used). : 6 mm : 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft) IMPORTANT: After installation, check the hydraulic oil level. Run the engine and check for oil leaks.



W2-7-4



6



4



W1F3-02-07-005



UPPERSTRUCTURE / Pilot Valve (Blank)



W2-7-5



UPPERSTRUCTURE / Pilot Valve DISASSEMBLE VALVE



FRONT/SWING



PILOT



10 10 11



1 11



12



12



2



13



13 3



14



4



5 5 15



6 6



16



7



7



17 8



8



18 9



9



19 19 20 20 W1F3-02-07-001



12345-



Screw Joint Cam Universal Joint Plate Oil Seal (4 Used)



678910 -



Bushing (4 Used) O-Ring (4 Used) Pusher (4 Used) Spring Seat (4 Used) Spring (4 Used)



11 12 13 14 15 -



W2-7-6



Spring (4 Used) Washer (4 Used) Spool (4 Used) Casing O-Ring



16 17 18 19 20 -



Bushing Spring Pin Port Plate Seal Washer (2 Used) Socket Bolt (2 Used)



UPPERSTRUCTURE / Pilot Valve Disassemble Front/Swing Pilot Valve • Be sure to read “Precautions for Disassembly and Assembly” thoroughly on page W1-1-1 before starting any repair work. • The spool (13) diameter and the casing (14) bore are selectively fitted. Do not replace individually. • Discriminate between the disassembled parts by port No. where the parts are located in order to avoid confusion. The port Nos. are indicated on the periphery of casing (14) by embossed letters. 1. Clamp the pilot valve to vise with port plate (8) facing downward and secure it. 2. Put a wrench on cam (2) and secure it. Then remove screw joint (1) and the cam from universal joint (3). : 22 mm, 32 mm CAUTION: As soon as loosening universal joint (3), the plate (4), bushings (6) (4 used) and pushers (8) (4 used) may come up same time for springs (10) (4 used) being compressed. Take care not to let these parts fly out.



IMPORTANT: Put on the mating mark to install the plate (4) in the right direction. 4. Remove plate (4) from casing (14). IMPORTANT: When bushings (6) (4 used) are still in casing (14), pry the bushing while moving pusher (8) left and right. Meanwhile take care not to damage the pusher. IMPORTANT: Put port Nos. on the spool (13) assembly and springs (10) (4 used) so as to avoid confusing each port. Take care not to damage spool (13). 5. Remove the pusher (8) assembly, the spool (13) assembly and springs (10) (4 used) from casing (14). 6. Remove pushers (8) (4 used), O-rings (7) (4 used) and oil seals (5) (4 used) from bushings (6) (4 used).



3. Install special tool (ST 7260) on universal joint (3). Rotate special tool (ST 7260) to left and remove universal joint (3). : 24 mm



Section A-A



ST 7260



A



A



3



W577-02-06-003



W2-7-7



UPPERSTRUCTURE / Pilot Valve



11 11 12



12 13



13



14



15



16



18 9



9



20



W1F3-02-07-001



W2-7-8



UPPERSTRUCTURE / Pilot Valve IMPORTANT: Do not remove the spool (13) assembly unless necessary. IMPORTANT: When removing spool (13) from spring seats (9) (4 used), push the spool in the spring seat, then direct it towards the bigger hole while remove it. However, do not push the spring seat in more than 6 mm (0.24 in).



13



11 9 W577-02-06-004



7. Remove spring seats (9) (4 used), springs (11) (4 used) and washers (12) (4 used) from spool (13). 8. Clamp the pilot valve on a vise and secure the pilot valve with the port plate (18) facing upward. 9. Remove socket bolts (20) (2 used) from casing (14). : 6 mm 10. Remove port plate (18), O-ring (15) and bushing (16) from casing (14).



W2-7-9



UPPERSTRUCTURE / Pilot Valve ASSEMBLE FRONT/SWING PILOT VALVE



1 3



2 8 5 4 6 7



9 11 10 12 13



14 16 15 17



18 19 20



12345-



Screw Joint Cam Universal Joint Plate Oil Seal (4 Used)



678910 -



Bushing (4 Used) O-Ring (4 Used) Pusher (4 Used) Spring Seat (4 Used) Spring (4 Used)



11 12 13 14 15 -



Spring (4 Used) Washer (4 Used) Spool (4 Used) Casing O-Ring



W2-7-10



16 17 18 19 20 -



W1F3-02-07-002



Bushing Spring Pin Port Plate Seal Washer (2 Used) Socket Bolt (2 Used)



UPPERSTRUCTURE / Pilot Valve Assemble Front/Swing Pilot Valve • Be sure to read “Precautions for Disassembly and Assembly” thoroughly on page W1-1-1 before starting the assembly work. • The seal parts shall be replaced with new ones when assembling. 1. Install bushing (16) and O-ring (15) to casing (14). 2. Install spring pin (17) to port plate (18) and seal washers (19) (2 used) to socket bolts (20) (2 used) respectively. IMPORTANT: Tighten socket bolts (20) (2 used) in turn slowly. 3. Install the port plate (18) assembly to casing (14) with socket bolts (20) (2 used). : 6 mm : 20.5±2 N⋅m (2.1±0.2 kgf⋅m, 15±1.4 lbf⋅ft) IMPORTANT: When installing spool (13) to spring seats (9) (4 used), insert the spool through bigger one of the two holes on the spring seat and move the spool to the smaller hole. However, do not insert the spool more than 6 mm (0.24 in).



IMPORTANT: Install spring (10) in the same position of when disassembling. 5. Install springs (10) (4 used) to casing (14). IMPORTANT: Install the spool (13) assemblies (4 used) in the same position of when disassembling. 6. Install the spool (13) assemblies (4 used) to casing (14). 7. Install O-rings (7) (4 used) and oil seals (5) (4 used) to bushings (6) (4 used). IMPORTANT: Apply a film of hydraulic oil to the circumference of pushers (8) (4 used). 8. Install pushers (8) (4 used) to bushings (6) (4 used). IMPORTANT: When it is difficult to install plate (4) because of the strong force from springs (10) (4 used), put the bushing (6) assemblies (4 used) on the four holes of casing (14) and then add plate (4). Simultaneously press the bushing assemblies (4 used) and tighten the universal joint (3) temporarily. 9. Align the mating mark put when disassembling to install the bushing (6) assemblies (4 used) and plate (4) to casing (14).



13



9 W577-02-06-004



4. Install washers (12) (4 used), springs (11) (4 used), spring seats (9) (4 used) to spools (13) (4 used) in order.



W2-7-11



UPPERSTRUCTURE / Pilot Valve



1 3



2 8



14



W1F3-02-07-002



W2-7-12



UPPERSTRUCTURE / Pilot Valve 10. Install universal joint (3) to casing (14) using special tool (ST 7260). : 24 mm : 47±2.9 N⋅m (4.8±0.3 kgf⋅m, 35±2.2 lbf⋅ft) 11. Screw universal joint (3) until pushers (8) (4 used) contact with cam (2) evenly. IMPORTANT: When tightening screw joint (1), do not move the location of cam (2). 12. Secure cam (2) with the spanner. Then install screw joint (1) to universal joint (3). : 32 mm : 22 mm : 69±4.9 N⋅m (7.0±0.5 kgf⋅m, 51±3.6 Ibf⋅ft) 13. Apply grease to the rotation portion of universal joint (3) and the top face of pusher (8).



W2-7-13



UPPERSTRUCTURE / Pilot Valve DISASSEMBLE TRAVEL, POSITIONING / AUXILIARY, BLADE / STABILIZER PILOT VALVE



20



7



20



8 6



19



9



19 18



10



4



18



5



17 16



17 16



15



6 15 4 11



14 14



3 12



3



13



2



2 21



1



1



W1LA-02-06-001



123456-



O-Ring (2 Used) Bushing (2 Used) Packing (2 Used) Bushing (2 Used) Steel Ball (2 Used) Socket Bolt (2 Used)



78910 11 -



Boot Set Screw Cam Pin Cover



13 14 15 16 17 -



Plug O-Ring Spring (2 Used) Spool (2 Used) Washer (2 Used)



W2-7-14



19 20 21 22 23 -



Shim (2 Used) Spring (2 Used) Spring Guide (2 Used) Pusher (2 Used) Casing



UPPERSTRUCTURE / Pilot Valve Disassemble Travel, Positioning/Auxiliary and Blade/Stabilizer Pilot Valve • Be sure to read “Precautions for Disassembly and Assembly” thoroughly on page W1-1-1 before starting any repair work. • As casing (21) and spool (15) cannot be disassembled, they cannot be replaced with new ones one by one. • Put identification tags on the disassembled parts by port to aid when re-assembling. IMPORTANT: Put the mating marks onto cam (9), pin (10), cover (11), and casing (21) before disassembling. 1. Clamp the pilot valve in a vise to remove boot (7) from cover (11).



IMPORTANT: Shim (17) adjusts the pressure of the spool (15) assemblies (2 used), they had better not be disassembled. If disassembling the spool (15) assemblies, record the number and thickness of shim (17). IMPORTANT: Be sure not to remove bushing (4) from cover (11) unless bushing (4) is damaged. 8. Pull bushings (4) (2 used) out of cover (11).



2. Remove set screw (8) from cam (9). Pull pin (10) out to remove cam (9) from cover (11). : 2 mm NOTE: LOCTITE is applied onto the set screw. Steel ball (5) cannot be disassembled from cam (9). 3. Loosen and remove socket bolts (6) (2 used) alternately. Remove cover (11) from casing (21). : 6 mm 4. Remove pusher (20) assemblies (2 used) from casing (21). 5. Remove bushings (2) (2 used) from pusher (20) assembly. Remove O-rings (1) (2 used) and packings (3) (2 used) from bushings (2) (2 used). IMPORTANT: Put identification tags on the disassembled parts by port. 6. Remove spool (15) assemblies (2 used) and springs (14) (2 used) from casing (21). 7. Remove spring guides (19) (2 used), springs (18) (2 used), washers (16) (2 used), and shims (17) (2 used) from spool (15) assemblies (2 used).



W2-7-15



UPPERSTRUCTURE / Pilot Valve ASSEMBLE TRAVEL, POSITIONING / AUXILIARY, BLADE / STABILIZER PILOT VALVE 8



7



10 9



5 20



3 6 2 11



1 19 18 14



17 16



12 13



15



W1LA-02-06-002



21 123456-



O-Ring (2 Used) Bushing (2 Used) Packing (2 Used) *Bushing (2 Used) Steel Ball (2 Used) Socket Bolt (2 Used)



78910 11 -



Boot Set Screw Cam Pin Cover



12 13 14 15 16 -



NOTE: As for the item with mark “ * ”, refer to W2-7-14.



W2-7-16



Plug O-Ring Spring (2 Used) Spool (2 Used) Washer (2 Used)



17 18 19 20 21 -



Shim (2 Used) Spring (2 Used) Spring Guide (2 Used) Pusher (2 Used) Casing



UPPERSTRUCTURE / Pilot Valve Assemble Travel, Positioning/Auxiliary and Blade/Stabilizer Pilot Valve • Be sure to read “Precautions for Disassembly and Assembly” thoroughly on page W1-1-1 before starting the assembly work. • Clean the parts and put them by port for assembling. 1. Install bushings (4) (2 used) to cover (11). IMPORTANT: Be sure to install shim (17) to the original condition. 2. Install washers (16) (2 used), shims (17) (2 used), springs (18) (2 used), and spring guides (19) (2 used) to spools (15) (2 used) in this order. IMPORTANT: Be sure to install the spool (15) assembly into the original hole when disassembling. 3. Install springs (14) (2 used) and spool (15) assemblies (2 used) to casing (21). 4. Install O-rings (1) (2 used) and packings (3) (2 used) to bushings (2) (2 used). 3 2 1



Lip Part



W585-02-06-005



5. Install pushers (20) (2 used) to bushing (2) assemblies (2 used). Install the bushing (2) assemblies to casing (21). 6. Clamp casing (21) in a vise. Tighten cover (11) with socket bolts (6) (2 used). : 6 mm : 23.5 N⋅m (2.4 kgf⋅m, 17 lbf⋅ft) 7. Install cam (9) to cover (11) with pin (10). 8. Apply LOCTITE #241 onto set screw (8). Install set screw (8) to cam (9) with pin (10). : 2 mm : 5 N⋅m (0.5 kgf⋅m, 4 lbf⋅ft) 9. Install boot (7) to cover (11).



W2-7-17



UPPERSTRUCTURE / Pilot Valve (Blank)



W2-7-18



UPPERSTRUCTURE / Pilot Shut-Off Valve REMOVE AND INSTALL PILOT SHUT-OFF VALVE CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.) Removal 1. Remove spring (3). 1



IMPORTANT: Attach identification tags to disconnected hoses for re-assembly. 2. Disconnect hoses (6 to 13) and pipes (14, 15). : 17 mm, 19 mm, 22 mm



2 3 5



3. Remove spring pin (5) then remove lever (1).



4



4. Remove bolts (2) (2 used) and remove pilot shut-off valve (4). : 17 mm



W178-02-08-001



14



13 12



2



15



11



Installation 1. Install pilot shut-off valve (4) with bolts (2) (2 used). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)



4



6 10



2. Install lever (1) with spring pin (5). 3. Connect hoses (6 to 13) and pipes (14, 15). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) : 22 mm : 39 N⋅m (4.0 kgf⋅m, 28.5 lbf⋅ft)



7 8 9



4. Install spring (5).



W2-8-1



W178-02-08-002



UPPERSTRUCTURE / Pilot Shut-Off Valve DISASSEMBLE PILOT SHUT-OFF VALVE 5



4



3



6



2



7



1



8 9



13



10 11



12



W178-02-08-005



1234-



Washer Backup Ring O-Ring Body



5678-



Socket Bolt Retaining Ring Washer Backup Ring



910 11 12 -



W2-8-2



O-Ring Spool Bracket Pin



13 - Socket Bolt (3 Used)



UPPERSTRUCTURE / Pilot Shut-Off Valve Disassemble Pilot Shut-Off Valve • Be sure to read “Precautions for Disassembly and Assembly” thoroughly on page W1-1-1 before starting the repair work. 1. Put the mating marks on body (4) and bracket (11). Remove retaining ring (6), washer (7), backup ring (8) and O-ring (9) from body (4) to remove the spool (10) assembly. 2. Remove washer (1), backup ring (2) and O-ring (3) from body (4). 3. Clamp spool (10) with a wooden pieces in a vise. Remove socket bolts (13) (3 used) and bracket (11). : 4 mm NOTE: Do not remove pin (12) unless necessary. 4. Remove socket bolt (5) from body (4). : 8 mm



W2-8-3



UPPERSTRUCTURE / Pilot Shut-Off Valve ASSEMBLE PILOT SHUT-OFF VALVE



12 13



11



4



5



Z



Z W178-02-08-006



Section Z－Z 10



6



7



8



9



4



3



2



1



11



13



T178-03-07-002



1234-



Washer Backup Ring O-Ring Body



5678-



Socket Bolt Retaining Ring Washer Backup Ring



910 11 12 -



W2-8-4



O-Ring Spool Bracket Pin



13 - Socket Bolt (3 Used)



UPPERSTRUCTURE / Pilot Shut-Off Valve Assemble Pilot Shut-Off Valve 1. Apply LOCTITE#262 on socket bolt (5) and install socket bolt (5) to body (4). : 8 mm : 29.4 N⋅m (3.0 kgf⋅m, 21.7 Ibf⋅ft) 2. Clamp spool (10) with a wooden pieces in a vise. Apply LOCTITE#262 on socket bolts (13) (3 used), then install bracket (11) onto spool (10). : 4 mm : 3.9 N⋅m (0.4 kgf⋅m, 2.9 lbf⋅ft) 3. Install O-ring (3), backup ring (2) and washer (1) to body (4). 4. Apply hydraulic oil to spool (10) and install spool (10) to body (4). 5. Install O-ring (9), backup ring (8) and washer (7) to body (4), and install retaining ring (6) to spool (10).



W2-8-5



UPPERSTRUCTURE / Pilot Shut-Off Valve (Blank)



W2-8-6



UPPERSTRUCTURE / Signal Control Valve REMOVE AND INSTALL SIGNAL CONTROL VALVE CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.) Removal 1. Remove the mounting bolts (14 used) of the swing device upper side covers (2 used) and the cab rear cover. Then, remove the covers (3 used). : 17 mm IMPORTANT: Attach identification tags to disconnected hoses for re-assembly. 2. Disconnect all hoses and pipes from each port. : 17 mm, 19 mm, 22 mm NOTE: When removing pipe from signal control valve, if a snap-on tool (GAN850812B: tool size: 19.05 mm) is used, it may be easier to remove the pipe.



Signal Control Valve



Control Valve



3. Disconnect the pressure sensor connectors (swing, auxiliary). 4. Remove socket bolts (20) (4 used) and remove the signal control valve. : 8 mm



Installation 1. Apply LOCTITE to socket bolts (20) (4 used). Install the signal control valve with them. : 8 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 2. Connect all hoses and pipes to each port. : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) : 22 mm : 39 N⋅m (4.0 kgf⋅m, 28.5 lbf⋅ft) 3. Connect the pressure sensor connectors (swing, auxiliary).



W2-9-1



20



T176-04-04-001



UPPERSTRUCTURE / Signal Control Valve



Pilot Valve Side C



PH A



E M D H B



F



SB G



PI



Pilot Valve Side



N



K



I SH



J DF SA



L T178-03-06-016



Pilot Valve Side Port Name Port A Port B Port C Port D Port E Port F Port G Port H Port I Port J Port K Port L Port M Port N Port SA Port SB Port PI Port PH Port SH Port DF



Connecting to Right Pilot Valve Right Pilot Valve Left Pilot Valve Left Pilot Valve Left Pilot Valve Left Pilot Valve Right Pilot Valve Right Pilot Valve   Travel Shockless Valve (Travel Pilot Valve) Travel Shockless Valve (Travel Pilot Valve) Positioning/Auxiliary Pilot Valve Positioning/Auxiliary Pilot Valve Pump 1 Regulator Pump 2 Regulator 4-Unit Solenoid Valve Unit Pilot Shut-Off Valve Shuttle Valve (Swing Parking Brake) Hydraulic Oil Tank



W2-9-2



Note Boom Raise Pilot Pressure Boom Lower Pilot Pressure Arm Roll-Out Pilot Pressure Arm Roll-In Pilot Pressure Left Swing Pilot Pressure Right Swing Pilot Pressure Bucket Roll-In Pilot Pressure Bucket Roll-Out Pilot Pressure Plug Plug Travel Reverse Pilot Pressure Travel Forward Pilot Pressure Positioning Raise/Auxiliary Open Pilot Pressure Positioning Lower/Auxiliary Close Pilot Pressure Pump 1 Control Pressure Pump 2 Control Pressure Primary Pilot Pressure Primary Pilot Pressure (Heating Circuit) Brake Release Pressure Returning to Hydraulic Oil Tank



UPPERSTRUCTURE / Signal Control Valve



Control Valve Side 3



1



5



Pressure Sensor (Auxiliary)



13 4



2 SK



SE 8



Pressure Sensor (Swing)



14 Control Valve Side



7 9 6



10



SN



SL



11



12



Control Valve Side Port Name Port 1 Port 2 Port 3 Port 4 Port 5 Port 6 Port 7 Port 8 Port 9 Port 10 Port 11 Port 12 Port 13 Port 14 Port SE Port SN Port SP Port SL Port SK



Connecting to Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Hydraulic Oil Tank  Control Valve Control Valve Pilot Pressure Shift Valve Pilot Pressure Shift Valve   Shuttle Valve  Control Valve



SP



T1F3-03-06-003



Note Boom Raise Pilot Pressure Boom Lower Pilot Pressure Arm Roll-Out Pilot Pressure Arm Roll-In Pilot Pressure Left Swing Pilot Pressure Right Swing Pilot Pressure Bucket Roll-In Pilot Pressure Bucket Roll-Out Pilot Pressure Returning to Hydraulic Oil Tank Plug Travel Reverse Pilot Pressure Travel Forward Pilot Pressure Positioning Raise/Auxiliary Open Pilot Pressure Positioning Lower/Auxiliary Close Pilot Pressure Plug Plug Pump 1 Flow Rate Control Valve Control Pressure Plug Bucket Flow Rate Control Valve Control Pressure



W2-9-3



UPPERSTRUCTURE / Signal Control Valve NOTE: Machines Equipped with Optional Auxiliary Flow Combining System Control Valve Side SM



Control Valve Side



SN



T1F3-03-06-004



Control Valve Side Port Name Port SM Port SN



Connecting to Auxiliary Flow Combiner Solenoid Valve Auxiliary Flow Combiner Reducing Valve



NOTE: The reducing valve and the auxiliary flow combiner solenoid valve are installed only on the machines equipped with the optional auxiliary flow combining system.



W2-9-4



Note Auxiliary Flow Combiner Valve Shift Pressure Auxiliary Flow Combiner Valve Shift Pressure



UPPERSTRUCTURE / Travel Shockless Valve REMOVE AND INSTALL SHOCKLESS VALVE



TRAVEL



CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.) Accumulator Charging Valve



Removal



3



1. Open the cover of the machine left side. Then, lock the cover with the stopper. IMPORTANT: Attach identification tags to disconnected hoses for re-assembly. 2. Disconnect connectors (4) (2 used) and hoses (3) (5 used). Cap open ends. : 19 mm



1, 2



3. Remove bolts (2) (2 used) and remove travel shockless valve (1). : 17 mm



Installation



3



1. Install travel shockless valve (1) with bolts (2) (2 used). : 17 mm : 50 N·m (5.1 kgf·m, 37 Ibf⋅ft) 2. Connect hoses (3) (5 used) and connectors (4) (2 used). : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft) 3. Close the cover.



W2-10-1



W1F3-02-10-001



4



UPPERSTRUCTURE / Travel Shockless Valve CONSTRUCTION SHOCKLESS VALVE



OF



TRAVEL A



13



1 14 2 3



B



4



4



5



T1F3-03-08-004



T1F3-03-08-005



Section A



6 7 T1F3-03-08-006



8



9



10



11



12 Section B



W2-10-2



UPPERSTRUCTURE / Travel Shockless Valve



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



Part Name Solenoid O-Ring Spool Body Spring Plug Orifice Plug Steel Ball Spring O-Ring Plug Nut Tube



Q’ty 2 2 2 1 2 6 2 2 2 2 4 2 2 2



Wrench Size (mm)



N⋅m



Tightening Torque (kgf⋅m)



(lbf⋅ft)



Remark 1B P14



1.6 to 2.0 13.2 to 17.6



(0.16 to 0.2) (1.3 to 1.8)



(1.2 to 1.5) (9.7 to 13.0) 9/32 1B P8



： 19



13.2 to 17.6 4.9 30 to 37



W2-10-3



(1.3 to 1.8) (0.5) (3.1 to 3.8)



(9.7 to 13.0) (3.6) (22 to 27)



UPPERSTRUCTURE / Travel Shockless Valve (Blank)



W2-10-4



UPPERSTRUCTURE / Solenoid Valve REMOVE AND INSTALL 4-UNIT SOLENOID VALVE UNIT CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.) Removal 3, 4



1. Disconnect the harness connector of each proportional solenoid valve (13 to 16).



5, 6



IMPORTANT: Attach identification tags to disconnected hoses for re-assembly. 2. Disconnect pilot hoses and pipes (1 to 9, 11, 12, 17, 18). Cap open ends. : 17 mm, 19 mm



2 18 1 Solenoid Valve Unit



3. Remove bolts (10) (2 used) and remove the solenoid valve unit. : 8 mm



17 16



Installation 1. Install the solenoid valve unit with bolts (10) (2 used). : 8 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 2. Connect pilot hoses and pipes (1 to 9, 11, 12, 17, 18). : 17 mm : 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft) : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft) 3. Connect the harness connector proportional solenoid valve (13 to 16).



7



15 14 13



of



each



W2-11-1



12 11 10



9



8



W1F3-02-11-001



UPPERSTRUCTURE / Solenoid Valve DISASSEMBLE PROPORTIONAL SOLENOID VALVE 1 3



2



4 5 6 7 8 9 10 11



13 12



14 15



16



17 18



W157-02-11-016



12345-



Socket Bolt (2 Used) Lock Nut O-Ring Adjusting Screw Spring



678910 -



Solenoid Spring O-Ring Diaphragm Spool



11 12 13 14 -



Washer Spring O-Ring O-Ring



W2-11-2



15 16 17 18 -



O-Ring Sleeve Plate Washer



UPPERSTRUCTURE / Solenoid Valve Disassemble Proportional Solenoid Valve IMPORTANT: Take care not to lose spring (7) provided in the groove of solenoid (6) when removing solenoid (6). Do not disassemble lock nut (2) and adjusting screw (4). 1. Remove socket bolts (1) (2 used) and solenoid (6). : 3 mm 2. Pull out spool (10) and remove diaphragm (9), washer (11) and spring (12). 3. Pull sleeve (16) out and remove O-rings (13, 14, 15), washer (18) and plate (17).



W2-11-3



UPPERSTRUCTURE / Solenoid Valve ASSEMBLE PROPORTIONAL SOLENOID VALVE



4



2



6



1



8



16



13



14



10



15



18



3, 5 9



7



17



11 12



W157-02-11-001



12345-



Socket Bolt (2 Used) Lock Nut O-Ring Adjusting Screw Spring



678910 -



Solenoid Spring O-Ring Diaphragm Spool



11 12 13 14 -



Washer Spring O-Ring O-Ring



W2-11-4



15 16 17 18 -



O-Ring Sleeve Plate Washer



UPPERSTRUCTURE / Solenoid Valve Assemble Proportional Solenoid Valve IMPORTANT: Apply grease to O-rings (13, 14, 15) and apply a film of hydraulic oil to sleeve (16). When inserting the sleeve, be sure to align the ports of the sleeve with the ports in the housing. Install sleeve so that the end faces of sleeve and body come to the same point. 1. Install washer (18), plate (17) into the housing. Install O-rings (13, 14, 15) on sleeve (16), and then insert the sleeve (16) assembly into the housing.



13



14



15



IMPORTANT: Lock nut (2), adjusting screw (4), spring (5) and O-ring (3) are not separated, so no need to assemble them. When assembling solenoid (6), take care not to drop spring (7). 3. Install solenoid (6) with socket bolts (1) (2 used). : 3 mm : 2.9 N⋅m (0.3 kgf⋅m, 2.2 lbf⋅ft) 6



16



7



1 W157-02-11-011



Housing



W157-02-11-005



IMPORTANT: Take care not to damage the edge portion in the bore of sleeve (16) when inserting the spool (10) assembly. After inserting spool in, check that the spool slides in and out smoothly without any restriction about 3 to 5 mm (0.12 to 0.20 in). Apply hydraulic oil to the spool. 2. Install diaphragm (9), washer (11) and spring (12) to spool (10). Then, install the spool (10) assembly into sleeve (16). Housing



10



9



16 12 11 W157-02-11-009



W2-11-5



UPPERSTRUCTURE / Solenoid Valve REMOVE AND INSTALL 3-UNIT SOLENOID VALVE (FOR PUMP CONTROL) NOTE: As for disassemble and assemble proportional solenoid valve, refer to “Disassemble and Assemble Proportional Solenoid Valve” on page W2-11-2. CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.)



2



1



Removal 1. Open cover (2) of the machine right side and secure it with stopper (1). 2. Remove the bolts (4 used) and remove the cover of the pump device upper side. : 17 mm 3. Disconnect connectors (8) from solenoid valves (7). IMPORTANT: Attach identification tags to disconnected hoses for re-assembly. 4. Disconnect hoses (6) (4 used) and hoses (9) (3 used) from solenoid valve unit (5). Cap open ends. : 17 mm, 19 mm



MCBB-07-003



3



4



6 5



5. Remove bolts (3) (4 used) and remove the solenoid valve unit (5) assembly from the frame. : 17 mm



7



6. Remove the bolts (2 used) and remove solenoid valve unit (5) from bracket (4). : 17 mm



T1F3-01-02-010



8 9



W2-11-6



UPPERSTRUCTURE / Solenoid Valve Installation 1. Install bracket (4) on solenoid valve unit (5) with the bolts (2 used). : 17 mm : 50 N·m (5.1 kgf·m, 37 Ibf⋅ft)



3



6



4



5



2. Install the solenoid valve unit (5) assembly on the frame with bolts (3) (4 used). : 17 mm : 50 N·m (5.1 kgf·m, 37 Ibf⋅ft) 3. Connect hoses (6) (4 used) and (9) (3 used) to solenoid valve unit (5). Connect the connectors to solenoid valve (7). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft) : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft) : 22 mm : 39 N⋅m (4.0 kgf⋅m, 28.5 Ibf⋅ft)



7



T1F3-01-02-010



8 9 1



2



4. Install the removed cover with the bolts (4 used). : 17 mm : 50 N·m (5.1 kgf·m, 37 Ibf⋅ft) 5. Remove stopper (1) then close cover (2).



MCBB-07-003



W2-11-7



UPPERSTRUCTURE / Solenoid Valve CONSTRUCTION OF 3-UNIT SOLENOID VALVE (FOR PUMP CONTROL) 1 2



3 4



5 6 7 8 9 10 11 12 13 14 15 16 T1F3-03-10-016



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



Part Name Adjust Screw Lock Nut Solenoid Socket Bolt Spring O-Ring Diaphragm Washer O-Ring Spring O-Ring Spool O-Ring Sleeve Plate Washer



Q’ty 3 3 3 6 3 3 3 3 3 3 3 3 3 3 3 3



Wrench Size (mm)



Tightening Torque N⋅m (kgf⋅m) (lbf⋅ft)



: 10



5+2−0



(0.5+0.2−0)



(3.7+1.5−0)



: 4



5+2−0



0.5+0.2−0



3.7+1.5−0



W2-11-8



Remark



UPPERSTRUCTURE / Solenoid Valve REMOVE AND INSTALL 2-UNIT SOLENOID VALVE (FOR BLADE/STABILIZER) CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.)



Solenoid Valve for Blade



Solenoid Valve for Stabilizer



Removal IMPORTANT: The one side of solenoid valve unit cannot be removed. Be sure to remove the solenoid valve unit as the plate (7) assembly. IMPORTANT: Attach identification tags to disconnected hoses for re-assembly. 1. Disconnect hoses (3, 5, 6) (4 used) and (9) (2 used). Cap open ends. : 22 mm, 19 mm 2. Disconnect connectors (2) (2 used) and (4) (2 used). 3. Remove bolts (1) (5 used) and remove the plate (7) assembly. : 17 mm



W1F3-04-04-004



1



2



3



1



5



4



4. Remove bolts (8) (4 used) and remove the solenoid valve units (2 used) from plate (7). : 17 mm



Installation 1. Install the solenoid valve units (2 used) on plate (7) with bolts (8) (4 used). : 17 mm : 50 N·m (5.1 kgf·m, 37 Ibf⋅ft) 2. Install the plate (7) assembly with bolts (1) (5 used). : 17 mm : 50 N·m (5.1 kgf·m, 37 Ibf⋅ft) 3. Connect connectors (2) (2 used) and (4) (2 used). 4. Connect hoses (3, 5, 6) (4 used) and (9) (2 used). : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft) : 22 mm : 39 N⋅m (4.0 kgf⋅m, 28.5 Ibf⋅ft)



W2-11-9



9



7, 8



6



Solenoid Valve for Blade



Solenoid Valve for Stabilizer



1



W1F3-02-11-002



UPPERSTRUCTURE / Solenoid Valve CONSTRUCTION OF 2-UNIT SOLENOID VALVE (FOR BLADE/STABILIZER)



1



2



3



4



5



T1F3-03-08-001



6



Item No. 1 2 3 4 5 6



Part Name Solenoid Piston O-Ring Body Spool Spring



Q’ty



Wrench Size (mm)



N⋅m



Tightening Torque (kgf⋅m) (lbf⋅ft)



2 2 2 1 2 2



Remark



1B P14



W2-11-10



UPPERSTRUCTURE / Pilot Relief Valve REMOVE AND INSTALL PILOT RELIEF VALVE CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.) Removal 1. Remove the bolts (6 used) then remove the cover of the swing device upper side. : 17 mm



1



2



3



IMPORTANT: Attach identification tags to disconnected hoses for re-assembly. 2. Disconnect hoses (2) (6 used). Cap open ends. : 17 mm, 19 mm, 27 mm 3. Remove bolts (4) (2 used) and remove pilot relief valve (1) from bracket (3). : 17 mm



Installation 1. Install pilot relief valve (1) on bracket (3) with bolts (4) (2 used). : 17 mm : 50 N·m (5.1 kgf·m, 37 Ibf⋅ft)



W1F3-02-12-001



2



2. Connect hoses (2) (6 used). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft) : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft) : 27 mm : 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft) 3. Install the removed cover with the bolts (6 used). : 17 mm : 50 N·m (5.1 kgf·m, 37 Ibf⋅ft)



W2-12-1



4



UPPERSTRUCTURE / Pilot Relief Valve CONSTRUCTION VALVE



OF



PILOT



RELIEF



1



2



3, 4



5



6



A



W1GL-02-12-002



10



9



Section A



8



7



T1F3-03-08-002



11 12 B



13



Section B



14



T1F3-03-08-003



T1F3-03-08-008



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



Part Name Body Plug Shim Shim Spring O-Ring O-Ring Plug Plug O-Ring Check Valve Spring O-Ring Plug



Q’ty 1 1 1 1 1 1 3 3 1 1 1 1 1 1



Wrench Size (mm)



N⋅m



Tightening Torque (kgf⋅m)



(lbf⋅ft)



59±5.9



(6.0±0.6)



(44±4.4)



Remark



0.5 mm 0.2 mm 1B P24 1B P11 26.5±3.0 39±4.0



(2.7±0.3) (4.0±0.4)



(19.5±2.2) (28.5±3.0) 1B P14



1B 49±4.9



W2-12-2



(5.0±0.5)



(36±3.6)



UPPERSTRUCTURE / Steering Valve REMOVE AND INSTALL STEERING VALVE CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.)



Travel Pilot Valve



1



Removal IMPORTANT: Attach identification tags to hoses to aid re-assembly. 1. Disconnect hoses (3) (4 used) from steering valve (4). Cap the open ends. 2. Remove bolts (2) (4 used) from stand (1) to remove steering valve (4).



Brake Valve Stand Mounting Bolt



Installation 1. Install steering valve (4) to stand (1) with bolts (2) (4 used). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)



2 Attachment Pedal



2. Connect hoses (3) (4 used) to steering valve (4). : 22 mm : 39 N⋅m (4.0 kgf⋅m, 28.5 Ibf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 Ibf⋅ft)



W1F3-02-14-002



1 2



Floor Plate



3



4 W216-02-12-005



W2-13-1



UPPERSTRUCTURE / Steering Valve DISASSEMBLE STEERING VALVE



14 17



35



36



37



38



19 18



16



39 5 15 6



4



5 33



3



2 1



11



12 13



12



21



10



20 32 31



9 8 7 1



2



3



4



5



6



24 34



30 26



27



28



25 24 23



28



22



26



29



27



T1F3-03-07-004



12345678910 -



O-Ring (2 Used) Plug (2 Used) Spring (2 Used) Holder (2 Used) Ball (2 Used) Seat (2 Used) Dust Seal Retaining Ring Bushing O-Ring



11 12 13 14 15 16 17 18 19 20 -



Seal Bearing Race (2 Used) Thrust Needle Housing Assembly Housing Sleeve Center Spring (6 Used) Pin Spool Screw



21 22 23 24 25 26 27 28 29 30 -



W2-13-2



Ball O-Ring Plate O-Ring (2 Used) Drive Ball (2 Used) Plug (2 Used) Spring (2 Used) Star Rotor



31 32 33 34 35 36 37 38 39 -



Spacer Cap Screw (6 Used) Screw Plug O-Ring Spring Poppet Valve Seat



UPPERSTRUCTURE / Steering Valve Disassemble steering valve IMPORTANT: The O-ring (1), plug (2), spring (3), holder (4), ball (5) and seat (6) are adjustment parts. Do not disassemble them. If disassemble them, the setting may change, malfunction of the base machine may result. IMPORTANT: Cover the open ends of vice with cloth. Lightly secure the valve. 1. Secure the steering valve in a vice with cap (32) upward.



4. Remove drive (25) and plate (23) to remove O-ring (22) from housing assembly (14). Remove screw (20) from housing (15) with a screwdriver. 5. Dismount the steering valve from the vise. Turn the housing (15) over. Remove ball (21), springs (28) (2 used), plugs (27) (2 used), and balls (26) (2 used) from housing (15). Place the steering valve on a clean cloth with care not to damage the machined surfaces. Remove retaining ring (8) from housing (15) with a screwdriver.



32 Vice



15



8



W202-02-14-002



2. Remove screws (33) (6 used) and (34) to remove cap (32). Remove O-ring (24) from cap (32). Tool: 5/16 inch-12 Point Flange Head Socket



W202-02-14-006



6. Turn spool (19) and sleeve (16) so that pin (18) is horizontal. From the cap (32) side, push spool (19) and sleeve (16) to remove bushing (9) from the steering valve.



3. Remove rotor (30) to remove O-ring (24) and spacer (31) from rotor (30). NOTE: Take care not to allow star (29) to drop out of rotor (30) when removing rotor (30).



W2-13-3



UPPERSTRUCTURE / Steering Valve



17



35



36



37



38



15



5



3



1 11



18



16



39 5



4 2



19



12 13



12



21



10 9 7 1



2



3



4



5



26



26



T1F3-03-07-004



W2-13-4



UPPERSTRUCTURE / Steering Valve 7. Remove seal (11) and dust seal (7) from bushing (9). NOTE: Take care not to damage bushing (9) when removing seal (11). 8. Remove bearing races (12) (2 used) and thrust needle (13) from spool (19). 9. Remove spool (19) and the sleeve (16) assembly from housing (15). NOTE: Remove the sleeve (16) assembly from housing (15) while slowly turning the sleeve (16) assembly so that sleeve (16) doesn’t score housing (15). 10. Remove pin (18) from the sleeve (16) assembly. 11. Push spool (19) of sleeve (16) inside into forward slightly then remove center springs (17) (6 used) from spool (19). 12. Turn spool (19) lightly while removing it from sleeve (16). 13. Remove O-ring (10) from housing (15) 14. Remove plug (35) from housing (15). 15. Remove spring (37), poppet (38) and valve seat (39) from housing (15) with a magnet.



W2-13-5



UPPERSTRUCTURE / Steering Valve ASSEMBLE STEERING VALVE 16



15



21 20 22



30 31



32 12



34



11



B



A



25



33 7



24



8



T1F3-03-07-002



9



10



13



17



18



19 23 24



View B



C



View A



29



C



D E



D



E



D



E E



D



T487-03-02-005 W1F3-02-13-001



Section C-C Section E-E



36



35



37



38



T1F3-03-07-003



39



Section D-D



26



6



5



4



3



2



1



T487-03-02-007



W2-13-6



27 28



T487-03-02-006



UPPERSTRUCTURE / Steering Valve



12345678910 -



O-Ring (2 Used) Plug (2 Used) Spring (2 Used) Holder (2 Used) Ball (2 Used) Seat (2 Used) Dust Seal Retaining Ring Bushing O-Ring



11 12 13 14 15 16 17 18 19 20 -



Seal Bearing Race (2 Used) Thrust Needle Housing Assembly Housing Sleeve Center Spring (6 Used) Pin Spool Screw



21 22 23 24 25 26 27 28 29 30 -



W2-13-7



Ball O-Ring Plate O-Ring (2 Used) Drive Ball (2 Used) Plug (2 Used) Spring (2 Used) Star Rotor



31 32 33 34 35 36 37 38 39 -



Spacer Cap Screw (6 Used) Screw Plug O-Ring Spring Poppet Valve Seat



UPPERSTRUCTURE / Steering Valve 16



15



32



B



A



25



T1F3-03-07-002



17



18



19



View B



C



View A



C



D E



D



E



D



E E



D



T487-03-02-005 W1F3-02-13-001



Section C-C Section E-E



36



35



37



38



T1F3-03-07-003



39



Section D-D



26



6



5



4



3



2



1



T487-03-02-007



W2-13-8



27 28



T487-03-02-006



UPPERSTRUCTURE / Steering Valve Assemble Steering Valve Precautions for before assemble • Check all parts for scores or coarse surfaces. If any, grind to a smooth finish using an oil stone.



3. Install pin (18) into spool (19) and sleeve (16). Level the ends of pin (18) with the outer diameter of sleeve (16).



IMPORTANT: Align the spring grooves on spool (19) and sleeve (16). 1. Install spool (19) into sleeve (16) while turning spool (19).



Pin (18)



Spring Groove W202-02-14-021



Spool (19)



Sleeve (16)



W202-02-14-019



2. Place spool (19) and sleeve (16) on a flat plate so that the spring grooves on them align. Install center springs (17) into special tool (ST 2497) with the back of 2-sets of three center springs (17) contacted each other. Install center springs (17) into spool (19) and sleeve (16) using special tool (ST 2497).



4. Install sleeve (16) assembly into housing (15) from the cap (32) mounting side. NOTE: Take care not to install the sleeve (16) assembly with excessive force into housing (15). While keeping pin (18) in the horizontal position and slightly turning the sleeve (16) assembly right and left, install the sleeve (16) assembly into housing (15) until the rear ends of both the sleeve (16) assembly and housing (15) level off.



Spool (19) ST 2497 Center Spring (17)



Sleeve (16)



W202-02-14-020



W2-13-9



UPPERSTRUCTURE / Steering Valve



15



21 20 22



12 11



B



A



7 8 9



View A



T1F3-03-07-002



10



13



19 23



View B



C



C



D E



D



E



D



E E



D



T487-03-02-005 W1F3-02-13-001



Section C-C Section E-E



T1F3-03-07-003



Section D-D



26



T487-03-02-007



W2-13-10



27 28



T487-03-02-006



UPPERSTRUCTURE / Steering Valve 5. Install O-ring (10), bearing races (12) (2 used) and thrust needle (13) to housing (15).



13



9. Lightly hold housing (15) with a vise. 10. Install O-ring (22) in housing (15). Install ball (21) and screw (20) in housing (15) as illustrated below. Install balls (26) (2 used), plugs (27) (2 used), and springs (28) (2 used) in housing (15) as illustrated below. Put plate (23) on housing (15). Align the bolt holes with tapped holes on housing (15).



12 10 15



Screw (20) Ball (21) W202-02-14-023



Housing (15)



6. Install dust seal (7) and seal (11) to bushing (9). 7. Install bushing (9) to spool (19) while tapping bushing (9) with a plastic hammer. NOTE: Check that bushing (9) comes in contact with bearing race (12) flat. W487-03-08-004



Driver



8 7



Spring (28)



15 Plug (27)



11 12



10 9



Ball (26) Housing (15)



W212-02-14-002



8. Install retaining ring (8) to housing (15). NOTE: After installing retaining ring (8) into housing (15), make sure that retaining ring (8) is correctly seated in the groove on housing (15) by expanding the inner diameter of retaining ring (8) with a screwdriver.



W2-13-11



W487-03-08-005



UPPERSTRUCTURE / Steering Valve 16



15



30 31



32 12



34



11



B



A



25



33 24 T1F3-03-07-002



13



View A



18



19 23 24



29



View B



C



C



D E



D



E



D



E E



D



T487-03-02-005 W1F3-02-13-001



Section C-C Section E-E



36



35



37



38



39



T1F3-03-07-003



Section D-D T487-03-02-006



T487-03-02-007



W2-13-12



UPPERSTRUCTURE / Steering Valve IMPORTANT: Steps 11 to 13 described above are important procedure to determine the valve timing. Carefully follow the procedures in these steps. 11. Turn spool (19) and the sleeve (16) assembly so that pin (18) is parallel to the port face on housing (15). Draw line (B) on the end face of the spline on drive (25) so that line (B) is parallel to line (C) at the yoke of drive (25). Insert drive (25) to install the yoke of drive (25) onto pin (18). (Line (B) on the end face of the spline on drive (25) is parallel to the port face on housing (15).)



14. Install spacer (31) into rotor (30). Install O-ring (24) on cap (32). Install cap (32) on rotor (30). 15. Install screws (33) (6 used) and screw (34) onto cap (32), tighten them with the specified torque. Tool: 5/16 inch-12 Point Flange Head Socket : 28.5 N⋅m (2.9 kgf⋅m, 21 Ibf⋅ft) 16. Install valve seat (39), poppet (38) and spring (37) into housing (15) then secure them with plug (35).



B Rotor (30) C



Draw Line (a)



A Star (29)



Drive (25) B Bolt Hole



Yoke Drive (25)



W487-03-08-006



C D



12. Install O-ring (24) to rotor (30).



Plate (23)



13. Face the O-ring (24) mounting side of rotor (30) toward plate (23). Draw line (a) on star (29) so that two tooth bottoms at the opposite sides are on line (A). Install star (29) onto drive (25) while aligning the spline pitch so that line (A) is parallel to line (B). Recheck that lines (A, B, C, and D) are all parallel to each other. Align the bolt holes of rotor (30) with those of housing (15) without disengaging the splines on drive (25) and star (29).



Pin (18)



Port Face W202-02-14-031



Port Face Drive (25) Make surface of pin (18) paralleled with port face



Pin (18) Yoke



Housing (15)



W487-03-08-007



W2-13-13



UPPERSTRUCTURE / Steering Valve (Blank)



W2-13-14



UPPERSTRUCTURE / Brake Valve REMOVE AND INSTALL BRAKE VALVE CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.)



1



2



Removal IMPORTANT: Attach tags to the disconnected hoses to aid re-assembling. 1. Disconnect hoses (1) (6 used) from brake valve (2). Cap the disconnected hose ends. : 17, 22, 27 mm 2. Remove bolts (4) (4 used) from frame (3) to remove brake valve (2). : 17 mm



1



W1F3-02-14-001



3



Installation 1. Install brake valve (2) to frame (3) with bolts (4) (4 used). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) 2. Connect all hoses (1) (6 used) to brake valve (2). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft) : 22 mm : 39 N⋅m (4.0 kgf⋅m, 29 Ibf⋅ft) : 27 mm : 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft)



W2-14-1



4



W1F3-02-14-002



UPPERSTRUCTURE / Brake Valve DISASSEMBLE BRAKE VALVE



1 2



5



28



11



27



8 3 7



4



26



10



6



7



12



9



13 15



14



16



25



9



29



3



24



17 23



30 31



42



22



32



21



33



16



34



20



35 41



18 36



20



40



19



37



39



28



43



38 44



45 46



47 43



44



45 46



48 47



W2-14-2



W1F3-02-14-003



UPPERSTRUCTURE / Brake Valve



12345678910 11 12 -



Rubber Brake Pedal Cotter Pin (4 Used) Stopper Bolt Bushing Lock Nut Bushing (2 Used) Pin Bushing (2 Used) Pin Boots Pin



13 14 15 16 17 18 19 20 21 22 23 24 -



Spring Pin Bushing Yoke Pin (2 Used) Link Roller Bushing Washer (2 Used) Seat Stopper Boots Socket Bolt (4 Used)



25 26 27 28 29 30 31 32 33 34 35 36 -



W2-14-3



Bracket Oil Seal T Flange O-Ring (2 Used) (1B, G45) Rod Return Spring Holder Spring Balance Spring Retainer Retainer Pilot Piston



37 38 39 40 41 42 43 44 45 46 47 48 -



Push Rod P Cylinder S Cylinder O-Ring (1B, P32) Plug Socket Bolt (4 Used) Spring (2 Used) Retaining Ring (2 Used) Retainer (2 Used) Plunder (2 Used) Spool (2 Used) Spring



UPPERSTRUCTURE / Brake Valve 1 2



5



28



11



27



8 3 7



4



26



10



6



7



12



9



13 15



14



16



25



9



29



3



24



17 23



30 31



42



22



32



21



33



16



34



20



35 41



19



36



18



20



40 37



39



28



43



38 44



45 46



47 43



44



45 46



48 47



W2-14-4



W1F3-02-14-003



UPPERSTRUCTURE / Brake Valve Disassemble Brake Valve • Be sure to read “Precautions for Disassembly and Assembly” thoroughly on page W1-1-1 before starting the disassembly work. IMPORTANT: Before disassembling, put matching marks on bracket (25), T flange (27), P cylinder (38), S cylinder (39). 1. Secure S cylinder (39) on a vice with the S cylinder (39) facing lower side. Except the roller (18) parts, remove cotter pins (3) (3 used) then remove pins (8), (10), (16). 2. Remove spring pin (13) from yoke (15) to remove pin (12). 3. Remove cotter pin (3) from link (17) then remove pin (16), washers (20) (2 used) and roller (18). 4. Remove seat (21), stopper (22) and boots (23) from T flange (27).



IMPORTANT: As the action force from springs is applied to socket bolt (42), slowly remove socket bolt (42) while push S cylinder (39) on top. 9. Remove socket bolts (42) (4 used) from S cylinder (39). 10. Remove S cylinder (39) and the P cylinder (38) assembly from T flange (27). 11. Pulling out the spool (47) assembly from P cylinder (38). 12. Remove plunger (46), spring (48) and retaining ring (44), retainer (45) from the spool (47) assembly. 13. Remove return spring (30), holder (31), rod (29), balance spring (33), spring (32), retainers (34), (35) and pilot piston (36), push rod (37) from T flange (27).



5. Remove socket bolts (24) (4 used) to remove bracket (25) from T flange (27). 6. Secure the T flange (27) position on a vice with the push rod (37) side facing down. IMPORTANT: The spool (47) assembly also is used in P cylinder (38). Be sure store the parts correctly without mixing. 7. Pulling out plug (41), spring (43) and the spool (47) assembly from S cylinder (39). 8. Remove plunger (46) and retaining ring (44), retainer (45) from the spool (47) assembly.



W2-14-5



UPPERSTRUCTURE / Brake Valve 2



ASSEMBLE BRAKE VALVE



1



12 11



8 15



14



25



27



39



42



38



41



A



16 10 16 18



21



24



23



W1F3-02-14-004



34



44



30 28 46



28 47



43



40 41 46



45 37



22



26



36



35



47



48



45



43



T1F3-03-09-002



5 12



13



View A



31



29 33



32



7



15 8 9



3



24



25



17 10 3



16



3 18



19



W2-14-6



20



W1F3-02-14-005



UPPERSTRUCTURE / Brake Valve



12345678910 11 12 -



Rubber Brake Pedal Cotter Pin (4 Used) *Stopper Bolt Bushing *Lock Nut Bushing (2 Used) Pin Bushing (2 Used) Pin Boots Pin



13 14 15 16 17 18 19 20 21 22 23 24 -



Spring Pin Bushing Yoke Pin (2 Used) Link Roller Bushing Washer (2 Used) Seat Stopper Boots Socket Bolt (4 Used)



25 26 27 28 29 30 31 32 33 34 35 36 -



NOTE: As for parts with * mark, refer to W2-14-2.



W2-14-7



Bracket Oil Seal T Flange O-Ring (2 Used) (1B, G45) Rod Return Spring Holder Spring Balance Spring Retainer Retainer Pilot Piston



37 38 39 40 41 42 43 44 45 46 47 48 -



Push Rod P Cylinder S Cylinder O-Ring (1B, P32) Plug Socket Bolt (4 Used) Spring (2 Used) Retaining Ring (2 Used) Retainer (2 Used) Plunder (2 Used) Spool (2 Used) Spring



UPPERSTRUCTURE / Brake Valve 2 1



12 11



8 15



14



25



27



39



42



38



41



A



16 17



10 16 18



21



24



23



W1F3-02-14-004



34



44



30 28 46



28 47



43



40 41 46



45 37



22



26



36



35



47



48



45



43



T1F3-03-09-002



5 12



13



View A



31



29 33



32



7



15 8 9



3



24



25



17 10 3



16



3 18



19



W2-14-8



20



W1F3-02-14-005



UPPERSTRUCTURE / Brake Valve Assemble Brake Valve • Be sure to read “Precautions for Disassembly and Assembly” thoroughly on page W1-1-1 before starting the assembly work.



10. Install spring (48), plunger (46) and spring (43) into P cylinder (38).



1. Install oil seal (26) into T flange (27).



11. Align the matching marks while placing S cylinder (39) onto P cylinder (38).



2. Secure T flange (27) in a vice with oil seal (26) facing down.



12. Install retainer (45) and retaining ring (44) to spool (47).



3. Install O-ring (28) to T flange (27).



13. Install the spool (47) assembly to S cylinder (39).



4. Apply hydraulic oil onto all parts of rod (29), pilot piston (36), push rod (37), plunger (46), spool (47).



14. Install plunger (46), spring (43) and plug (41) to S cylinder (39). : 130 to 180 N⋅m (13.0 to18.0 kgf⋅m, 94 to 130 Ibf⋅ft)



5. Install push rod (37), pilot piston (36) and retainer (35), retainer (34), return spring (30), balance spring (33), spring (32), holder (31), rod (29) into T flange (27) in that order.



15. Joint T flange (27), P cylinder (38), S cylinder (39) with socket bolts (42) (4 used). : 60 to 75 N⋅m (6.0 to 7.5 kgf⋅m, 43 to 54 Ibf⋅ft)



6. Install O-ring (28) to P cylinder (38). 7. Align the matching marks while placing P cylinder (38) on the T flange (27) assembly. 8. Install retainer (45) and retaining ring (44) to spool (47). 9. Install the spool (47) assembly to P cylinder (38).



W2-14-9



UPPERSTRUCTURE / Brake Valve 2 1



12 11



8



15



14



25



39



27



A



16 17 10 16 18



21



24



23



W1F3-02-14-004



22



T1F3-03-09-002



13



View A



12 15 8 3 24 25 17 10 16 3 3 18



W2-14-10



20



W1F3-02-14-005



UPPERSTRUCTURE / Brake Valve 16. Secure the cylinder assembly in a vice with the S cylinder (39) side facing down. 17. Install bracket (25) to T flange (27) with socket bolts (24) (4 used). : 60 to 75 N⋅m (6.0 to 7.5 kgf⋅m, 43 to 54 Ibf⋅ft)



26. Secure link (17) with lock nut (6). : 6.0 to 10 N⋅m (0.6 to 1.0 kgf⋅m, 4.3 to 7.2 Ibf⋅ft) 27. Install rubber (1) onto brake pedal (2).



18. Install boots (23), stopper (22) and seat (21) to T flange (27). 19. Apply grease onto all pin hole of brake pedal (2), bracket (25), yoke (15) and link (17). 20. Install yoke (15) into brake pedal (2) with pin (12) and spring pin (13). 21. Install roller (18), washers (20) (2 used) onto link (17) with pin (16). Lock them with cotter pin (3). 22. Install the link (17) assembly with pin (10) and bracket (25). Lock them with cotter pin (3). 23. Install boots (11) to the brake pedal (2) assembly, then install it to bracket (25) with pin (8). Lock them with cotter pin (3). 24. Install yoke (15) to link (17) with pin (16), lock them with cotter pin (3). 25. Adjust the play of link (17) with stopper bolt (4) to 0 mm.



W2-14-11



UPPERSTRUCTURE / Brake Valve (Blank)



W2-14-12



UPPERSTRUCTURE / Accumulator Charging Valve REMOVE AND INSTALL ACCUMULATOR CHARGING VALVE CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.) Removal IMPORTANT: Attach identification tags to disconnected hoses for re-assembly. 1. Disconnect connector (1) and hoses (2) (4 used). Cap open ends. : 17 mm, 22 mm, 27 mm



1



2



2



2. Remove socket bolts (4) (2 used) and remove accumulator charging valve (3). : 5 mm



Installation 1. Install accumulator charging valve (3) with socket bolts (4) (2 used). : 5 mm : 12 N·m (1.2 kgf·m, 8.9 Ibf⋅ft) 2. Connect connector (1) and hoses (2) (4 used). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft) : 22 mm : 39 N⋅m (4.0 kgf⋅m, 28.5 Ibf⋅ft) : 27 mm : 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft)



W2-15-1



3, 4



Travel Shockless Valve



W1F3-02-10-001



UPPERSTRUCTURE / Accumulator Charging Valve CONSTRUCTION OF CHARGING VALVE



ACCUMULATOR



1 5



2



6 3



4 7 8



9 10



11 12 13 14 23



24 15



21



16 17 22



18 19 20



W1F3-02-15-001



W2-15-2



UPPERSTRUCTURE / Accumulator Charging Valve



Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24



Part Name Lock Nut Adjusting Screw Nut O-Ring Spring Seat Spring Spool Plug Body Plug Piston O-Ring Spring Spring Seat Spring O-Ring O-Ring Backup Ring Check Valve Sleeve Plug Compensator Plunger Spring O-Ring



Q’ty 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 3



Wrench Size (mm)



N⋅m



Tightening Torque (kgf⋅m)



(lbf⋅ft)



45



(4.6)



(33)



18



(1.8)



(13)



40



(4.1)



(29.5)



10 7



(1.0) (0.7)



(7.4) (5.2)



W2-15-3



Remark



UPPERSTRUCTURE / Accumulator Charging Valve (Blank)



W2-15-4



UPPERSTRUCTURE / Transmission Control Valve REMOVE AND INSTALL TRANSMISSION CONTROL VALVE CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.) Removal 1. Open the front right side cover of the machine. 1



2



IMPORTANT: Attach identification tags to disconnected hoses for re-assembly. 2. Disconnect connectors (1) (2 used) and hoses (2) (6 used). Cap open ends. : 19 mm 3. Remove bolts (3) (2 used) transmission control valve (4). : 17 mm



and



remove



W1GL-02-16-001



Installation



2



1. Install transmission control valve (4) with bolts (3) (2 used). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) 2. Connect connectors (1) (2 used) and hoses (2) (6 used). : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)



W2-16-1



4



3



UPPERSTRUCTURE / Transmission Control Valve CONSTRUCTION CONTROL VALVE 28



OF



TRANSMISSION



30



29



31



1 B



2



C



27 3



4 18



13



17



16



Section B



15



14



A



12



W1GL-02-16-002



19



1



W1F3-02-16-001



*2



5



6



7



20 21 22 23 8



*1 24 25



9



12 T1F3-03-03-006



26



Section A



W2-16-2



11 Section C



10



W1GL-02-16-003



UPPERSTRUCTURE / Transmission Control Valve



Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 *1 *2



Part Name Solenoid Body Orifice Orifice O-Ring Spool Plug Spring Spool Plug O-Ring Solenoid Plug Spring O-Ring Spring Plug Plunger Adjusting Screw Seal Lock Nut Spring Guide Spring Guide Spring Guide Spool Plug Plug O-Ring Orifice Spool Spring Guide Nut Tube



Q’ty 1 1 1 1 2 1 3 2 1 2 3 1 1 1 2 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 2 2



Wrench Size (mm)



N⋅m



Tightening Torque (kgf⋅m)



(lbf⋅ft)



5.1 to 6.4 7.8 to 9.8



(0.5 to 0.7) (0.8 to 1.0)



(3.8 to 4.7) (5.8 to7.2)



Remark



1B P14



31 to 37



(3.2 to 3.8)



(23 to 27)



4.9 74 to 88



(0.5) (7.5 to 9.0)



(3.6) (55 to 65)



1B P11 : 22



1B P20



: 5 : 17



19 to 23



(1.9 to 2.3)



(14 to 17)



20 to 29



(2.0 to 3.0)



(14.5 to 21.5)



74 to 88



(7.5 to 9.0)



(55 to 65)



13.0 to 17.5



(1.3 to 1.8)



(9.6 to 13.0) 1B P8



: 19



5.1 to 6.4



(0.5 to 0.7)



(3.8 to 4.7)



4.9 30 to 37



(0.5) (3.1 to 3.8)



(3.6) (22 to 27)



W2-16-3



UPPERSTRUCTURE / Transmission Control Valve (Blank)



W2-16-4



MEMO ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... 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MEMO ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... 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SECTION 3



UNDERCARRIAGE ―CONTENTS― Group 1 Swing Bearing



Group 5 Axle



Remove and Install Swing Bearing ......... W3-1-1 Disassemble Swing Bearing ................... W3-1-4 Assemble Swing Bearing........................ W3-1-6



Remove and Install Axle ......................... W3-5-1 Disassemble Front Axle.......................... W3-5-6 Assemble Front Axle ............................ W3-5-12 Disassemble Front Differential.............. W3-5-20 Assemble Front Differential .................. W3-5-24 Disassemble Rear Axle ........................ W3-5-28 Assemble Rear Axle ............................ W3-5-34 Disassemble and ASSEMBLE Rear Differential................................... W3-5-40 Disassemble Steering Cylinder ............. W3-5-44 Assemble Steering Cylinder ................. W3-5-46



Group 2 Travel Motor Remove and Install Travel Motor ............ W3-2-1 Disassemble Travel Motor...................... W3-2-4 Assemble Travel Motor ........................ W3-2-12 Disassemble Brake Valve .................... W3-2-18 Assemble Brake Valve ......................... W3-2-20



Group 3 Center Joint Remove and Install Center Joint ........... W3-3-1 Disassemble Center Joint....................... W3-3-4 Assemble Center Joint ......................... W3-3-6 Maintenance Standard ........................... W3-3-9



Group 6 Axle Lock Cylinder Remove and Install Axle Lock Cylinder .............................. W3-6-1 Disassemble and Assemble Axle Lock Cylinder .............................. W3-6-4



Group 4 Transmission Remove and Install Transmission............ W3-4-1 Disassemble Transmission ..................... W3-4-6 Disassemble Final Drive and Differential.......................................... W3-4-16 Assemble Final Drive and Differential.... W3-4-18 Assemble Transmission........................ W3-4-20 Adjusting Gear Clearance..................... W3-4-30



Group 7 Operate-Check Valve Remove and Install Operate-Check Valve (for Axle Lock Cylinder) ................ W3-7-1 Construction of Operate-Check Valve (for Axle Lock Cylinder)................ W3-7-2



CBBW-3-1



(Blank)



CBBW-3-2



UNDERCARRIAGE / Swing Bearing REMOVE AND INSTALL SWING BEARING Before removing the swing bearing, the upperstructure must be removed first. For removal and installation of the upperstructure, refer to “Remove and Install Main Frame” section. In this section, the procedure starts on the premise that the upperstructure has already been removed. Mark



Removal 1. Put mating marks on inner race (1) of swing bearing (4) and chassis (2).



1



2 W105-03-01-001



2. Remove bolts (3) (36 used) from inner race (1) of swing bearing (4). : 30 mm



3 W158-03-01-001



CAUTION: Swing bearing weight: 220 kg (490 Ib) 3. Attach lifting tools (ST 0050), lift swing bearing (4) off.



ST 0050



4



W3-1-1



W110-03-01-004



UNDERCARRIAGE / Swing Bearing Installation Clean the matching surfaces of the chassis and swing bearing. 1. Apply THREEBOND#1102 to the matching surfaces of the chassis and swing bearing. CAUTION: Swing bearing weight: 220 kg (490 Ib) IMPORTANT: Failure to align the mating marks may result in misalignment of the inner race soft zone. 2. Lift the swing bearing. Align the mating marks both on the chassis and swing bearing.



W110-03-01-004



Front Side Position for Grease Fitting “S” (Soft Zone) Marking Position 8°



Position of Plug



10°



19°



Position for Grease Fitting W178-03-01-001



3. Install bolts (3) (36 used) to the inner race of the swing bearing and tighten to specification. : 30 mm : 490 N⋅m (50 kgf⋅m, 360 Ibf⋅ft)



3 W158-03-01-001



W3-1-2



UNDERCARRIAGE / Swing Bearing 4. After installing the swing bearing, fill the grease bath with grease (Shell Alvania EP2 or equivalent) until the pinion of the swing bearing is covered A in grease. A: 5 mm (0.2 in)



Swing Bearing



Grease Level



Pinion



A



Grease Bath



W3-1-3



W175-03-01-002



UNDERCARRIAGE / Swing Bearing DISASSEMBLE SWING BEARING 1



2



3



4



9



7



6



5



W157-03-01-003



8



1



8 2



9 7 6



5



W157-03-01-002



1 - Outer Race 2 - Seal 3 - Pin



4 - Plug 5 - Seal



6 - Ball (121 Used) 7 - Inner Race



W3-1-4



8 - Grease Fitting (2 Used) 9 - Support (121 Used)



UNDERCARRIAGE / Swing Bearing Disassemble Swing Bearing • Be sure to read “Precautions for Disassembly and Assembly” thoroughly on page W1-1-1 before starting any repair work. 1. Tap stopper pin (3) of plug (4) up from the bottom side. NOTE: Since pin (3) was crimped after being installed, grind the crimped part with a grounder.



CAUTION: Swing bearing weight: 220 kg (490 Ib) 3. Unseat outer race (1) of swing bearing horizontally and slightly by crane using lifting tools (ST 0050). Remove seals (2, 5). 4. Place the inner race (7) of swing bearing onto wooden blocks while holding outer race (1) by crane. 5. Remove balls (6) (121 used) and supports (9) (121 used) out from the plug hole, while rotating the outer race (1). Magnet rod (A) can be used to remove the balls out, and a hooked wire (B) can be used to remove supports (9).



3



4



1 2 A 7



W105-03-01-007



2. Pull plug (4) out. NOTE: Insert a bolt into the hole (M10, Pitch 1.5 mm) from it plug (4) was pull out. Then tap or pull the bolt from inside. 6



5



W105-03-01-009



B



4



9, 10



W105-03-01-008



W105-03-01-010



6. Remove seal (2) from outer race (1) and remove seal (5) from inner race (7) with scrapper.



W3-1-5



UNDERCARRIAGE / Swing Bearing ASSEMBLE SWING BEARING 1



2



3



4



9



7



6



5



W157-03-01-003



8



1



8 2



9 7 6



5



W157-03-01-002



1 - Outer Race 2 - Seal 3 - Pin



4 - Plug 5 - Seal



6 - Ball (121 Used) 7 - Inner Race



W3-1-6



8 - Grease Fitting (2 Used) 9 - Support (121 Used)



UNDERCARRIAGE / Swing Bearing Assemble Swing Bearing IMPORTANT: Be sure to apply grease to balls (6) and to supports (9).



2. Tap plug (4) into outer race (1) and then, drive pin (3) into the pin hole. Crimp the head of pin (3) with a punch.



CAUTION: Swing bearing weight: 220 kg (490 Ib)



3



1. Lift the outer race horizontally and match it with the inner race coaxially. Rotating the outer race, insert balls (6), support (9) into the plug hole one by one with a round bar.



1



4



2



W142-03-01-007



3. Install lifting tools (ST 0050) onto outer race (4) and lift outer race (4). Thoroughly degrease the slots for seals (2, 5). Apply THREEBOND # 1745 (to seal (2)) and # 1735 (to seal (5)). Then assemble seals (2, 5) into the slots.



6 5



W142-03-01-005



4. Fill grease 0.5 L (0.132 US gal) (Alvania EP2 grease or equivalent) through the grease fitting (8). Rotate the outer race while filling. NOTE: Fill grease from two places (0.30 L).



9



W142-03-01-006



W3-1-7



UNDERCARRIAGE / Swing Bearing (Blank)



W3-1-8



UNDERCARRIAGE / Travel Motor REMOVE AND INSTALL TRAVEL MOTOR CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.) Removal IMPORTANT: Attach identification tags to disconnected hoses to aid re-assembly. 1. Remove socket bolts (1) (8 used) and split flanges (8) (4 used) from travel motor (7). Disconnect main hoses (2) (2 used), then cap all disconnected hose ends. 2. Disconnect drain hose (4) and pilot hose (3). Cap all disconnected hose ends. : 27 mm



Front Side



2



3



4



5



1 6



CAUTION: Travel Motor Weight: 85 kg (190 lb) 3. Loosen mounting socket bolts (5) (4 used) from travel motor (7), then support the lower side of travel motor (7) by a forklift. Remove socket bolts (5) (4 used). 4. Remove travel motor (7) from transmission (6).



W3-2-1



2



8



7 W1F3-03-02-001



UNDERCARRIAGE / Travel Motor Installation Front Side



2



CAUTION: Travel Motor Weight: 85 kg (190 lb) 1. Install travel motor (7) onto transmission (6) with socket bolts (5) (4 used).



3



4



5



1 6



2. Connect drain hose (4) and pilot hose (3). : 22 mm : 27 mm : 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft) 3. Connect main hoses (2) (2 used) with socket bolts (1) (8 used) and split flanges (8) (4 used).



2



8



7 W1F3-03-02-001



W3-2-2



UNDERCARRIAGE / Travel Motor (Blank)



W3-2-3



UNDERCARRIAGE / Travel Motor DISASSEMBLE TRAVEL MOTOR 50



1



52 53



2



3



4



5



6



7



51



8 9



10



49 48 11



45, 46, 47



12



44



13 14



43



15 16, 17 18



42 40



20



41



21



39



23 24



38 37



22



19



25 26



36



27



34



28 29 30 31



33



32



35



59



2



W1GL-03-02-007



2



45, 46, 47



16, 17 57 57



56



56 54



58



W1F3-03-02-002



55



36



55 36



W3-2-4



W1F3-03-02-003



UNDERCARRIAGE / Travel Motor



12345678910 11 12 13 14 15 -



Head Cover Brake Valve O-Ring (2 Used) Pin Spring Spring Collar Spring Collar Bushing O-Ring Spring Retaining Ring Control Piston Sleeve Retaining Ring



16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 -



O-Ring (3 Used) Cover Adjusting Screw Lock Nut Pin Adjusting Screw Lock Nut Rotor Adjusting Plate Spring Screw Bolt (7 Used) Bearing Ring Bearing Adjusting Shim



31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 -



W3-2-5



Oil Seal Shim Key Retaining Ring Retaining Ring Housing Drive Shaft Retainer Plate Center Joint Plunger (7 Used) Lock Nut Adjusting Screw O-Ring Pin (2 Used) O-Ring



46 47 48 49 50 51 52 53 54 55 56 57 58 59 -



O-Ring Cover Valve Plate Socket Bolt Piston Ring (2 Used) Servo Piston Lock Pin Socket Bolt (4 Used) Socket Bolt (8 Used) Plug (2 Used) Relief Valve (2 Used) Socket Bolt (4 Used) Socket Bolt (2 Used)



UNDERCARRIAGE / Travel Motor 1



52 53 50



2



3



4



5



6



7



51



8 9



10



49 48 11



45, 46, 47



12



44



13 14



43



15 16, 17 18



42 40



20



41



21



39



23 24



38 37



22



19



25 26



36



27



34



28 29 30 31



33



32



35



59



2



W1GL-03-02-007



2



45, 46, 47



16, 17 57 57



56



56 54



58



W1F3-03-02-002



55



36



55 36



W3-2-6



W1F3-03-02-003



UNDERCARRIAGE / Travel Motor Disassemble Travel Motor • Be sure to read “Precautions for Disassembly and Assembly” thoroughly on page W1-1-1 before starting any repair work. CAUTION: Travel Motor Weight: 85 kg (190 lb) 1. Set the travel motor onto wooden block (100×500 mm (3.9×19.7 in)) with drive shaft (37) facing down. NOTE: When the work bench is used Work bench: ST 5092 Upper Plate: ST 7333 2. Remove socket bolts (59) (2 used). Remove brake valve (2) and O-rings (3) (2 used). : 5 mm IMPORTANT: Do not to disassemble relief valves (57) (2 used). 3. Remove relief valves (57) (2 used) and plugs (56) (2 used) from head cover (1). : 27 mm, 32 mm 4. Record the measurement of A part before removing cover (17). 17 17



18



CAUTION: Take care when removing cover (17) as the spring inside may fly out. 5. Remove socket bolts (54) (4 used). Remove O-ring (16) and cover (17). : 6 mm 6. Remove bushing (9), spring (6), collar (7) and spring (5) from head cover (1) in order. 7. Remove spring collar (8) and spring (11) from cover (17). 8. Remove O-rings (10, 16) (3 used respectively), adjusting screw (18), lock nut (19) and pin (20) from cover (17). 9. Remove retaining ring (12) from the inside of cover (17). Remove the sleeve (14) assembly. 10. Pull control piston (13) out from sleeve (14) then remove retaining ring (15) from control piston (13). 11. Remove socket bolts (58) (4 used) from head cover (1). Remove cover (47) and O-rings (45), (46). : 10 mm



19



A



W1GL-03-02-006



W3-2-7



UNDERCARRIAGE / Travel Motor 1



42



41 21



39



23



22



37 36



34



31



33



32



W1GL-03-02-007



W1F3-03-02-002



55



36



55 36



W3-2-8



W1F3-03-02-003



UNDERCARRIAGE / Travel Motor 12. Record measurements of B, C parts before removing lock nuts (22, 41) and adjusting screws (21, 42).



16. Secure rotor (23) by using screw bar (M8, Pitch 1.25 mm (0.05 in), Length 120 mm (4.7 in)) to prevent rotor (23) removing, then remove adjusting screw (42). Screw Bar



B



Lock Nut Washer



C



42



41 22



21 W1GL-03-02-003



W1GL-03-02-005



13. Loosen lock nuts (22, 41) and remove adjusting screws (21), (42). : 19 mm : 6 mm 14. Install adjusting screw (42) (M12, Pitch 1.75 mm (0.1 in), Length 100 mm (3.9 in)) into the location where adjusting screw (21) is inserted, the angle of center shaft (39) should be zero.



17. Place housing (36) horizontally. Remove key (33) from drive shaft (37). 18. Remove retaining ring (34) from housing (36). Remove shim (32). 19. Place the housing (36) assembly on press stand with rotor (23) side facing down. Pull drive shaft (37) assembly out. 20. Pull oil seal (31) out from housing (36).



Temporarily Mounting Adjusting Screw (42)



39



W1GL-03-02-004



15. Put matching marks onto the contact surface of head cover (1) and housing (36). Remove socket bolts (55) (8 used). Remove head cover (1) from housing (36). : 14 mm



W3-2-9



UNDERCARRIAGE / Travel Motor 1



52 53 50



4



51



49



W1GL-03-02-007



W1F3-03-02-002



W1F3-03-02-003



W3-2-10



UNDERCARRIAGE / Travel Motor 21. Secure head cover (1) on the vice with valve plate (48) facing up. 22. Remove socket bolt (49) and piston (50) from servo piston (52). : 12 mm 23. Remove rings (51) (2 used) from piston (50). CAUTION: Heat lock pin (53). Take care not to burn yourself. 24. Heat the mounting portion of lock pin (53) using a torch. NOTE: LOCTITE is used for lock pin (53). Heat it with slow fire. 25. Remove pin (4) from servo piston (52). 26. Pull servo piston (52) out from head cover (1).



W3-2-11



UNDERCARRIAGE / Travel Motor ASSEMBLE TRAVEL MOTOR



1



52 53



50



2



3



4



5



6



7



51



8 9



10



49 48 11



45, 46, 47



12



44



13 14



43



15 16, 17 18



42 40



20



41



21



39



23 24



38 37



22



19



25 26



36



27



34



28 29 30 31



33



32



35



59



2



W1GL-03-02-007



2



45, 46, 47



16, 17 57 57



56



56 54



58



W1F3-03-02-002



55



36



55 36



W3-2-12



W1F3-03-02-003



UNDERCARRIAGE / Travel Motor



12345678910 11 12 13 14 15 -



Head Cover Brake Valve O-Ring (2 Used) Pin Spring Spring Collar Spring Collar Bushing O-Ring Spring Retaining Ring Control Piston Sleeve Retaining Ring



16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 -



O-Ring (3 Used) Cover Adjusting Screw Lock Nut Pin Adjusting Screw Lock Nut Rotor Adjusting Plate Spring Screw Bolt (7 Used) Bearing Ring Bearing Adjusting Shim



31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 -



Oil Seal Shim Key Retaining Ring Retaining Ring Housing Drive Shaft Retainer Plate Center Joint Plunger (7 Used) Lock Nut Adjusting Screw O-Ring Pin (2 Used) O-Ring



W3-2-13



46 47 48 49 50 51 52 53 54 55 56 57 58 59 -



O-Ring Cover Valve Plate Socket Bolt Piston Ring (2 Used) Servo Piston Lock Pin Socket Bolt (4 Used) Socket Bolt (8 Used) Plug (2 Used) Relief Valve (2 Used) Socket Bolt (4 Used) Socket Bolt (2 Used)



UNDERCARRIAGE / Travel Motor 1



52 53 50



2



3



4



5



6



7



51



8 9



10



49 48 11



45, 46, 47



12



44



13 14



43



15 16, 17 18



42 40



20



41



21



39



23 24



38 37



22



19



25 26



36



27



34



28 29 30 31



33



32



35



59



2



W1GL-03-02-007



2



45, 46, 47



16, 17 57 57



56



56 54



58



W1F3-03-02-002



55



36



55 36



W3-2-14



W1F3-03-02-003



UNDERCARRIAGE / Travel Motor Assemble Travel Motor • Be sure to read “Precautions for Disassembly and Assembly” thoroughly on page W1-1-1 before starting any repair work. 1. Secure head cover (1) to a vice with valve plate (48) facing up.



7. Install retaining rings (15, 12) to control piston (13) and sleeve (14). 8. Apply hydraulic oil to cover (17), control piston (13) and sleeve (14). 9. Install O-ring (10) to cover (17).



2. Apply hydraulic oil on servo piston (52), then insert it into head cover (1) and install pin (4). 3. Apply LOCTITE #241 on lock pin (53) and insert it into servo piston (52) to secure pin (4). 4. Install rings (51) (2 used) to piston (50). Install piston (50) to servo piston (52) with socket bolt (49). : 12 mm : 190 N⋅m (19.5 kgf⋅m, 140 lbf⋅ft) 5. Install O-ring (45) to head cover (1), install O-ring (46) to cover (47). Install cover (47) to head cover (1) with socket bolts (58) (4 used). : 10 mm : 120 N⋅m (12 kgf⋅m, 89 lbf⋅ft)



10. Install control piston (13) to sleeve (14), then insert the sleeve (14) assembly and pin (20) into cover (17). 11. Install spring collar (8) and spring (11) into the cover (17) assembly. 12. Install O-rings (16) (3 used) onto head cover (1) and the cover (17) mounting surface. 13. Install spring (5), collar (7), spring (6) and bushing (9) into the large chamber of head cover (1). 14. Install the cover (17) assembly to head cover (1) with socket bolts (54) (4 used). : 6 mm : 96 N⋅m (9.8 kgf⋅m, 71 lbf⋅ft)



6. Install adjusting screw (18) and lock nut (19) into cover (17) with the measurement of A part as recorded before disassembling. 18



19



A



W1GL-03-02-006



W3-2-15



UNDERCARRIAGE / Travel Motor



1



42



41 21



39



23



22



37 36



34



31



33



32



W1GL-03-02-007



57 57



56



56



W1F3-03-02-002



55



36



55 36



W3-2-16



W1F3-03-02-003



UNDERCARRIAGE / Travel Motor CAUTION: After heating housing (36), start installation work. 15. Heat housing (36) to 50 to 80°C, then install the drive shaft (37) assembly into housing (36). If the drive shaft (37) assembly cannot be installed, insert it by using a bar.



20. Install adjusting screw (42) (M12, Pitch 1.75 mm (0.1 in), Length 100 mm (3.9 in)) into the location where adjusting screw (21) is inserted, the angle of center shaft (39) should be zero.



16. Install oil seal (31) and shim (32) into housing (36) with the rotor (23) side facing down, then install retaining ring (34). Temporarily Mounting Adjusting Screw (42)



17. Install key (33) into drive shaft (37). 18. Place the travel motor on wooden block (100× 500 mm (3.9×20 in)) with the drive shaft (37) facing down. NOTE: When using work stand: Work Bench: ST 5092 Upper Plate: ST 7333 19. Remove screw bar, lock nut and washer from rotor (23).



W1GL-03-02-008



21. Align the matching marks and install head cover (1) to housing (36) with socket bolts (55) (8 used). : 14 mm : 295 N⋅m (30 kgf⋅m, 215 lbf⋅ft) 22. Remove temporarily tightened adjusting screw (42).



Screw Bar Lock Nut



23. Install adjusting screw (42), lock nut (41), adjusting screw (21) and lock nut (22) into housing (36) with the measurements of B and C as recorded before disassembling.



Washer



B



W1GL-03-02-003



C



42



41 22



21



W1GL-03-02-005



24. Install relief valves (57) (2 used) and plug (56) to head cover (1). : 27 mm : 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft) : 32 mm : 83±5 N⋅m (8.5±0.5 kgf⋅m, 62±3.6 lbf⋅ft)



W3-2-17



UNDERCARRIAGE / Travel Motor DISASSEMBLE BRAKE VALVE



B



8



16, 17 A



W1F3-03-02-002



13



14



2



1



15



3



12 Section A



4



5



6



7 9



10



11



8



Section B



T1F3-03-05-034



12345-



O-Ring (2 Used) Cover Socket Bolt (4 Used) Plug (2 Used) Spring (2 Used)



678910 -



Check Valve (2 Used) O-Ring (2 Used) Plug O-Ring Shuttle Valve



11 12 13 14 15 -



Check Valve Assembly (2 Used) Cover Socket Bolt (4 Used) Valve Casing Counterbalance Valve



W3-2-18



16 - Plug 17 - Orifice



UNDERCARRIAGE / Travel Motor Disassemble Brake Valve 1. Remove socket bolts (13) (4 used). Remove cover (12) from valve casing (14). : 10 mm 2. Remove socket bolts (3) (4 used). Remove cover (2) from valve casing (14). : 10 mm IMPORTANT: Be sure to turn counterbalance valve when pulling it out. It may be stuck otherwise. 3. Turn counterbalance valve (15) while pulling it out from valve casing (14) slowly. CAUTION: When removing plug (4), spring (5) will fly out due to spring force. 4. Remove plugs (4) (2 used), springs (5) (2 used) and check valve (6). : 36 mm 5. Pull check valve assembly (11) out from valve casing (14) with a socket wrench. 6. Remove plug (8) from valve casing (14). 7. Pull shuttle valve (10) out from valve casing (14) with a socket wrench. : 4 mm 8. Remove plug (16) from valve casing (14). 9. Remove orifice (17) from valve casing (14). : 3 mm



W3-2-19



UNDERCARRIAGE / Travel Motor ASSEMBLE BRAKE VALVE



B



8



16, 17 A



W1F3-03-02-002



13



14



2



1



15



3



12 Section A



4



5



6



7 9



10



11



8



Section B



T1F3-03-05-034



12345-



O-Ring (2 Used) Cover Socket Bolt (4 Used) Plug (2 Used) Spring (2 Used)



678910 -



Check Valve (2 Used) O-Ring (2 Used) Plug O-Ring Shuttle Valve



11 12 13 14 15 -



Check Valve Assembly (2 Used) Cover Socket Bolt (4 Used) Valve Casing Counterbalance Valve



W3-2-20



16 - Plug 17 - Orifice



UNDERCARRIAGE / Travel Motor Assemble Brake Valve 1. Install orifice (17) and plug (16) to valve casing (14). 2. Install shuttle valve (10) and plug (8) into valve casing (14). 3. Install check valve assemblies (11) (2 used) to valve casing (14). 4. Install check valves (6) (2 used) to check the valve assembly (11). 5. Install spring (5) to plug (4), then install the plug (4) assembly to valve casing (14). : 36 mm : 167 N⋅m (17 kgf⋅m, 123 lbf⋅ft) IMPORTANT: Turn counterbalance valve (15) slowly while inserting it to valve casing (14) and check that it can move smoothly. 6. Insert counterbalance valve (15) into valve casing (14). 7. Install cover (12) to valve casing (14) with socket bolts (13) (4 used). : 10 mm : 120 N⋅m (12 kgf⋅m, 89 lbf⋅ft) 8. Install cover (2) to valve casing (14) with socket bolts (3) (4 used). : 10 mm : 120 N⋅m (12 kgf⋅m, 89 lbf⋅ft)



W3-2-21



UNDERCARRIAGE / Travel Motor (Blank)



W3-2-22



UNDERCARRIAGE / Center Joint REMOVE AND INSTALL CENTER JOINT CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.) NOTE: When removing and installing the center joint, remove the main hoses (5 used) on the back of boom and remove the center joint easily.



1



2



3



4



Removal 1. Remove the swing device upper side cover mounting bolts (2 used) and remove the cover. : 17 mm Center Joint



2. Disconnect connectors (6) (2 places upper and lower). 3. Remove bolts (5) (2 places upper and lower). : 17 mm 4. Remove bolts (4) (3 used) and pull out the slip ring (3) assembly from center joint. (Length: approx. 670 mm (26.4 in)) 5. Remove bolts (2) (5 used) and remove stopper (1). : 24 mm IMPORTANT: Attach identification tags to disconnected hoses for re-assembly. 6. Disconnect hoses (37 used) from the center joint. Plug all disconnected hose ends and the ports on the center joint. : 17 mm, 19 mm, 22 mm, 27 mm, 36 mm NOTE: Upperstructure side: 15 used Undercarriage side: 22 used Refer to COMPONENT OPERATION / Others (Undercarriage) group in the T/M on page T3-11-2.



W3-3-1



6



5 T1F3-03-10-014



UNDERCARRIAGE / Center Joint 7. Install eyebolts (M16, Pitch 2.0 mm) (2 used) into the bolt (2) holes.



1



2



3



4



CAUTION: Center joint assembly weight: 93 kg (210 lb). Center Joint



IMPORTANT: The propeller shaft and transmission are under the center joint. When lifting the center joint while disassembling, be careful not to damage the propeller shaft and transmission. 8. Remove bolts (7) (4 used), and then lift the center joint assembly. : 22 mm



Installation CAUTION: Center joint assembly weight: 93 kg (210 lb). IMPORTANT: The propeller shaft and transmission are under the installation position of center joint. When lifting the center joint, take care not to damage the propeller shaft and transmission. 1. Apply LOCTITE to bolts (7) (4 used). Lift the center joint, then install the center joint on the chassis frame with bolts (7) (4 used). : 22 mm : 180 N⋅m (18.5 kgf⋅m, 130 lbf⋅ft) 2. Connect hoses (37 used) to the center joint. : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft) : 22 mm : 39 N⋅m (4.0 kgf⋅m, 29 lbf⋅ft) : 27 mm : 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)



6



5 T1F3-03-10-014



Chassis Frame



7



W1F3-03-03-002



W3-3-2



UNDERCARRIAGE / Center Joint 3. Apply LOCTITE#577 to bolts (2) (5 used). Install stopper (3) with bolts (2) (5 used). : 24 mm : 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)



1



2



3



4



4. Insert slip ring (3) into the center joint. Center Joint



5. Install slip ring (3) with bolts (4) (3 used). 6. Connect connector (6) (2 places upper and lower). 7. Secure connector (6) with bolt (5) (2 places upper and lower). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)



6



5 T1F3-03-10-014



W3-3-3



UNDERCARRIAGE / Center Joint DISASSEMBLE CENTER JOINT



1



2 3 4



5



5 12



3



11



6



10



T1F3-03-10-001



9



1 - Spindle 2 - O-Ring 3 - Bushing (2 Used)



456-



Body Oil Seal (15 Used) Bolt (6 Used)



8



789-



W3-3-4



7



O-Ring Bolt (4 Used) O-Ring



10 - Cover 11 - Plate 12 - O-Ring



UNDERCARRIAGE / Center Joint Disassemble Center Joint CAUTION: Center joint weight: 93kg (210 lb) 1. Remove mounting bolt (6) of cover (10) diagonally, and install eyebolts (M10, Pitch 1.5 mm, length 18 mm: ST 0001). Then, secure center joint on workbench (ST 5103).



IMPORTANT: Use two picks for easy removal. Take care not to damage the seal groove with the picks. 5. Remove oil seals (5) (15 used) from body (4).



IMPORTANT: Be sure to make the mating marks on body (4) and spindle (1). 2. Remove bolts (6) (6 used) and remove cover (10) and O-rings (11, 12). : 17 mm 3. Remove bolt (8) and remove plate (11). : 17 mm



3 4, 5



IMPORTANT: Take care not to scratch the seal slide face of spindle (1). 4. Install puller onto the center joint, pull out spindle (1).



W105-03-03-015



Puller



6. Remove bushings (3) (2 used) and O-rings (2, 12) from body (4).



W202-03-03-011



NOTE: There is a hole for the harness at the center of spindle (1). Make a plate to cover the hole. Place the plate cap between the puller and spindle (1) to pull out spindle.



W3-3-5



UNDERCARRIAGE / Center Joint ASSEMBLE CENTER JOINT



1



2 3 4



5



5 12



3



11



6



10



T1F3-03-10-001



9



1 - Spindle 2 - O-Ring 3 - Bushing (2 Used)



456-



Body Oil Seal (15 Used) Bolt (6 Used)



8



789-



W3-3-6



7



O-Ring Bolt (4 Used) O-Ring



10 - Cover 11 - Plate 12 - O-Ring



UNDERCARRIAGE / Center Joint Assemble Center Joint CAUTION: Body (4) weight: 40 kg (89 lb) 1. Install O-rings (2, 12) into body (4). NOTE: If bushing (3) is removed, be sure to reinstall bushing (3) before reassembling. 2. Install oil seals (5) (15 used) into body (4). IMPORTANT: After installing the seals, apply grease to the inner wall of body (4), and the seals. 3. Put spindle (1) on workbench, install spindle (1) into body (4), align the mating marks made during disassembly. IMPORTANT: Slowly and straightly insert spindle (1) along with the center of body (4), because the clearance between body (4) and spindle (1) is approximately 0.1 mm.



0.1 mm



4. Tap body (4) lightly with a plastic hammer, insert body (4) until it touches spindle (1). 5. Install plate (11) onto spindle (1) with bolts (8) (4 used). : 17 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 6. Install O-ring (7) to body (4) and install O-ring (9) to spindle (1). 7. Install cover (10) with bolts (6) (6 used). : 17 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)



W105-03-03-024



W3-3-7



UNDERCARRIAGE / Center Joint When replacing the body or spindle with a new one, the following procedures are required: Press bushing (3) into body. 1. Clean body (4) and bushing (3). 2. Press bushing (3) into body (4) using pressing tool. Pressing force: 0.5 to 1.5 tons Pressing tool (1): ST 7331



1 4



3



W105-03-03-029



W3-3-8



UNDERCARRIAGE / Center Joint MAINTENANCE STANDARD



Parts Name



Allowable Limit (basis of judgement) 1. Wear more than 0.2 mm (0.008 in)



Remedy Replace



2. Scored, abnormal wear



Replace 3. Uneven wear (wear range is less Replace than 180°) uneven wear Bushing



T157-01-01-040



Body, Spindle



Cover



Sliding surface of Scored or something hurt it. sealed part Sliding surface of 1) Scored more than 0.1 mm (0.004 in). body and spindle 2) Scored less than 0.1 mm (0.004 in) except sealed deep. part 1) Wear more than 0.5 mm (0.02 in) deep. Abnormal wear. Sliding surface of 2) Wear less than 0.5 mm (0.02 in) plate deep. 3) Scored less than 0.5 mm (0.02 in) deep and able to repair. 1) Wear less than 0.5 mm (0.02 in). Sliding surface of 2) Wear less than 0.5 mm (0.02 in). plate 3) Scored less than 0.5 mm (0.02 in) and able to repair.



W3-3-9



Replace Replace Repair with oil stone



Replace



Repair to smooth Repair to smooth Replace Repair to smooth Repair to smooth



UNDERCARRIAGE / Center Joint (Blank)



W3-3-10



UNDERCARRIAGE / Transmission REMOVE AND INSTALL TRANSMISSION CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.) When removing and installing the transmission, the propeller shaft and the pipe of travel motor must be removed. Refer to the pages for the “Remove and Install Propeller Shaft”, “Remove and Install Travel Motor”. IMPORTANT: Be sure to bleed air from hydraulic and brake circuits when installing transmission. Refer to TROUBLESHOOTING / Troubleshooting B group in the T/M. Removal



1



2



3



4



5



6



7



8



IMPORTANT: In order to keep the balance of weight, remove the travel motor when removing the transmission. 1. Disconnect hoses (8) (2 used), and hose (7) from travel motor (10). Cap all disconnected hose ends. : 17 mm, 27 mm : 12 mm IMPORTANT: Attach identification tags to hoses to aid re-assembly. 2. Remove nut (20) (4 used) and plate (3). Remove cover (19). : 17 mm



Rear Side



20



19 18 17



3. Disconnect hoses (1) (2 used) and hose (11) from transmission (16). Cap all disconnected hose ends. : 19 mm



16 15 14 12, 13 11 10



9 W1F3-03-02-004



3



4



5



7



4. Remove nut (12, 13). Remove cover (5). : 19 mm 5. Disconnect connector (4) from transmission (16). : 13 mm Rear Side



18 16



15



14 12, 13 11



10



9 W1F3-03-02-005



W3-4-1



UNDERCARRIAGE / Transmission CAUTION: Propeller shaft (9) weight: 30 kg (66 lb)



3



4



5



7



6. Remove nuts (15) (8 used), and then insert bar inside fork (14) and lever it toward the rear side in order to lower propeller shaft (9) onto the ground. : 14 mm CAUTION: Propeller shaft (23) weight: 30 kg (66 lb)



Rear Side



7. Remove nuts (24) (8 used), and then insert bar in between flanges (21, 22), and lever it toward the front side in order to lower propeller shaft (23) to the ground. : 14 mm



18 16



15



14 12, 13 11



10



9 W1F3-03-02-005



3



CAUTION: Transmission (16) weight : 140 kg (310 lb) Travel motor (10) weight : 85 kg (190 lb) Plate (3) weight : 43 kg (951 lb)



21



22



23



8. Loosen bolts (18) (3 used) at plate (3), hold the lower side of transmission by using a forklift, and then remove bolts (18) (3 used). : 30 mm



24 Front Side



IMPORTANT: It is afraid that connector (2) and wiring might be broken if transmission (16) assembly is lowered directly onto the ground. 9. Lower transmission (16) assembly slightly (about 100 mm), disconnect connector (2), remove clip (17), and lower transmission (16) onto the ground. : 17 mm



1 18 W1F3-03-04-001



1



2



3



10. Remove bolts (25) (3 used), and then remove plate (3) form transmission (16). : 30 mm Rear Side



25



18



17



16



10 W1F3-03-02-004



W3-4-2



UNDERCARRIAGE / Transmission Installation 25



2



3



CAUTION: Travel motor (10) weight: 85 kg (190 lb) Transmission (16) weight: 140 kg (310 lb) Plate (3) weight: 43 kg (95 lb) 1. Install plate (3) to transmission (16) with bolts (25) (3 used). : 30 mm : 540 N⋅m (55 kgf⋅m, 400 lbf⋅ft)



20



2. Connect connector (2). Install clip (17) to plate (3). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 3. Install the transmission (16) assembly to chassis with bolts (18) (3 used). : 30 mm : 540 N⋅m (55 kgf⋅m, 400 lbf⋅ft)



19 18 17



16



W1F3-03-02-004



3



21



22



CAUTION: Propeller shaft (23) weight: 30 kg (66 lb) 23



4. Install propeller shaft (23) to flange (21) with nuts (24) (8 used). : 14 mm : 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft) 5. Connect hoses (1) (2 used) to transmission (16). : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)



24



1 18



16 4



6. Install cover (19) to plate (3) with bolts (30) (4 used). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)



5



W1F3-03-04-001



7. Connect hose (11) and connector (4) to transmission (16). : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) 8. Install cover (5) to transmission (16) with bolt (12) and nut (13) : 13 mm : 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft) 16



12, 13 11 W1F3-03-02-005



W3-4-3



UNDERCARRIAGE / Transmission 9. Connect hoses (6) and (7) to travel motor (10). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 27 mm : 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft)



6



7



8



10. Connect hoses (8) (2 used) to travel motor (10). : 12 mm : 140 N⋅m (14.0 kgf⋅m, 103 lbf⋅ft) CAUTION: Propeller shaft (23) weight: 30 kg (66 lb) 11. Connect propeller shaft (9) to transmission (16) with nuts (15) (8 used) at fork (14). : 14 mm : 108 N⋅m (11.0 kgf⋅m, 80 lbf⋅ft)



W3-4-4



16



15 14



10



9 W1F3-03-02-005



UNDERCARRIAGE / Transmission (Blank)



W3-4-5



UNDERCARRIAGE / Transmission 56



DISASSEMBLE TRANSMISSION



55



W1F3-03-05-005



A Part



W1F3-03-05-006



8



9



10 11 114 13 14



15 16 17, 18 19 20 21



22



23



24



25



7 26 27 28, 29, 30, 31



6 5 A Part



32



4



33



3



34



54 2



35



12



36 37 38 39



1



40 41



53 50



52 51 49 48



47



46 45 44



43 42



W1F3-03-05-007



W3-4-6



UNDERCARRIAGE / Transmission



12345678910 11 12 13 14 -



Flange Relief Valve Shaft Retaining Ring O-Ring Drive Case Plug O-Ring Spring Bearing Retaining Ring Piston Ring (2 Used) Piston Seal Ring



15 16 17 18 19 20 21 22 23 24 25 26 27 28 -



O-Ring O-Ring Seal Ring Backup Ring (2 Used) Piston Retaining Ring O-Ring Gasket O-Ring Seal Ring Plate Retaining Ring Ring Gear Plate



29 30 31 32 33 34 35 36 37 38 39 40 41 42 -



W3-4-7



Friction Plate (11 Used) Plate (10 Used) Spacer Retaining Ring Shim Retaining Ring U-Ring O-Ring Bearing Sun Gear Cover Retaining Ring Disc Carrier Plate (6 Used)



43 44 45 46 47 48 49 50 51 52 53 54 55 56 -



Shim Friction Plate (6 Used) Piston Disc Spring (3 Used) Gear Case Socket Bolt (9 Used) Disc Spring (2 Used) Seal Ring O-Ring (2 Used) Retaining Ring Retaining Ring Hose Hose (2 Used)



UNDERCARRIAGE / Transmission B Part



65



66



108



109 63 110 64 111



W1F3-03-05-005 W1F3-03-05-006



57 58 59 60 61 62 63, 64



65 66 67 68 69 70 71 72 73 74



75, 76



B Part



77 107



78



106



79



105



80



103, 104



81



102



82 83



101



84 85



100



86 87



99 98



88 89 90 91 92 97 96



95 94 93 112 47



113 W1F3-03-05-008



W3-4-8



UNDERCARRIAGE / Transmission



12345678910 11 12 13 14 -



Flange Relief Valve Shaft Retaining Ring O-Ring Drive Case Plug O-Ring Spring Bearing Retaining Ring Piston Ring (2 Used) Piston Seal Ring



15 16 17 18 19 20 21 22 23 24 25 26 27 28 -



O-Ring O-Ring Seal Ring Backup Ring (2 Used) Piston Retaining Ring O-Ring Gasket O-Ring Seal Ring Plate Retaining Ring Ring Gear Plate



29 30 31 32 33 34 35 36 37 38 39 40 41 42 -



Friction Plate (11 Used) Plate (10 Used) Spacer Retaining Ring Shim Retaining Ring Ring O-Ring Bearing Sun Gear Cover Retaining Ring Disc Carrier Plate (6 Used)



43 44 45 46 47 48 49 50 51 52 53 54 55 56 -



57 58 59 60 61 62 63 64 65 66 67 68 69 70 -



Retaining Ring (3 Used) Plate (3 Used) Needle bearing (3 Used) Planetary Gear (3 Used) Needle bearing Carrier Shift fork Shoe (2 Used) Plug Pin Retaining Ring Retaining Ring Gear Plug



71 72 73 74 75 76 77 78 79 80 81 82 83 84 -



Bearing Bearing Shaft Bearing Shift Interlock Controller Socket Bolt (3 Used) Gear Cover Bearing Cover Plate Bolt (8 Used) Flange Lock Plate



85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 -



Bolt (2 Used) Plate O-Ring Gear Seal Retaining Ring Cover Bolt (7 Used) Bearing Seal Plate O-Ring Bolt (8 Used) Flange Plate



100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 -



W3-4-9



Shim Friction Plate (6 Used) Piston Disc Spring (3 Used) Gear Case Socket Bolt (9 Used) Disc Spring (2 used) Seal Ring O-Ring (2 Used) Retaining Retaining Hose Hose (2 Used) Bolt (2 Used) Lock Plate Clutch Shim Retaining Ring Retaining Ring Bearing Retaining Ring Socket Bolt Spring Pin Lever Bolt Cover O-Ring Plate



UNDERCARRIAGE / Transmission 56



55



W1F3-03-05-005



A Part



W1F3-03-05-006



8



9



10 11 114 13 14



15 16 17, 18 19 20 21



22



23



24



25



7 26 27 28, 29, 30, 31 32



6 5 A Part



4



33



3



34



54 2



35



12



36 37 38 39



1



40 41



53 50



52 51 49 48



47



W3-4-10



46 45 44



43 42



W1F3-03-05-007



UNDERCARRIAGE / Transmission Disassemble Transmission 1. Disconnect hoses (56) (2 used) and pipe (55) from gear case (47). : 19 mm, 27 mm



8. Remove screw and breather from gear case (47). : 5 mm : 12 mm Breather



2. Loosen plug (7). : 24 mm 3. Remove socket bolts (48) (9 used) and retaining ring (11). Remove drive case (6) from gear case (47). : 12 mm 4. Remove plug (7), O-ring (8), spring (9) and the piston (13) assembly from drive case (6). : 24 mm 5. Remove seal ring (14) from piston (13). 6. Remove disc springs (49) (2 used) from piston (19). 7. Pull piston (19) out from gear case (47) by using a compressor. NOTE: Plug port A then supply air by using pressure to pull piston (19) out.



Screw



W1GL-03-04-009



9. Remove O-ring (15), seal ring (17) and backup rings (18) (2 used) from gear case (47). 10. Remove retaining ring (20) from gear case (47). 11. Remove gasket (22) from gear case (47) by using an offset driver. 12. Remove O-ring (23) from gasket (22).



A



13. Remove O-ring (21) from gear case (47). 14. Remove plates (42) (6 used) and friction plates (44) (6 used) from gear case (47). 15. Remove plate (25) from gear case (47). B



W1GL-03-04-009



W3-4-11



UNDERCARRIAGE / Transmission



A Part



8



9



10 11 114 13 14



15 16 17, 18 19 20 21



22



23



24



25



7 26 27 28, 29, 30, 31 32



6 5 4



33



3



34



54 2



35



12



36 37 38 39



1



40 41



53 50



52 51 49 48



47



46 45 44



43 42



W1F3-03-05-007



W3-4-12



UNDERCARRIAGE / Transmission 16. Remove retaining ring (26) from gear case (47), and then pull the shaft (3) assembly out from gear case (47). 17. Secure the shaft (3) assembly on a vice with relief valve (2) facing down. 18. Remove retaining ring (34) and shim (33) from shaft (3). Remove sun gear (38). 19. Remove retaining ring (40) from ring gear (27). Remove ring gear (27) from piston (45). 20. Remove the cover (39) assembly from shaft (3). 21. Remove retaining ring (32) from cover (39). Remove bearing (37) from cover (39). 22. Remove spacer (31), plates (30) (10 used) and friction plates (29) (11 used) and plate (28) from shaft (3). 23. Remove disc carrier (41) and shim (43) from shaft (3). 24. Remove seal ring (24) from disc carrier (41). 25. Remove piston (45), disc springs (46) (3 used) and plate (114) from shaft (3). 26. Remove retaining ring (54) from shaft (3). 27. Remove shaft (3) from a vice. 28. Remove retaining rings (4, 53) from shaft (3) to remove shaft (3) from flange (1). 29. Remove bearing (10) and relief valve (2) from shaft (3). 30. Remove piston ring (12) from shaft (3). 31. Remove ring (51) and seal (50) from flange (1). 32. Remove O-rings (52) (2 used) from flange (1).



W3-4-13



UNDERCARRIAGE / Transmission B Part



65



66



108



109 63 110 64 111



W1F3-03-05-005 W1F3-03-05-006



57 58 59 60 61 62 63, 64



65 66 67 68 69 70 71 72 73 74



75, 76



B Part



77 107



78



106



79



105



80



103, 104



81



102



82 83



101



84 85



100



86 87



99 98



88 89 90 91 92 97 96



95 94 93 112 47



113 W1F3-03-05-008



W3-4-14



UNDERCARRIAGE / Transmission 33. Remove retaining ring (107) from gear (69). Remove the carrier (62) assembly from gear case (47). 34. Remove retaining rings (57) (3 used) and plates (58) (3 used) from carrier (62). 35. Remove planetary gears (60) (3 used) and needle bearings (61) (3 used) from carrier (62). 36. Remove retaining ring (105) from carrier (62). Remove bearing (106) from carrier (62). 37. Remove bolt (111) from lever (110). Remove clutch (102) and shoes (64) (2 used) from shift fork (63). : 17 mm 38. Remove plug (65) from gear case (47), tap and remove spring pin (109) to gear case (47) inside from shift fork (63). : 10 mm 39. Pull the lever (76) assembly out from gear case (47) then remove shift fork (63) from inside. 40. Remove socket bolts (76) (3 used). Remove shift interlock controller (75) from gear case (47). : 6 mm 41. Pull shaft (73) out from gear (69). 42. Remove retaining ring (67) from gear case (47). Remove the gear (68) assembly from gear case (47). 43. Remove retaining ring (104) and shim (103) from gear (69). Remove gear (77) from gear (69). 44. Remove the cover (78) assembly from gear (69). 45. Remove retaining ring (68) from cover (78). Remove bearing (71) from cover (78). 46. Remove bearing (72) from gear (69).



W3-4-15



UNDERCARRIAGE / Transmission DISASSEMBLE FINAL DRIVE AND DIFFERENTIAL



79 80 81 82 83 101



84 85



100



86 87



99 98



88 89 90 91 92 97 96



95 94 93 112 47



113 W1F3-03-05-008



47 79 80 81 82 83 84 -



Gear Case Bearing Cover Plate Bolt (8 Used) Flange Lock Plate



85 86 87 88 89 90 91 -



Bolt (2 Used) Plate O-Ring Gear Seal Retaining Ring Cover



92 93 94 95 96 97 98



-



Bolt (2 Used) Bearing Seal Plate O-ring Bolt (8 Used) Flange



W3-4-16



99 100 101 112 113 -



Plate Bolt (2 Used) Lock Plate Cover O-ring



UNDERCARRIAGE / Transmission Disassemble Final Drive and Differential 1. Remove bolts (85, 100) (2 used respectively) from lock plate (84, 100). 2. Remove plate (86, 99), O-ring (87, 96) from gear (88). : 17 mm 3. Remove the flange (83, 98) assembly from gear (88). NOTE: When bolts (82, 97) are not replaced, do not remove plates (81, 95) from flanges (83, 98). 4. Remove seal (89, 94) from cover (80) and gear case (47). 5. Remove bolts (92) (7 used) from cover (80) then pull cover (80) out using removed bolts (92) (3 used). : 19 mm 6. Remove the cover (80) assembly and cover (91) from gear (88). 7. Remove retaining ring (90) from cover (80). Remove bearing (79) and O-ring (113) from cover (80). 8. Remove bearing (93) and cover (112) from gear case (47).



W3-4-17



UNDERCARRIAGE / Transmission ASSEMBLE FINAL DRIVE AND DIFFERENTIAL



79 80 81 82 83 101



84 85



100



86 87



99 98



88 89 90 91 92 97 96



95 94 93 112 47



113 W1F3-03-05-008



47 79 80 81 82 83 84 -



Gear Case Bearing Cover Plate Bolt (8 Used) Flange Lock Plate



85 86 87 88 89 90 91 -



Bolt (2 Used) Plate O-Ring Gear Seal Retaining Ring Cover



92 93 94 95 96 97 98



-



Bolt (7 Used) Bearing Seal Plate O-ring Bolt (8 Used) Flange



W3-4-18



99 - Plate 100 - Bolt (2 Used) 101 - Lock Plate 112 - Cover 113 - O-ring



UNDERCARRIAGE / Transmission Assemble Final Drive 1. Insert bearing (79) into cover (80), and lock it with retaining ring (90).



8. Install flanges (83, 98) to gear (88), and attach O-rings (87, 96).



2. Attach seal (89) and O-ring (113) to cover (80).



9. Mount flanges (83, 98) with plates (86, 99), and bolts (85) (2 used) and (100), and then fasten them with lock plates (84, 101). : 17 mm : 46 N⋅m (5.0 kgf⋅m) (34 lb)



3. Install cover (91) and the cover (80) assembly to gear (88). 4. Install cover (112) to gear case (47). 5. Install the gear (88) assembly into gear case (47), and lock it with bolts (92) (7 used). : 19 mm : 79 N⋅m (8 kgf⋅m) (58 lb) 6. Install bearing (93) into the gear (88) assembly. 7. Install seal (94) into gear case (47) as shown below. 98



2.0+1.0 mm



94



47



W1GL-03-04-001



(0.08+0.04 in)



W3-4-19



UNDERCARRIAGE / Transmission ASSEMBLB TRANSMISSION



56



55



W1F3-03-05-005



A Part



W1F3-03-05-006



A Part



8



9



10 11 114 13 14



15 16 17, 18 19 20 21



22



23



24



25



7 26 27 28, 29, 30, 31



6 5



32



4



33



3



34



54 2



35



12



36 37 38 39



1



40 41



53 50



52 51 49 48



47



46 45 44



43 42



W1F3-03-05-007



W3-4-20



UNDERCARRIAGE / Transmission



12345678910 11 12 13 14 -



Flange Relief Valve Shaft Retaining Ring O-Ring Drive Case Plug O-Ring Spring Bearing Retaining Ring Piston Ring (2 Used) Piston Seal Ring



15 16 17 18 19 20 21 22 23 24 25 26 27 28 -



O-Ring O-Ring Seal Ring Backup Ring (2 Used) Piston Retaining Ring O-Ring Gasket O-Ring Seal Ring Plate Retaining Ring Ring Gear Plate



29 30 31 32 33 34 35 36 37 38 39 40 41 42 -



W3-4-21



Friction Plate (11 Used) Plate (10 Used) Spacer Retaining Ring Shim Retaining Ring U-Ring O-Ring Bearing Sun Gear Cover Retaining Ring Disc Carrier Plate (6 Used)



43 44 45 46 47 48 49 50 51 52 53 54 55 56 -



Shim Friction Plate (6 Used) Piston Disc Spring (3 Used) Gear Case Socket Bolt (9 Used) Disc Spring (2 Used) Seal Ring O-Ring (2 Used) Retaining Ring Retaining Ring Pipe Hose (2 Used)



UNDERCARRIAGE / Transmission B Part



65



66



108



109 63 110 64 111



W1F3-03-05-005



B Part W1F3-03-05-006



57 58 59 60 61 62 63, 64



65 66 67 68 69 70 71 72 73 74



75, 76



77 107



78



106



79



105



80



103, 104



81



102



82 83



101



84 85



100



86 87



99 98



88 89 90 91 92 97 96



95 94 93 112 47



113 W1F3-03-05-008



W3-4-22



UNDERCARRIAGE / Transmission



12345678910 11 12 13 14 -



Flange Relief Valve Shaft Retaining Ring O-Ring Drive Case Plug O-Ring Spring Bearing Retaining Ring Piston Ring (2 Used) Piston Seal Ring



15 16 17 18 19 20 21 22 23 24 25 26 27 28 -



O-Ring O-Ring Seal Ring Backup Ring (2 Used) Piston Retaining Ring O-Ring Gasket O-Ring Seal Ring Plate Retaining Ring Ring Gear Plate



29 30 31 32 33 34 35 36 37 38 39 40 41 42 -



Friction Plate (11 Used) Plate (10 Used) Spacer Retaining Ring Shim Retaining Ring Ring O-Ring Bearing Sun Gear Cover Retaining Ring Disc Carrier Plate (6 Used)



43 44 45 46 47 48 49 50 51 52 53 54 55 56 -



57 58 59 60 61 62 63 64 65 66 67 68 69 70 -



Retaining Ring (3 Used) Plate (3 Used) Needle bearing (3 Used) Planetary Gear (3 Used) Needle bearing Carrier Shift fork Shoe (2 Used) Plug Pin Retaining Ring Retaining Ring Gear Plug



71 72 73 74 75 76 77 78 79 80 81 82 83 84 -



Bearing Bearing Shaft Bearing Shift Interlock Controller Socket Bolt (3 Used) Gear Cover Bearing Cover Plate Bolt (8 Used) Flange Lock Plate



85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 -



Bolt (2 Used) Plate O-Ring Gear Seal Retaining Ring Cover Bolt (7 Used) Bearing Seal Plate O-Ring Bolt (8 Used) Flange Plate



100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 -



W3-4-23



Shim Friction Plate (6 Used) Piston Disc Spring (3 Used) Gear Case Socket Bolt (9 Used) Disc Spring (2 used) Seal Ring O-Ring (2 Used) Retaining Ring Retaining Ring Pipe Hose (2 Used) Bolt (2 Used) Lock Plate Clutch Shim Retaining Ring Retaining Ring Bearing Retaining Ring Socket Bolt Spring Pin Lever Bolt Cover O-Ring Plate



UNDERCARRIAGE / Transmission B Part



65



66



108



109 63 110 64 111



W1F3-03-05-005



B Part W1F3-03-05-006



57 58 59 60 61 62 63, 64



65 66 67 68 69 70 71 72 73 74



75, 76



77 107



78



106



79



105



80



103, 104



81



102



82 83



101



84 85



100



86 87



99 98



88 89 90 91 92 97 96



95 94 93 112 47



113 W1F3-03-05-008



W3-4-24



UNDERCARRIAGE / Transmission Assemble Transmission 1. Install bearing (73) and needle bearing (60) to gear (68). 2. Install bearing (71) to cover (78) and secure it with retaining ring (68). 3. Install gear (69) to the cover (78) assembly. 4. Install the cover (78) assembly to gear case (47) and secure them with retaining ring (67). 5. Install gear (69) and shim (103) to gear (77), secure them with retaining ring (104). 6. Install shoes (64) (2 used) to shift fork (63), install the shift fork (63) assembly to cluch (102). 7. Install the shift fork (63) assembly into gear case (47). Install the pin (66) assembly to gear case (47). Align the spring pin (109) hole of pin (66) to secure them with spring pin (109). 8. Install lever (110) to gear case (47) with bolt (111). : 17 mm : 65 N⋅m (6.6 kgf⋅m, 48 lbf⋅ft) 9. Install plug (65) to gear case (47). : 10 mm : 95 N⋅m (10 kgf⋅m, 72 lbf⋅ft) 10. Install bearing (106) to carrier (62) and secure it with retaining ring (105). 11. Install needle bearings (59) (3 used), planetary gears (60) (3 used), plates (58) (3 used) and retaining rings (57) (3 used) to carrier (62) in order. 12. Install the carrier (62) assembly to gear (69) and secure them with retaining ring (107).



W3-4-25



UNDERCARRIAGE / Transmission 56



55



W1F3-03-05-005



A Part



W1F3-03-05-006



A Part



8



9



10 11 114 13 14



15 16 17、18 19 20 21



22



23



24



25



7 26 27 28、29、30、31



6 5



32



4



33



3



34



54 2



35



12



36 37 38 39



1



40 41



53 50



52 51 49 48



47



W3-4-26



46 45 44



43 42



W1F3-03-05-007



UNDERCARRIAGE / Transmission 13. Install bearing (10) into shaft (3) and secure them with retaining ring (4).



18. Install plate (114) and the piston (45) assembly to the shaft (3) assembly, and then install shim (43) into inside.



14. Install piston rings (12) (2 used) to shaft (3). 15. Install shaft (3) to flange (1) and secure it with retaining ring (53). Install seal (50) into the flange (1) inside, secure it with ring (51). 16. Install retaining ring (54), U-ring (35) and O-ring (36) to shaft (3) in order. CAUTION: When install U-ring (35), be sure to put the groove of U-ring (35) facing the disc carrier (41) side. 17. Install disc springs (46) (3 used) to piston (45).



19. Install seal ring (24) to disc carrier (41), install the disc carrier (41) assembly to the shaft (3) assembly. 20. Install plate (28) friction plates (29) (11 used) and plates (30) (10 used), spacer (31) to the shaft (3) assembly (disc carrier) in order. 21. Install bearing (37) to cover (39), secure it with retaining ring (32). 22. Install ring gear (27) to the shaft (3) assembly (plate part). 23. Install the cover (39) assembly to the ring gear (27) assembly, secure them with retaining ring (40). 24. Install sun gear (38), shim (33) and retaining ring (34) to the shaft (3) assembly.



49



25. Install gear case (47) to the shaft (3) assembly, secure it with retaining ring (26).



46



CAUTION: Install plate (25) with machined part facing retaining ring (26).



26. Install plate (25), friction plates (44) (6 used) and plates (42) (6 used) to the ring gear (27) out race part alternatively.



45 114



the



W1GL-03-04-010



W3-4-27



UNDERCARRIAGE / Transmission 56



ASSEMBLB TRANSMISSION 73



55



75, 76



W1F3-03-05-005



A Part



W1F3-03-05-006



A Part



8



9



10 11 114 13 14



15 16 17, 18 19 20 21



22



23



24



25



7 26 27 28, 29, 30, 31



6 5



32



4



33



3



34



54 2



35



12



36 37 38 39



1



40 41



53 50



52 51 49 48



47



46 45 44



43 42



W1F3-03-05-007



W3-4-28



UNDERCARRIAGE / Transmission 27 Install O-ring (23) to gasket (22). 28. Install O-ring (21) to the gear case (47) inside, install gasket (22) and secure them with retaining ring (20).



36. Install piston (13), spring (9) and plug (7) to drive case (6) in order. : 24 mm : 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft) 37. Install O-ring (5) to drive case (6).



29. Install seal ring (17) and backup rings (18) (2 used) to the gear case (47) inside. Install O-ring (15). 30. Install piston (19) to gear case (47). 31. Align disc springs (49) (2 used) on piston (19) surface.



38. Install shaft (73) to shaft (3), install shift interlock controller (75) to gear case (47) with socket bolts (76) (3 used). : 6 mm : 23 N⋅m (2.5 kgf⋅m, 18.1 lbf⋅ft) 39. Connect hoses (56) (2 used) and pipe (55) to gear case (47).



49 19



114



W1GL-03-04-010



32. Install O-ring (16) to the flange of piston (19) side on drive case (6). 33. Install drive case (6) to gear case (47) with socket bolts (48) (9 used) and retaining ring (11). : 10 mm : 79 N⋅m (8 kgf⋅m, 58 lbf⋅ft) 34. Install seal ring (14) to piston (13). 35. Install O-ring (8) to plug (7).



W3-4-29



UNDERCARRIAGE / Transmission ADJUSTING GEAR CLEARANCE When assembling the drive pinion, error in adjusting shim may occur due to the big gear clearance. A) Correct clearance between gear and pinion. Meshing Surface (Concave Part)



Meshing Surface (Convex Part)



W1GL-03-05-021



W1GL-03-05-019



W1GL-03-05-020



B) Increasing clearance of pinion is necessary. Meshing Surface (Concave Part)



Meshing Surface (Convex Part)



Clearance of pinion W1GL-03-05-027



Reducing Thickness of Shim for Pinion W1GL-03-05-022



W1GL-03-05-023



C) Decreasing clearance of pinion is necessary.



Meshing Surface (Concave Part)



Meshing Surface (Convex Part)



Clearance of pinion W1GL-03-05-027



Increasing Thickness of Shim for Pinion



W1GL-03-05-025



W1GL-03-05-026



W3-4-30



UNDERCARRIAGE / Axle REMOVE AND INSTALL AXLE 1



CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.)



2 3



Removal of Front Axle 1. Loosen mounting nuts (4) (20 used) from tires (3) (4 used) and tire rings (2) (2 used). : 30 mm



2 4 T1F3-01-02-002



3



2. Jack up frame (1) with tire (3) floated then put the blocks under the machine. 90 to 110°



CAUTION: Tire (3) weight: 98 kg (220 lb) Tire ring (2) weight: 17 kg (38 lb) 3. Remove nuts (4) (20 used). Remove tires (3) (4 used) and tire rings (2) (2 used). : 30 mm



Front Axle



4. Disconnect brake hoses (5) (2 used) and grease hose (7). : 17 mm, 22 mm



5



7



5. Disconnect steering hoses (14) (2 used) from steering cylinder (13). : 22 mm



W1GL-03-08-003



Block



8 6 9



5



10



CAUTION: Propeller shaft weight: 20 kg (44 lb) 6. Remove nuts (12) (8 used) and propeller shaft (11). 13, 14



7. Remove nuts (10) (2 used) and bolt (9). : 24 mm



4



CAUTION: Front axle (6) weight: 590 kg (1300 lb) CAUTION: Pin (8) weight: 14 kg (31 lb) (Outer Diameter 60 mm (2.4 in)) 1. Lift front axle (6) off to remove pin (8), then remove front axle (6).



W3-5-1



12



11



W1F3-03-05-013



UNDERCARRIAGE / Axle Installation of Front Axle



5



7



CAUTION: Front axle (9) weight: 590 kg (1300 lb) CAUTION: Pin (8) weight: 14 kg (31 lb) (Outer Diameter 60 mm (2.4 in))



8 6 9



5



10



1. Lift front axle (6) off, then install front axle (6) with pin (8). 2. Lock pin (8) with bolt (9) and nuts (10) (2 used). : 24 mm : 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)



13, 14



W1F3-03-05-013



12



11



4



3. Connect steering hoses (14) to steering cylinder (13). : 22 mm : 39 N⋅m (4.0 kgf⋅m, 28.5 lbf⋅ft) 4. Connect brake hoses (5) (2 used) and grease hose (7). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 22 mm : 39 N⋅m (4.0 kgf⋅m, 29 lbf⋅ft) CAUTION: Propeller shaft (11) weight: 30 kg (66 lb) 5. Install propeller shaft (11) with bolts and nuts (12) (8 used). : 14 mm : 108 N⋅m (11.0 kgf⋅m, 80 lbf⋅ft)



1 2 3



CAUTION: Tire (3) weight: 98 kg (220 lb) Tire ring (2) weight: 17 kg (38 lb) 6. Install tire (3), tire ring (2) and tire (3) to front axle (6) in order, then temporarily tighten them with nuts (4). (The installing order for both sides are the same.) : 30 mm



2 4



3



T1F3-01-02-002



7. Remove the block from frame (1). 8. Tight tires (3) (4 used) and tire rings (2) (2 used) with nuts (4) (20 used): : 30 mm : 600 N⋅m (61 kgf⋅m, 440 lbf⋅ft)



Front Axle



W3-5-2



Block



W1GL-03-08-003



UNDERCARRIAGE / Axle CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.)



1



1 2 3



Removal of Rear Axle 1. Loosen mounting nuts (4) (20 used) from tires (1) (4 used) and tire rings (2). : 30 mm 4 2



T1F3-01-02-002



2. Jack up frame (3) with tire (1) floated, then put the blocks under the machine. CAUTION: Tire (1) weight: 98 kg (220 lb) Tire ring (2) weight: 17 kg (38 lb)



90° to 110°



3. Remove nuts (4) (20 used). Remove tires (1) (4 used) and tire rings (2) (2 used). : 30 mm 4. Remove brake pipes (5) (2 used). Rear Axle



CAUTION: Propeller shaft (10) weight: 30 kg (66 lb)



Block SA-096



5



6



5. Remove nuts (9) (8 used). Propeller shaft (10). : 14 mm CAUTION: Rear Axle Weight: 440 kg (97.0 lb)



10



6. Lift rear axle (7) off to remove nut (6) (8 used) and bolts (8) (8 used). : 30 mm



9 7 8 W1F3-03-05-014



4



W3-5-3



UNDERCARRIAGE / Axle Installation of Rear Axle



6



5



CAUTION: Rear axle (7) weight: 440 kg (970 lb) 1. Lift rear axle (7), then install rear axle (7) to frame (3) with bolts (8) (8 used) and nuts (6) (8 used). : 30 mm : 560 N⋅m (57.0 kgf⋅m, 410 lbf⋅ft)



10 9



7



2. Connect brake pipe (5). : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)



8 W1F3-03-05-014



4



CAUTION: Propeller shaft (10) weight: 30 kg (66 lb) 1



1



3. Install propeller shaft (10) to rear axle (7) with nuts (9) (8 used). : 14 mm : 108 N⋅m (11gf⋅m, 80 lbf⋅ft)



2 3



CAUTION: Tire (3) weight: 98 kg (220 lb) Tire ring (2) weight: 17 kg (38 lb) 4. Install tire (1), tire ring (2) and tire (1) into rear axle (7) in order then temporarily tighten them with nuts (4) (10 used). The installing order for both sides are the same. : 30 mm



4 2



T1F3-01-02-002



5. Remove the block from frame (3). 6. Tighten tires (1) (4 used) and tire rings (2) (2 used) with nuts (4) (20 used) : 30 mm : 600 N⋅m (61 kgf⋅m, 440 lbf⋅ft) 90 ～ 110°



Rear Axle



W3-5-4



Block



SA-096



UNDERCARRIAGE / Axle (Blank)



W3-5-5



UNDERCARRIAGE / Axle DISASSEMBLE FRONT AXLE 2 3 4



8 7



5



1



6



4 3 2



9



10



22



16 17 18



15 12



11



13



19



23



24



21



20



14



25 45



46



44 26 28



29



30



27



31



32 33



34 35



36 37



38



39



40



41 42



47



48



34



56



43



57



58 59



60



61 49



50



55 54



53



52



51



W1F3-03-05-011



W3-5-6



UNDERCARRIAGE / Axle 12345678910 11 12 13 14 15 16 17 18 -



Body O-Ring (2 Used) Seal Ring (2 Used) Bearing (2 Used) Bushing Shaft Seal Axle Shaft Retaining Ring Bolt (16 Used) Washer (16 Used) Double Joint Shaft Retaining Ring Shaft Seal Bushing Joint Housing Bolt Bearing Pin Shim



19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36



-



Gasket Ring Bearing Bushing Hub Carrier O-Ring Bearing Wheel Stud (10 Used) Bearing Pin Bolt (4 Used) Stopper Bolt O-Ring Ring Gear O-Ring Bolt (6 Used) Spring Guide (6 Used) Spring (6 Used) Plate Ring



37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54



-



W3-5-7



U-Ring Piston Nut (6 Used) U-Ring Ring Bearing Nut Retaining Ring Plate (6 Used) Plate Retaining Ring Friction Plate (5 Used) Bolt (2 Used) Plug Planetary Carrier Thrust Plate (4 Used) Planetary Gear (4 Used) Needle Bearing (4 Used) Thrust Plate (4 Used)



55 56 57 58 59 60 61 62



-



Retaining Ring (4 Used) Lock Washer Gear Retaining Ring Retaining Ring Sun Gear Shaft Washer Plug



UNDERCARRIAGE / Axle



2 3



8



4



1



7



6



5



4 3 2 9



10



16



22



17 15



11



12 13



19



18



23



24



21



20



14 25 45 26



44



27



28



35 36 37 30



31



32



33



46



38



39 40



41 42



43



34 47



29 48



56



57



58



59



60



61 49 50



55



54 53



52



51



W1F3-03-05-011



W3-5-8



UNDERCARRIAGE / Axle Disassemble Front Axle 1. Remove plugs (49, 62) and drain oil. : 8 mm, 22 mm



9. Remove bearing nut (42) from joint housing (15).



Remove bolts (48) (2 used). Remove planetary carrier (50) from hub carrier (22). : 8 mm



10. Remove the ring gear (30) assembly from joint housing (15). 11. Pull the piston (38) assembly from ring gear (30). 12. Remove nuts (39) (6 used) from the piston (38) assembly. Remove bolts (32) (6 used), spring guides (33) (6 used) and springs (34) (6 used). : 10 mm



22



48



13. Remove plate (35) from ring gear (30).



48



14. Remove U-rings (40, 37) and rings (41, 36) from piston (38).



50 62 49



W1GL-03-05-006



3. Remove retaining rings (55) (4 used). Remove thrust plates (54) (4 used), planetary gears (52) (4 used), needle bearings (53) (4 used) and thrust plates (51) (4 used) from planetary carrier (50). 4. Remove retaining ring (46) from ring gear (30). Remove plate (45), plates (44) (6 used) and friction plate (47) (5 used). 5. Remove retaining ring (59) from sun gear shaft (60). Remove gear (57). 6. Remove retaining ring (58) from gear (57). 7. Remove lock washer (56) and retaining ring (43) from ring gear (30). 8. Pull sun gear shaft (60) from double joint shaft (11).



W3-5-9



UNDERCARRIAGE / Axle 2 3 4



1



6



5



4 3 2



16



22



17 18



15



11



13



19



20



24



21



14



26 27



W1F3-03-05-011



W3-5-10



UNDERCARRIAGE / Axle 15. Remove O-ring (31) from ring gear (30). 16. Remove O-ring (23) from hub carrier (22). 17. Remove O-ring (29) from joint housing (15). 18. Remove the hub carrier (22) assembly from joint housing (15). 19. Remove outer races of bearings (20, 24), bushing (21) and gasket ring (19) from hub gear (22). IMPORTANT: When removing bearing pins (17, 26), the inner race of bearing (4) should be removed together. Take care not to damage it. 20. Remove bolts (27) (4 used). Remove bearing pin (26), O-ring (2) and seal ring (3) from joint housing (15). : 24 mm 21. Remove bolts (16) (4 used). Remove bearing pin (17), shim (18), O-ring (2), and seal ring (3) from joint housing (15). : 24 mm 22. Remove joint housing (15) from body (1). 23. Pull outer race of bearing (4) (2 used) from body (1). 24. Pull double joint shaft (11) out from body (1). 25. Remove bearing inner races (4) (2 used) from bearing pins (17, 26). 26. Remove shaft seals (6, 13) from joint housing (15) and body (1). The other side should be removed in the same way. NOTE: Remove bushings (5, 14) from body (1) and joint housing (15) if necessary



W3-5-11



UNDERCARRIAGE / Axle ASSEMBLE FRONT AXLE 4



17



2 16



20



21



25 24 35



36 37 40 41 38 44 47 45 46



18 6



52



1



51



5



53



8



54、55 61



13



60 43



7



59



11



58



3



49



15



50



26



27



29 31



14



19



22



48 23 32



33



34 39



30 42 56 57 W1F3-03-05-003



W3-5-12



UNDERCARRIAGE / Axle 12345678910 11 12 13 14 15 16 -



Body O-Ring (2 Used) Seal ring (2 Used) Bearing (2 Used) Bushing Shaft Seal Axel Shaft Retaining Ring *Bolt (16 Used) *Washer (16 Used) Double Joint Shaft *Retaining Ring Shaft Seal Bushing Joint Housing Bolt (4 Used)



17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -



Bearing Pin Shim Gasket Ring Bearing Bushing Hub Carrier O-Ring Bearing Wheel Stud (10 Used) Bearing Pin Bolt (4 Used) *Stopper Bolt O-Ring Ring Gear O-Ring Bolt (6 Used)



33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 -



NOTE: As for marked “ * ”, refer to page W3-5-6



W3-5-13



Spring Guide (6 Used) Spring (6 Used) Plate Ring U-Ring Piston Nut (6 Used) U-Ring Ring Bearing Nut Retaining Ring Plate (6 Used) Plate Retaining Ring Friction Plate (5 Used)



48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 -



Bolt (2 Used) Plug Planetary Carrier Thrust Plate (4 Used) Planetary Gear (4 Used) Needle Bearing (4 Used) Thrust Plate (4 Used) Retaining Ring (4 Used) Lock Washer Gear Retaining Ring Retaining Ring Sun Gear Shaft Washer Plug



UNDERCARRIAGE / Axle



4



17



2 16



20



21



25 24 35



36 37 40 41 38 44 47 45 46



18 6



52



1



51



5



53



8



54、55 61



13



60 43



7



59



11



58



3



49



15



50



26



27



29 31



14



19



22



48 23 32



33



34 39



30 42 56 57



W1F3-03-05-003



W3-5-14



UNDERCARRIAGE / Axle Assemble Front Axle 1. Install shaft seals (6, 13) to body (1) and joint housing (15). 2. Install outer races (2 used) of bearing (4) to body (1). 3. Insert double joint shaft (11) into body (1). IMPORTANT: Be sure to check double joint shaft (11) and differential are connected. 4. Apply grease onto O-rings (2) (2 used). Install O-rings (2) (2 used), seal rings (3) (2 used) and inner races (2 used) of bearing (4) to bearing pins (17, 26). 5. Apply grease on shim (18) then install it to the bearing pin (17) assembly. 6. Install inner race of bearing (20) to joint housing (15). 7. Install joint housing (15) to body (1) with the bearing pins (17) and (26) assembly and secure them with bolts (16) (4 used) and bolts (27) (4 used). : 24 mm : 280 N⋅m (29 kgf⋅m, 207 lbf⋅ft) 8. Install gasket ring (19) and the outer races of bearings (20, 24) to hub carrier (22). 9. Install the hub carrier (22) assembly to joint housing (15), install bushing (21) and the inner race of bearing (24). 10. Install ring gear (30) to hub carrier (22) and temporary tighten them with bearing nut (42). : 1550 + 500 N⋅m (155 + 51 kgf⋅m, 1140 + 370 lbf⋅ft) 11. Measure the preload of hub carrier (22). Preload: 8 to 12 N⋅m (0.8 to 1.2 kgf⋅m, 5.9 to 8.9 lbf⋅ft) 12. If the preload torque is within specified value, remove bearing nut (42) and ring gear (30) again



W3-5-15



UNDERCARRIAGE / Axle



35



36 37 40 41 38



60 43 59



11



58



15



29 31



32



33



34 39



30 42 56 57 W1F3-03-05-003



W3-5-16



UNDERCARRIAGE / Axle 13. Install rings (36, 41) and U-rings (37, 40) to piston (38). Apply grease after installing them. 38



36



IMPORTANT: When installing the ring gear (30) assembly to joint housing (15), tighten bearing nut (42) while rotating the ring gear (30) assembly in the direction of clockwise and counterclockwise several times. 19. Install the ring gear (30) assembly to joint housing (15) with bearing nut (42). : 1550 + 500 N⋅m (155 + 51 kgf⋅m, 1140 to 370 lbf⋅ft)



37 40



41



W1F3-03-05-020



20. Lock bearing nut (42) with retaining ring (43). 14. Install piston (38) to ring gear (30). Secure it with plate (35), bolts (32) (8 used), spring guides (33) (6 used), springs (34) (6 used) and nuts (39) (6 used). : 10 mm



21. Apply grease on thrust washer (56) and adhere it to retaining ring (43).



15. Install bolt so that the dimensions A should be 0.5 to 1.5 mm (0.02 to 0.06 in) and B should be 3.75 to 4.25 mm (0.15 to 0.17 in). : 10 mm : 11 N⋅m (1.1 kgf⋅m, 8 lbf⋅ft)



23. Insert sun gear shaft (60) into gear (57) and secure it with retaining ring (58, 59)



38



B



22. Insert double joint shaft (11) into sun gear shaft (60).



A



39 56



32



43



W1F3-03-05-021



16. After adjusting, secure nuts (39) (6 used) with LOCTITE # 242. 17. Apply grease on O-ring (29) then install it to ring gear (30). 18. Apply grease on O-ring (31) then install it to joint housing (15).



W3-5-17



UNDERCARRIAGE / Axle



44 47 45 46



52 51 53 54、55 61



49 50



22



48 23



30



W1F3-03-05-003



W3-5-18



UNDERCARRIAGE / Axle IMPORTANT: There are two cut-off grooves on the periphery of each of six plates (44). When attaching, align directions of cut-off grooves.



30. After assembling the front axle, install straight edge to adjust toe-in. Straight Edge A1



24. Install plate (44), friction plate (47) into the inside of ring gear (30) in order, then install plate (45) and secure them with retaining ring (46). 25. Install O-ring (23) into the groove on the outer race of hub carrier (22).



A2 Straight Edge



26. Install thrust plate (51), needle bearing (53), planetary gear (52) and thrust plate (54) to planetary carrier (50) in order and lock them with retaining ring (55). (3 places) NOTE: When disassembling, washer (61) should not be removed normally. When replace planetary carrier (50), it should be replaced together with washer (61).



Tie Rod End



Tie Rod End W1GL-03-05-017



Measure the dimension A1 between the notch marked on straight edge, and measure the dimension A2 after rotating both sides of wheel hub to 180°. Then adjust with tie rod end so that dimension of A1 and A2 is the same



27. Install the planetary carrier (50) assembly to the hub carrier (22) assembly and secure them with bolts (48) (2 used). : 8 mm : 55 N⋅m (5.6 kgf⋅m, 40 lbf⋅ft) 28. Install plug (49) into planetary carrier (50). : 8 mm : 69 N⋅m (7.0 kgf⋅m, 50 lbf⋅ft) 29. Supply oil into the differential and the wheel hub, then install plug (62). : 22 mm : 79 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft) Differential Front Axle: 8.5 L (2.2 US gal.) Wheel Hub Front: Each 2.1 L (0.55 US gal.) x 2



W3-5-19



UNDERCARRIAGE / Axle DISASSEMBLE FRONT DIFFERNTIAL 1 2



3 4 5 6 7 8 9 10



11



16 19 16



17



19



18



14



15



17 13



12



18



20



22



21



23 19 18 24



25



18 30 28 26 27



29



32



31



33 34



W1F3-03-05-017



123456789-



Lock Plate Nut Washer Flange Guard Seal Bearing Ring Shim



10 11 12 13 14 15 16 17 18 -



Bearing Drive Pinion Spring Pin (4 Used) Spring Pin (4 Used) Bevel Gear Differential Case Thrust Washer (2 Used) Side Gear (2 USed) Thrust Washer (4 Used)



19 20 21 22 23 24 25 26 27 -



W3-5-20



Pinion Gear (4 Used) Differential Case Washer (12 Used) Socket Bolt (12 Used) Spider Body Shim Bearing Bearing



28 29 30 31 32 33 34 -



Shim O-Ring Body Bolt (16 Used) Washer (16 Used) Plug Plug



UNDERCARRIAGE / Axle Disassemble the Front Differential To disassemble the differential, it is needed to remove left and right tie rods. See “Remove Steering Cylinder”. CAUTION: Front axle weight: 590 kg (1300 lb)



9. Remove side gear (17), thrust washers (18) (4 used), piston gears (19) (4 used) and spider (23) from differential case (20). 10. Remove side gear (17) and slide washer (16) form differential case (20).



1. Remove plugs (33, 34), and discharge oil. : 19 mm 2. Remove bolts (31) (16 used) and washers (32) (16 used), and separate bodies (24, 30). : 27mm 3. Remove the outer race of bearing (27), shim (28) and O-ring (29) from body (30). 4. Remove the outer race of bearing (26) and shim (25) from body (24). 5. Remove the inner races of bearings (27, 26) from differential cases (15, 20) assemblies. IMPORTANT: Make sure to mark matching mark before disassembling the differential. 6. With bevel gear (14) positioned lower, remove socket bolts (22) (12 used), washers (21) (12 used), and separate differential cases (15, 20). : 10 mm 7. Drive bevel gear (14) out of differential case (15), by using a plastic hammer. 8. Remove spring pins (12) (4 used), spring pins (13) (4 used) and thrust washer (16) from differential case (15).



W3-5-21



UNDERCARRIAGE / Axle



1 2



3



4 5 6 7 8



9 10



11 14



24



W1F3-03-05-017



W3-5-22



UNDERCARRIAGE / Axle 11. Remove lock plate (1) from flange (4). 12. Remove nut (2), washer (3) and flange (4) from drive pinion (11). NOTE: Do not remove guard (5) from flange (4) unless replacement is made. 13. Drive drive pinion (11) out of bevel gear (14), by using a plastic hammer. 14. Withdraw inner race of bearing (10) and ring (8) from drive pinion (11). 15. Remove the inner races of bearings (10, 7), shim (9) and seal (6) from body (24).



W3-5-23



UNDERCARRIAGE / Axle ASSEMBLE FRONT DIFFERENTIAL 1



3



2



4 5 6 7 8 9 10



29



14



27



28



11



21



30



22 25 Axle Shaft Axle Shaft



15 20



24



W1F3 05-03-016



26



17



16



19



23



18



12, 13



32 31



1 - Lock Plate



10 - Bearing



19 - *Pinion Gear (4 Used)



28 - Shim



2 - Nut



11 - Drive Pinion



20 - Defferential Cace



29 - O-Ring



3 - Washer



12 - Spring Pin (4 Used)



21 - Washer (12 Used)



30 - Body



4 - Flange



13 - Spring Pin (4 Used)



22 - Socket Bolt (12 Used)



31 - Bolt (16 Used)



5 - Guard



14 - Bevel Gear



23 - Spider



32 - Washer (16 Used)



6 - Seal



15 - Defferential Cace



24 - Body



33 - *Plug



7 - Bearing



16 - Threst Washer (2 Used)



25 - Shim



34 - *Plug



8 - Ring



17 - Side Gear (2 Used)



26 - Bearing



9 - Shim



18 - Threst Washer (4 Used)



27 - Bearing



NOTE: As for marked “ * ”, refer to page W3-5-20



W3-5-24



UNDERCARRIAGE / Axle Assemble the Front Differential 1. Install shim (9) and the outer races of bearings (10, 7) to body (24).



8. Install four spring pins (13) and spring pins (12) (4 used) to differential case (15), and then mount bevel gear (14).



2. Install the inner race of bearing (10) with drive pinion (11).



9. Place the assembly on work bench, with bevel gear (14) positioned lower.



3. Install the drive pinion (11) assembly to body (24); temporarily assemble ring (8), inner races of ring (7) of bearing, flange (4) and washer (3). Tighten them with nut (2). : 41 mm : 430 N⋅m (4.2 kgf⋅m, 30 lbf⋅ft) 4. Adjust pre load of drive pinion (11) to 1.0 – 2.0 N⋅m (0.1 – 0.2 kgf⋅m, 0.74 – 1.48 lbf⋅ft). 5. Remove nut (2), washer (3) and flange (4) again. : 41 mm 6. Attach seal (6) to body (24). 7. Attach flange (4) and washer (3) to drive pinion (11) assembly with nut (2), and affix them with lock plate (1). : 41 mm : 430 N⋅m (4.2 kgf⋅m, 30 lbf⋅ft)



10. Grease thrust faces of side gears (17) (2 used), and install thrust washers (16) (2 used). 11. Grease and install pinion gears (19) (4 used) and four thrust washers (18) to spider (23). 12. Install the side gear (17) assembly to differential case (15). 13. Install the spider (23) assembly to differential case (15). 14. Grease and install the side gear (17) assembly to differential case (20). 15. Install the differential case (20) assembly to the differential case (15) assembly by aligning matching marks.



W3-5-25



UNDERCARRIAGE / Axle



1



3



2



4 5 6 7



9 10



14



29



27



28



11



21



30



22 25 Axle Shaft Axle Shaft



15 20



24



W1F3-03-05-016



26



17



16



19



23



18



W3-5-26



12, 13



32 31



UNDERCARRIAGE / Axle 16. Affix differential assembly to bevel gear (14) with socket bolts (22) (12 used) and washers (21) (12 used). : 10 mm : 145 N⋅m (15 kgf⋅m, 107 lbf⋅ft) 17. Install the inner races of bearings (26, 27) to differential assembly. 18. Install shim (25) and the outer race of bearing (26) to body (24). 19. Install shim (28), the outer race of bearing (27), and O-ring (29) to body (30). 20. Install differential assembly to body (24). 21. Affix body (30) to body (24) assembly with bolts (31) (16 used) and washers (32) (16 used). : 27 mm : 410 N⋅m (42 kgf⋅m, 300 lbf⋅ft) 22. Attach plug (33) to body (24). : 19 mm : 79 N⋅m (8 kgf⋅m, 58 lbf⋅ft) 23. Apply oil inside body (24), and install plug (34). Front axle: 8.5 L (2.25 US gal.)



W3-5-27



UNDERCARRIAGE / Axle DISASSEMBLE REAR AXLE 4



3 2 1



6 18



17 15



14



7



5



16



13



8 10



12



11



9 32 19



20



21



22 23



24



25



26



27 28



29



30 31



33 43



34



35



38 36 37



39



40 41



42 44



45



50 49



48



47



46



W1F3-03-05-018



W3-5-28



UNDERCARRIAGE / Axle



12345678910 11 12 13 -



Body Axle Shaft O-Ring Knuckle Bolt (18 Used) Washer (18 Used) Bolt (16 Used) Washer (16 Used) Screen Sheet Gasket Ring Bearing Bushing Hub Carrier



14 15 16 17 18 19 20 21 22 23 24 25 26 -



O-Ring Bearing O-Ring Ring Gear O-Ring Wheel Stud (10 Used) Bolt (6 Used) Spring Guide (6 Used) Spring (6 Used) Plate Ring U-Ring Piston



27 28 29 30 31 32 33 34 35 36 37 38 39 -



W3-5-29



Nut (6 Used) U-Ring Ring Bearing Nut Retaining Ring Plate (6 Used) Friction Plate (5 Used) Plate Retaining Ring Seal Lock Washer Gear Retaining Ring



40 41 42 43 44 45 46 47 48 49 50 51 -



O-Ring Sun Gear Shaft Washer Bolt (2 Used) Plug Planetary Carrier Thrust Plate (4 Used) Planetary Gear (4 Used) Needle Bearing (4 Used) Thrust Plate (4 Used) Retaining Ring (4 Used) Plug



UNDERCARRIAGE / Axle 4



3 2 1



6 18



17 15



14



7



5



16



13



8 10



12



11



9 32 19



20



21



22 23



24



25



28 26 27



29



30 31



33 43



34



35



38 36 37



39



40 41



42 44



45



50 49



48



47



46



W1F3-03-05-018



W3-5-30



UNDERCARRIAGE / Axle Disassemble Rear Axle 1. Remove plugs (44, 51) and drain oil. : 8 mm、22 mm 2. Remove bolts (43) (2 used). Remove planetary carrier (45) from hub carrier (13). : 8 mm



11. Remove nuts (27) (6 used) from the piston (26). Remove bolts (20) (6 used), spring guides (21) (6 used) and springs (22) (6 used). : 10 mm 12. Remove piston (26) and plate (23) from ring gear (17).



13



13. Remove U-ring (25, 28) and ring (24, 29) from piston (26). 43 43



14. Remove O-ring (18) from ring gear (17).



45



15. Remove O-ring (14) from hub carrier (13).



51



44



16. Remove O-ring (16) from knuckle (4).



W1GL-03-05-006



3. Remove retaining rings (50) (4 used). Remove thrust plates (49) (4 used), planetary gears (47) (4 used), needle bearings (48) (4 used) and thrust plates (46) (4 used) from planetary carrier (45). NOTE: When disassembling, the washer (42) should not be removed normally. When replace planetary carrier (45), it should be replaced together with washer (42). 4. Remove retaining ring (35) from ring gear (17). Remove plate (34), plates (32) (6 used) and friction plates (33) (5 used). 5. Remove retaining ring (39). Remove the sun gear shaft (41) assembly from axle shaft (2). 6. Remove gear (38) and O-ring (40) from sun gear shaft (41). 7. Remove lock washer (37) and retaining ring (31) from knuckle (4). 8. Remove bearing nut (30) from knuckle (4). 9. Remove the ring gear (17) assembly from knuckle (4). 10. Pull the piston (26) assembly out from ring gear (17).



W3-5-31



UNDERCARRIAGE / Axle



3



4



2 1



6



5



15 13 10



11



12



9



36



W1F3-03-05-018



W3-5-32



UNDERCARRIAGE / Axle 17. Remove the hub carrier (13) assembly from knuckle (4). 18. Remove the outer races of bearings (11, 15) and gasket ring (10) from hub carrier (13). 19. Remove the inner race of bearing (11) and bushing (12) from knuckle (4). 20. Remove bolts (5) (18 used) and washer (16 used). Remove knuckle (4) from body (1). 21. Remove O-ring (3), screen sheet (9) and seal (36) from knuckle (4). 22. Pull axle shaft (2) out from body (1).



W3-5-33



UNDERCARRIAGE / Axle ASSEMBLE REAR AXLE 4



3 2 1



5



6 17 15



14



7



18



16



13



8 10



12



11



9 32 19



20



21



22 23



24



25



28 26 27



29



30 31



33 43



34



35



38 36 37



39



40 41



42 44



45



50 49



48



47



46



W1F3-03-05-018



W3-5-34



UNDERCARRIAGE / Axle 12345678910 11 12 13 -



Body Axle Shaft O-Ring Knuckle Bolt (18 Used) Washer (18 Used) Bolt (16 Used) Washer (16 Used) Screen Sheet Gasket Ring Bearing Bushing Hub Carrier



14 15 16 17 18 19 20 21 22 23 24 25 26 -



O-Ring Bearing O-Ring Ring Gear O-Ring Wheel Stud (10 Used) Bolt (6 Used) Spring Guide (6 Used) Spring (6 Used) Plate Ring U-Ring Piston



27 28 29 30 31 32 33 34 35 36 37 38 39 -



W3-5-35



Nut (6 Used) U-Ring Ring Bearing Nut Retaining Ring Plate (6 Used) Friction Plate (5 Used) Plate Retaining Ring Seal Lock Washer Gear Retaining Ring



40 41 42 43 44 45 46 47 48 49 50 51 -



O-Ring Sun Gear Shaft Washer Bolt (2 Used) Plug Planetary Carrier Thrust Plate (4 Used) Planetary Gear (4 Used) Needle Bearing (4 Used) Thrust Plate (4 Used) Retaining Ring (4 Used) Plug



UNDERCARRIAGE / Axle 3



4



2 1



6 18



17 15



14



7



5



16



13



8 10



12



11



9 32



20



21



22 23



24



25



26



27 28



29



30 31



33 43



34



35



38 36 37



39



40 41



42 44



45



50 49



48



47



46



W1F3-03-05-018



W3-5-36



UNDERCARRIAGE / Axle Assemble Rear Axle 1. Insert axle shaft (2) into body (1) inside. IMPORTANT: Be sure to check that axle shaft (2) and differential are connected. 2. Install the inner race of bearing (11) and bushing (12) to knuckle (4). 3. Install O-ring (3), screen sheet (9) and seal (36) to knuckle (4).



10. Install the piston (26) to assembly ring gear (17) and secure it with bolts (20) (6 used), spring guides (21) (6 used), springs (22) (6 used) and nuts (27) (6 used). : 10 mm 11. Install bolt so that the dimension A should be 3.75 to 4.25 mm (0.15 to 0.17 in). : 10 mm : 11 N⋅m (1.1 kgf⋅m, 8 lbf⋅ft)



4. Install knuckle (4) to body (1) with bolt (5) (18 used) and washer (6) (18 used).



27 20



5. Install the outer race of bearing (11, 15) and gasket ring (10) into hub carrier (13). 6. Install the hub carrier (13) assembly to knuckle (4), then install the inter race of bearing (15) to hub carrier (13). 7. Install O-ring (16) to knuckle (4) then install O-ring (18) to ring gear (17). 8. Install rings (24, 29) and U-rings (25, 28) to piston (26). Apply grease after installing them. 28 24



A



26



W1F3-03-05-023



12. After adjusting, secure nuts (27) (6 used) with LOCTITE #242.



29



25



26



W1F3-03-05-022



9. Install plate (23) to piston (26).



W3-5-37



UNDERCARRIAGE / Axle 4



3



2 1



5



6 18



17 15



14



7



16



13



8 10



12



11



9 32



20



21



22 23



24



25



26



27 28



29



30 31



33 43



34



35



38 36 37



39



40 41



42 44



45



50 49



W3-5-38



48



47



46 W1F3-03-05--018



UNDERCARRIAGE / Axle IMPORTANT: When installing the ring gear (17) assembly to knuckle (4), tighten bearing nut (30) while rotating the ring gear (17) assembly in the direction of clockwise and counterclockwise several times.



21. Install O-ring (14) to hub carrier (13).



13. Install the ring gear (17) assembly to knuckle (4) with bearing nut (30). : 1550 + 550 N⋅m (160 + 55 kgf⋅m, 1140 + 410 lbf⋅ft)



23. Install plug (44) to planetary carrier (45). Supply oil to differential and wheel hub inside. Differential: 2.0 L (0.528 US gal.)



22. Install the planetary carrier (45) assembly to hub carrier (13) with bolt (43) (2 used). : 8 mm : 55 N⋅m (5.6 kgf⋅m, 41 lbf⋅ft)



14. Lock bearing nut (30) with retaining ring (31). 15. Apply grease on lock washer (37) and adheres to retaining ring (31). 16. Install retaining ring (39) to gear (38), then install O-ring (40) to sun gear shaft (41). 17. Install the sun gear shaft (41) assembly to the gear (38) assembly. 18. Install the gear (38) assembly to axle shaft (2). 19. Install plate (32) and friction plate (33) into the inside of ring gear (17) in order, install plate (34) secure it with retaining ring (35). IMPORTANT: Install thrust plates (46, 49) with the wide side of L-link facing bearing side. 20. Install thrust plate (46), needle bearing (48), planetary gear (47) and thrust plate (49) to planetary carrier (45) in order and lock them with retaining ring (50). (4 places) NOTE: When disassembling, the washer (42) should not be removed normally. When replace planetary carrier (45), it should be replaced together with washer (42).



W3-5-39



UNDERCARRIAGE / Axle DISASSEMBLE and ASSEMBLE REAR DIFFERENTIAL 1



2 3 4 5 6 7 8 9 10 11 15 19



16



17



19



18



17



14



16



13



18



12



20



22



21 17



23



19



30



18 25



26



27



18



28



29



24 32



34



33



31



35



36 W1F3-03-05-019



W3-5-40



UNDERCARRIAGE / Axle



123456789-



Lock Plate Nut Washer Flange Guard Seal Bearing Ring Shim



10 11 12 13 14 15 16 17 18 -



Bearing Drive Pinion Spring Pin (4 Used) Spring Pin (4 Used) Bevel Gear Differential Case Thrust Washer (2 Used) Side Gear (2 Used) Thrust Washer (4 Used)



19 20 21 22 23 24 25 26 27 -



W3-5-41



Pinion Gear (4 Used) Differential Case Washer (12 Used) Socket Bolt (12 Used) Spider Body Shim Bearing Bearing



28 29 30 31 32 33 34 35 36 -



Shim O-Ring Body Bolt (16 Used) Washer (16 Used) Plug Plug Axle Shaft Axle Shaft



UNDERCARRIAGE / Axle



1



2 3 4 5 6 7 8 9 10 11 15 19



16



17



19



18



17



14



16



13



18



12



20



22



21 17



23



19



30



18 25



26



27



18



28



29



24 32



34



33



31



35



36 W1F3-03-05-019



W3-5-42



UNDERCARRIAGE / Axle Disassemble and Assemble Rear Differential The structure of rear differential and front differential are the same. Refer to W 3-5-20 to W 3-5-27 for front differential. Oil Quantity: 10.3 L (2.7 US gal.)



W3-5-43



UNDERCARRIAGE / Axle DISASSEMBLE STEERING CYLINDER



1



2



3



4



5



W1F3-03-05-001



14



13



12 32



11



10 9



32



8



7



6



19



15



16



17



18



20



21



22



23



22



3



30



31



30



29



28



27 26



25 24



W1F3-03-05-010



12345678-



Ball Joint Collar Piston Rod Collar Ball Joint Lock Pin Nut Tie Rod



910 11 12 13 14 15 16 -



Joint Differential Housing Joint Tie Rod Nut Lock Pin O-Ring Collar



17 18 19 20 21 22 23 24 -



Scraper Ring U-Ring Bolt (4 Used) Guide Shim V Type Backup Ring (2 Used)



Seal Ring O-Ring



W3-5-44



25 26 27 28 29 30 31 32 -



Collar O-Ring Scraper Ring U-Ring Guide O-Ring (2 Used) Cylinder Lock Nut (2 Used)



UNDERCARRIAGE / Axle Disassemble Steering Cylinder 1. Remove pins (6, 14) and nuts (7,13) from ball joints (1, 5). : 41 mm 2. Remove ball joints (1, 5) from wheel hub. 3. Move collars (2, 4) toward body (10) of the differential. Remove tie rods (8, 12) from piston rod (3), by using wrenches at joints (9, 11) and piston rod (3). : 32 mm, 55 mm 4. Remove bolts (19, 22) (4 used respectively). Remove guide (20) from differential housing (10). : 22 mm 5. Pull the piston rod (3) out from cylinder (31). 6. Remove cylinder (31) from differential housing (10). 7. Remove O-ring (30) (2 used) from cylinder (31) 8. Remove the guide (29) assembly from differential housing (10). 9. Remove V type backup rings (22) (2 used) and seal ring (23) from piston rod (3). 10. Remove scraper rings (17) (2 used), U-rings (18) (2 used) and shim (21) from guide (20). 11. Remove O-ring (26), scraper ring (27), and u-ring from guide (29). 12. Remove O-rings (15, 24) from collars (16, 25). 13. Remove O-rings (30) (2 used) from cylinder (31).



W3-5-45



UNDERCARRIAGE / Axle ASSEMBLE STEERING CYLINDER 1



2



3



4



5



W1F3-03-05-001



14



11



16



13



15



3



17 18



12345678-



Ball Joint Collar Piston Rod Collar Ball Joint Lock Pin Nut Tie Rod



910 11 12 13 14 15 16 -



12 32



20



19



11



10 9



30



31



21



Joint Differential Housing Joint Tie Rod Nut Lock Pin O-Ring Collar



32



22



17 18 19 20 21 22 23 24 -



8



7



10



23



30



22



Scraper Ring U-Ring Bolt (4 Used) Guide Shim V Type Backup Ring (2 Used)



Seal Ring *O-Ring



W3-5-46



6



28



25 26 27 28 29 30 31 32 -



29



26



27



* Collar O-Ring Scraper Ring U-Ring Guide O-Ring (2 Used) Cylinder Lock Nut (2 Used)



W1F3-03-05-002



UNDERCARRIAGE / Axle Assemble Steering Cylinder 1. Attach O-rings (30) (2 used) to cylinder (31), and apply grease to mounting face. 2. Install O-ring (26), U-ring (28) and scraper ring (27) to guide (29), and apply grease to the inside and outside of guide (29).



13. Lock nuts (7, 13) with split pins (6, 14). IMPORTANT: Be sure to install piston rod (3) so that the dimensions of part A on both sides are the same.



3. Install U-ring (18), scraper ring (17) and shim (21) to guide (20), and apply grease to the inside. 4. Install seal ring (23) and two V-shaped backup rings on piston rod (3), and apply grease to them. 5. Install O-rings (15, 24) to collars (16, 25) respectively, and apply grease to them. 6. Install guide (29) assembly to body (10) of the differential. 7. Install the cylinder (31) assembly to body (10) of the differential.



A



A



W1GL-03-05-016



14. After adjusting, mount them with lock nut (32). : 19 mm : 70 to 80 N⋅m (7.0 to 8.0 kgf⋅m, 50 to 58 lbf⋅ft)



8. Install the piston rod (3) assembly on cylinder (31). 9. Affix guide (20) to body (10) of the differential with bolts (19) (4 used). : 22 mm : 185 N⋅m (18.9 kgf⋅m, 136 lbf⋅ft) 10. Install collars (16, 25) on piston rod (3). NOTE: Carry out assembly so that chamfered side of collars (16, 25) faces body (10) of the differential. 11. Install tie rods (8, 12) assembly to piston rod (3). : 32 mm, 55 mm : 350 N⋅m (35.7 kgf⋅m, 260 lbf⋅ft) 12. Install ball joints (1, 5) to wheel hub, and affix them with nuts (7, 13). : 41 mm : 300 N⋅m (30 kgf⋅m, 220 lbf⋅ft)



W3-5-47



UNDERCARRIAGE / Axle (Blank)



W3-5-48



UNDERCARRIAGE / Axle Lock Cylinder REMOVE AND CYLINDER



INSTALL AXLE



LOCK



CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.) In this section, the procedure starts on the premise that the front axle has already been removed. Removal 1. Disconnect pipes (1) (2 used) from check valve (2). Cap the open ends. : 19 mm IMPORTANT: Do not remove check valve (2). The rod (6) will drop when cap is removed because the air supplying. 2. Remove socket bolts (7) (2 used), then install eyebolts (M8, Pitch 1.25 mm) to the removed bolt holes. : 6 mm CAUTION: Axle lock cylinder weight: 30 kg (66 lb)



1 2 3



4



5 6 W1F3-03-06-003



7



3. Attach a wire rope on eyebolt to hold it by crane. 4. Remove bolts (5) (4 used) from chassis (4). : 22 mm



2



5. Lower axle lock cylinder (3) while lifing it off chassis (4).



3



W1F3-03-06-002



W3-6-1



UNDERCARRIAGE / Axle Lock Cylinder Installation 1. Remove socket bolts (7) (2 used), then install eyebolts (M8, Pitch 1.25 mm) to the removed bolt holes.



7



CAUTION: Axle lock cylinder weight: 30 kg (66 lb) 2



2. Hoist axle lock cylinder (3) and place it on chassis (4). Install them with bolts (5) (4 used). : 22 mm : 180 N⋅m (18 kgf⋅m, 130 lbf⋅ft) 3



3. Remove eyebolt, then install socket bolts (7) (2 used). : 6 mm : 20 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft) 4. Connect pipes (1) (2 used). : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)



W1F3-03-06-002



1 2 3



4



5 6 W1F3-03-06-003



W3-6-2



UNDERCARRIAGE / Axle Lock Cylinder (Blank)



W3-6-3



UNDERCARRIAGE / Axle Lock Cylinder DISASSEMBLE AND ASSEMBLE AXLE LOCK CYLINDER



2



A



1



3



2



7



View A



3 6 4



5



W1F3-03-06-001



1 - Socket Bolt (4 Used) 2 - Check Valve



3 - Housing 4 - Rod



5 - Retaining Ring 6 - Dust Seal



W3-6-4



7 - Seal



W1F3-03-06-002



UNDERCARRIAGE / Axle Lock Cylinder Disassemble Axle Lock Cylinder • Be sure to read “Precautions for Disassembly and Assembly” thoroughly on page W1-1-1 before starting any repair work.



Assemble Axle Lock Cylinder • Be sure to read “Precautions for Disassembly and Assembly” thoroughly on page W1-1-1 before starting any repair work.



CAUTION: Axle lock cylinder weight: 30 kg (66 lb)



CAUTION: Housing (3) weight: 16 kg (35 lb) Rod (4) weight: 11.5 kg (25 lb)



1. Place the axle lock cylinder on a workbench horizontally.



1. Install seal (7), dust seal (6) and retaining ring (5) to housing (3).



2. Remove socket bolts (1) (4 used) and remove check valve (2).



IMPORTANT: Apply hydraulic oil to the inner surface of housing (3) and seals (6, 7).



CAUTION: Housing (3) weight: 16 kg (35 lb) Rod (4) weight: 11.5 kg (25 lb)



2. Install rod (4) to housing (3). CAUTION: Axle lock cylinder weight: 30 kg (66 lb)



3. Supply air to the hole of the housing (3) port to push rod (4) out. 4. Remove retaining ring (5) from housing (3) and remove dust seal (6, 7).



3. Temporarily install check valve (2) to the housing (3) assembly with socket bolts (1) (2 used).



W3-6-5



UNDERCARRIAGE / Axle Lock Cylinder (Blank)



W3-6-6



UNDERCARRIAGE / Operate-Check Valve REMOVE AND INSTALL OPERATE-CHECK VALVE (FOR AXLE LOCK CYLINDER) CAUTION: Be sure to bleed air from hydraulic oil tank before starting the work. (Refer to “Bleeding Air from Hydraulic Oil Tank” on page W1-4-1.) Removal 1. Disconnect pipes (2) (2 used) from operate-check valve (1). Cap the open ends. : 19 mm



2 1



Axle Lock Cylinder



2. Remove socket bolts (3) (4 used) to remove operate-check valve (1) from the axle lock cylinder. Cap the open ends of the axle lock cylinder. : 6 mm



W1F3-03-06-003



Installation 1. Install operate-check valve (1) to the axle lock cylinder with socket bolts (3) (4 used). : 6 mm : 20 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft)



3



2. Connect pipes (2) (2 used). : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)



1



W1F3-03-06-002



Axle Lock Cylinder



W3-7-1



UNDERCARRIAGE / Operate-Check Valve CONSTRUCTION OF OPERATE-CHECK VALVE (FOR AXLE LOCK CYLINDER)



1



2



5



4



3



6



7



8



9



T1F3-03-10-002



Item



Parts Name



Q’ty



1



Plug



1



2



O-Ring



1



3



Piston



1



4



Body



1



5



Sleeve



1



6



Poppet



1



7



O-Ring



1



8



Spring



1



9



Plug



1



Wrench Size (mm) ：27



Tighten Torque N⋅m



(kgf⋅m)



(lbf⋅ft)



120±12



(12±0.12)



(89±8.9)



Remarks



1B P18



1B P26 ：36



360±36



W3-7-2



(36±3.6)



(265±26.5)



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MEMO ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... 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SECTION 4



FRONT ATTACHMENT — CONTENTS — Group 1 Front Attachment



Group 3 Hose-Rupture Safety Valve



Hydraulic Circuit Pressure Release Procedure...............................W4-1-1 Remove and Install Monoblock Boom Front Attachment ..................................W4-1-2 Remove and Install 2-Piece Boom Front Attachment ................................W4-1-10 Maintenance Standard .........................W4-1-18 Standard Dimensions for Arm and Bucket Connection...............W4-1-21 Standard Dimensions for Arm and Boom Connection ................W4-1-22



Remove and Install Hose-Rupture Safety Valve.................. W4-3-1 Construction of Hose-Rupture Safety Valve.................. W4-3-4



Group 4 Operate-Check Valve



Group 2 Cylinder Remove and Install Cylinder (Monoblock Boom, 2-Piece Boom).......W4-2-1 Disassemble Cylinder (Boom (Monoblock/2-Piece) and Bucket)................................................W4-2-20 Assemble Cylinder (Boom (Monoblock/2-Piece) and Bucket)................................................W4-2-22 Disassemble Cylinder (Positioning) .....W4-2-24 Assemble Cylinder (Positioning) ..........W4-2-26 Disassemble Cylinder (Arm) ................W4-2-27 Assemble Cylinder (Arm) .....................W4-2-29 Disassemble Cylinder (Stabilizer, Blade)................................W4-2-31 Assemble Cylinder (Stabilizer, Blade)................................W4-2-33 Maintenance Standard .........................W4-2-35



CBBW-4-1



Remove and Install Operate-Check Valve (for Blade/Stabilizer) ................... W4-4-1 Construction of Operate-Check Valve (for Blade/Stabilizer) ................... W4-4-2



(Blank)



CBBW-4-2



FRONT ATTACHMENT / Front Attachment HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE NOTE: Do not start the engine. Operate pilot pump with the power from battery to deliver pilot pressure to the spool of control valve. 1. Push pilot control shut-off lever (1) forward (UNLOCK position).



6



1



5



2. Pull engine stop knob (2) fully out and secure it using special tool (ST 7334). IMPORTANT: Battery will deplete. Be sure to operate key switch for short period. 3. Turn the key switch to START position and operate the lever for releasing pressure from hydraulic circuit 4 to 5 times. Releasing Circuit Boom/Bucket Arm *Positioning/ Auxiliary *Stabilizer/Blade



4



Operating Lever Right Control Lever (5) Left Control Lever (4)



MCBB-01-016



Attachment Pedal (3)



3



Stabilizer/Blade Lever (6)



NOTE: *: Optional 4. Push engine stop knob (2) in.



W4-1-1



2



FRONT ATTACHMENT / Front Attachment REMOVE AND INSTALL MONOBLOCK BOOM FRONT ATTACHMENT



1



Removal CAUTION: Prevent person from injury. Metal fragments may fly when a hammer is used to remove the pins. Be sure to wear necessary protection, such as goggles, hardhat and etc. 1. Remove grease hose (1) from the adapter on the boss at the boom cylinder rod side. (2 places both left and right) : 17 mm



Boom Cylinder



2. Remove nuts (4) and bolts (6) from boom cylinder rod pin (3). Then remove stopper (5). (2 places both left and right) : 24 mm



W1F3-04-01-007



2, 3



1



CAUTION: Boom cylinder weight: 150 kg (330 lb) 3. Hoist and hold the boom cylinder. By using a bar and hammer, drive pin (3) into the position where thrust plate (2) can be removed. NOTE: When pin (3) cannot be removed, start the engine and operate the boom lever to adjust the hole position of the boom cylinder piston rod end.



5



4, 6 Boom Cylinder



W1GL-04-01-006



W4-1-2



FRONT ATTACHMENT / Front Attachment 4. Place the boom cylinder on a bench of 1 m height. Start the engine. Operate the boom lever to retract the boom cylinder. Secure the boom cylinder rod as illustrated by using a wire. Stop the engine.



Bench



Boom Cylinder



5. Remove the boom cylinder. Refer to “Remove Boom Cylinder” on page W4-2-10.



Wire



6. Remove other boom cylinder in the same procedures as steps 3 to 5. W554-02-03-007



CAUTION: The pin sometimes releases suddenly. Be sure no one stands in the way. 7. Tap pin (3) out by using a bar and hammer. Remove thrust plate (2).



Pressure Release Button



8. After stopping the engine, push the pressure release button on the air breather to release any remaining pressure from the hydraulic oil tank. Remove the cap to release the residual pressure from the hydraulic circuit. Refer to “Hydraulic Circuit Pressure Release Procedure” on page W4-1-1.



Cap Hydraulic Oil Tank



W1F3-01-04-002



9. Disconnect hoses (7), (8) for bucket cylinder and arm cylinder. Attach a cap onto all the open ends of disassembled hoses. : 36 mm



W1F3-04-01-010



7



W4-1-3



8



FRONT ATTACHMENT / Front Attachment 10. Open cover (9). Remove bolts (10) (4 used) and cover (11). : 17 mm



9



11



W4-1-4



10



W1F3-02-03-001



FRONT ATTACHMENT / Front Attachment CAUTION: Boom foot pin (12) weight: 33 kg (73 lb)



12



11. Remove bolt (15), spring washer (16), plate (14) and block (13) from the plate of boom foot pin (12). : 27 mm



13 14 15 16 W178-04-01-001



Boom and Arm Cylinder Center of Gravity



CAUTION: Front attachment weight: 2670 kg (5890 lb)



Boom Assembly Center of Gravity



A



12. Attach a wire rope onto the boom. Slightly hoist to take up any slack of wire rope.



D C



B



13. Insert a bar between the plate of boom foot pin (12) and the bracket. Slightly pull the plate out.



W1F3-04-01-002



Unit: mm (in)



14. Pull boom foot pin (12) out while rotating the plate slowly by hand. NOTE: When boom foot pin (12) cannot be removed, adjust the position of the boom foot pin (12) hole by hoisting and lowering the front attachment.



A



3035 (119)



B



3340 (131)



C



782 (31)



D



1978 (78)



12



15. After hoisting the front attachment, move the machine backward. 16. Place the front attachment on wooden blocks. Plate



Insert a bar. Bracket



W178-04-01-001



W4-1-5



FRONT ATTACHMENT / Front Attachment Installation



Boom and Arm Cylinder Center of Gravity



CAUTION: Prevent person from injury. Metal fragments may fly when a hammer is used to install the pins. Be sure to wear necessary protection, such as goggles, hardhat and etc. CAUTION: Front attachment weight: 2671 kg (5890 lb)



Boom Assembly Center of Gravity



A



D



1. Hoist the front attachment. Move the machine forward, aligning the boom foot pin (12) holes. Insert the thrust plates into boom left and right sides and adjust the clearance between the plate and frame within 1 mm. (Adjust the position of the boom foot pin hole by hoisting and lowering the front attachment.)



C



B



W1F3-04-01-002



Unit: mm (in) A



3035 (119)



B



3340 (131)



C



782 (31)



D



1978 (78)



12



2. Drive in boom foot pin (12). Install stopper bolt (15), washer (16), plate (14) and block (13). : 27 mm : 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)



13 14 15 16



Boom and Arm Cylinder Center of Gravity



W178-04-01-001



9



3. Install cover (11) with bolts (10) (4 used). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 4. Close cover (9).



11



W4-1-6



10



W1F3-02-03-001



FRONT ATTACHMENT / Front Attachment 5. Remove the caps from hoses and pipings. Install the bucket cylinder hoses (7) and the arm cylinder hoses (8). : 36 mm : 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft)



W1F3-04-01-010



8



7



CAUTION: Boom cylinder weight: 150 kg (330 lb) 6. Install the boom cylinder. Refer to “Install Boom Cylinder” on page W4-2-12.



Boom Cylinder



3



W105-04-02-040



2



7. Hoist the boom cylinder. Insert thrust plates (2) (2 used), and then drive in pin (3) to install boom cylinders to both sides. 6



8. Install stopper (5) and secure it with bolt (6) and nuts (4) (2 used). (2 places both left and right) : 24 mm : 270 N⋅m (27.5 kgf⋅m, 405 Ibf⋅ft)



Boom Cylinder



5 4 W178-04-01-004



W4-1-7



FRONT ATTACHMENT / Front Attachment 9. Connect grease pipe (1) onto the boss at boom cylinder rod side. (2 places both left and right) : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)



1



W105-04-01-002



10. Add grease to the boom cylinder rod side, bottom side and boom foot side.



Right Boom Cylinder Rod Side Arm Cylinder Bottom Side Left Boom Cylinder Rod Side Boom Foot Side



W1F3-04-01-010



W4-1-8



FRONT ATTACHMENT / Front Attachment 11. Install thrust plates (17) into arm left and right sides. Adjust total clearance of left and right within 1.5 mm or less.



Arm and Bucket Center of Gravity



12. After installing arm, add grease to grease fitting (18) on the boom-connecting boss of the arm. IMPORTANT: For handling of HN bushing for the front attachment, check following requirements. Precautions for pressing the bushing in: If a hammer is used to drive the bushing in, the bushing may be damaged. Use a press.



F



E



Precautions when reinforcing the arm: Welding heat for arm reinforcement may cause oil to leak from the bushing and decrease lubrication performance. If oil leak occurs because of heated bushing after welding, replace the bushing.



W1F3-04-01-002



Unit: mm (in) E



3661 (144)



F



782 (31)



Special tools should be used to pull the bushing out or press it in. Special Tool: ST 1454 17



17



18



18



M157-07-157



W4-1-9



FRONT ATTACHMENT / Front Attachment REMOVE AND INSTALL 2-PIECE BOOM FRONT ATTACHMENT



1



Removal CAUTION: Prevent person from injury. Metal fragments may fly when a hammer is used to remove the pins. Be sure to wear necessary protection, such as goggles, hardhat and etc. 1. Remove grease hose (1) from the adapter on the boss at the boom cylinder rod side. (2 places both left and right) : 17 mm 2. Remove nuts (4) and bolts (6) from boom cylinder rod front pin (3). Then remove stopper (5). (2 places both left and right) : 24 mm



W1F3-04-01-007



1 2, 3 5



CAUTION: Boom cylinder weight: 160 kg (352 lb) 3. Hoist and hold the boom cylinder. By using a bar and hammer drive pin (3) into the position where thrust plate (2) can be removed. NOTE: When pin (3) cannot be removed, start the engine and operate the boom lever to adjust the hole position of the boom cylinder piston rod end.



4, 6 Boom Cylinder



W1F3-04-01-008



W4-1-10



FRONT ATTACHMENT / Front Attachment 4. Place the boom cylinder on a bench of 1 m height. Start the engine. Operate the boom lever to retract the boom cylinder. Secure the boom cylinder rod as illustrated by using a wire. Stop the engine.



Bench



Boom Cylinder



5. Remove the boom cylinder. Refer to “Remove Boom Cylinder” on page W4-2-10.



Wire



6. Remove other boom cylinder in the same procedures as steps 3 to 5. W554-02-03-007



CAUTION: The pin sometimes comes out suddenly. Be sure no one stands in the way. 7. Tap pin (3) out by using a bar and hammer. Remove thrust plate (2). 8. After stopping the engine, push the pressure release button on the air breather to release any remaining pressure from the hydraulic oil tank. Remove the cap to release the residual pressure from the hydraulic circuit. Refer to “Hydraulic Circuit Pressure Release Procedure” on page W4-1-1.



Pressure Release Button Cap Hydraulic Oil Tank



7



W1F3-01-04-002



9. Disconnect hoses (7, 8) for bucket cylinder and arm cylinder. Attach a cap onto all the open ends of disassembled hoses. : 36 mm



8



W4-1-11



W1F3-04-01-013



FRONT ATTACHMENT / Front Attachment 10. Open cover (9). Remove bolts (10) (4 used) and cover (11). : 17 mm



9



11



W4-1-12



10



W1F3-02-03-001



FRONT ATTACHMENT / Front Attachment CAUTION: Boom foot pin (12) weight: 33 kg (73 lb)



12



11. Remove bolt (15), spring washer (16), plate (14) and block (13) from the plate of boom foot pin (12). : 27 mm



13 14 15 16 W178-04-01-001



Boom and Arm Cylinder Center of Gravity



A B



Front Attachment Assembly Center of Gravity



CAUTION: Front attachment weight: 3212 kg (7081 lb) 12. Attach a wire rope onto the boom. Slightly hoist to take up any slack of wire rope.



F



E D C W1F3-04-01-001



Unit: mm (in)



13. Insert a bar between the plate of boom foot pin (12) and the bracket. Slightly pull the plate out. 14. Pull boom foot pin (12) out while rotating the plate slowly by hand. NOTE: When boom foot pin (12) cannot be removed, adjust the position of the boom foot pin hole by hoisting and lowering the front attachment.



A



3155 (124)



B



2573 (101)



C



4031 (159)



D



944 (37)



E



1750 (69)



F



2286 (90)



12



Plate



Insert a bar. Bracket



15. After hoisting the front attachment, move the W178-04-01-001



machine backward. 16. Place the front attachment on wooden blocks.



W4-1-13



FRONT ATTACHMENT / Front Attachment Installation Boom and Arm Cylinder Center of Gravity



CAUTION: Prevent person from injury. Metal fragments may fly when a hammer is used to install the pins. Be sure to wear necessary protection, such as goggles, hardhat and etc.



A



Front Attachment Assembly Center of Gravity



B



CAUTION: Front attachment weight: 3212 kg (7081 lb) 1. Hoist the front attachment. Move the machine forward, aligning the boom foot pin holes. Insert the thrust plates into boom left and right sides and adjust the clearance between the plate and frame within 1 mm. (Adjust the position of the boom foot pin hole by hoisting and lowering the front attachment.)



F



E D C W1F3-04-01-001



Unit: mm (in) A



3155 (124)



B



2573 (101)



C



4031 (159)



D



944 (37)



E



1750 (69)



F



2286 (90)



2. Drive in boom foot pin (12). Install stopper bolt (15), washer (16), plate (14) and block (13). : 27 mm : 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)



12



13 14 15 16



3. Install cover (11) with bolts (10) (4 used). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)



W178-04-01-001



9



4. Close cover (9).



11



W4-1-14



10



W1F3-02-03-001



FRONT ATTACHMENT / Front Attachment 5. Remove the caps from hoses and pipings. Install bucket cylinder hoses (7) and arm cylinder hoses (8). : 36 mm : 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)



CAUTION: Boom cylinder weight: 160 kg (352 lb)



7



8



W1F3-04-01-013



6. Install the boom cylinder. Refer to “Install Boom Cylinder” on page W4-2-12. 7. Hoist the boom cylinder. Insert thrust plates (2) (2 used), and then drive in pin (3) to install boom cylinders to both sides. 8. Install stopper (5) and secure it with bolt (6) and nuts (4) (2 used). (2 places both left and right) : 30 mm : 550 N⋅m (56 kgf⋅m, 405 Ibf⋅ft)



Boom Cylinder



W105-04-02-040



1 2, 3 5



4, 6 Boom Cylinder



W1F3-04-01-008



W4-1-15



FRONT ATTACHMENT / Front Attachment 9. Connect grease pipe (1) onto the boss at boom cylinder rod side. (2 places both left and right) : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)



1



W1F3-04-01-007



10. Add grease to the boom cylinder rod side, bottom side and boom foot side.



Right Boom Cylinder Rod Side Arm Cylinder Bottom Side Lift Boom Cylinder Rod Side



Second Boom Foot Side Left Boom Foot Side Right Boom Foot Side MCBB-07-007



W4-1-16



FRONT ATTACHMENT / Front Attachment 11. Install thrust plates (17) into arm left and right sides. Adjust total clearance of left and right within 1.5 mm or less.



Arm and Bucket Center of Gravity



12. After installing arm, add grease to grease fitting (18) on the boom-connecting boss of the arm. IMPORTANT: For handling of HN bushing for the front attachment, check following requirements. Precautions for pressing the bushing in: If a hammer is used to drive the bushing in, the bushing may be damaged. Use a press. Precautions when reinforcing the arm: Welding heat for arm reinforcement may cause oil to leak from the bushing and decrease lubrication performance. If oil leak occurs because of heated bushing after welding, replace the bushing.



D C W1F3-04-01-001



Unit: mm (in) C



4031 (159)



D



944 (37)



307±1.0 mm (12±0.04 in)



Special tools should be used to pull the bushing out or press it in. Special Tool: ST 1454



17



17 W1GL-04-01-012



18



W1GL-04-01-011



W4-1-17



FRONT ATTACHMENT / Front Attachment MAINTENANCE STANDARD Pin and Bushing N F C



L



A



M



B



E D



I



G



K



J



H W1GL-04-01-002



W1F3-04-01-001



Unit: mm (in)



Item A



B



C



D



E



F



Standard



Allowable Limit



Pin



80 (3.15)



79.0 (3.11)



Bushing



80 (3.15)



81.5 (3.21)



Pin



80 (3.15)



79.0 (3.11)



Boss (Main Frame)



80 (3.15)



81.5 (3.21)



Bushing (Boom Cylinder)



80 (3.15)



81.5 (3.21)



Pin



80 (3.15)



79.0 (3.11)



Bushing (Boom Cylinder)



80 (3.15)



81.5 (3.21)



Boss (Boom)



80 (3.15)



81.5 (3.21)



Pin



80 (3.15)



79.0 (3.11)



Bushing



80 (3.15)



81.5 (3.21)



Pin



71 (2.80)



70.0 (2.76)



Boss (Arm)



71 (2.80)



72.5 (2.85)



Bushing (Arm Cylinder)



71 (2.80)



72.5 (2.85)



Pin



71 (2.80)



70.0 (2.76)



Boss (Boom)



71 (2.80)



72.5 (2.85)



Bushing (Arm Cylinder)



71 (2.80)



72.5 (2.85)



W4-1-18



Remedy



Replace



FRONT ATTACHMENT / Front Attachment Unit: mm (in)



Item



G



H



I



J



K



L



M



N



Standard



Allowable Limit



Pin



65 (2.56)



64.0 (2.52)



Boss (Arm)



65 (2.56)



66.5 (2.62)



Bushing (Bucket Cylinder)



65 (2.56)



66.5 (2.62)



Pin



71 (2.80)



70.0 (2.76)



Bushing



71 (2.80)



72.5 (2.85)



Bushing (Bucket Cylinder)



71 (2.80)



72.5 (2.85)



Pin



71 (2.80)



70.0 (2.76)



Bushing



71 (2.80)



72.5 (2.85)



Pin



80 (3.15)



79.0 (3.11)



Bushing



80 (3.15)



81.5 (3.21)



Pin



80 (3.15)



79.0 (3.11)



Bushing



80 (3.15)



81.5 (3.21)



Pin



110 (4.33)



109.0 (4.29)



Bushing



110 (4.33)



111.5 (4.39)



Pin



110 (4.33)



109.0 (4.29)



Bushing



110 (4.33)



111.5 (4.39)



Pin



80 (3.15)



79.0 (3.11)



Bushing



80 (3.15)



81.5 (3.21)



IMPORTANT: When replacing HN bushing, press fit it in with a press.



W4-1-19



Remedy



Replace



FRONT ATTACHMENT / Front Attachment Point



B



C



A



D



W105-04-01-020



Unit: mm (in)



A



Standard



Allowable Limit



178.5 (7.028)



90 (3.54)



B



79 (3.11)



－



C



95 (3.74)



－



D



81 (3.19)



－



Remedy



Replace



Side Cutter B



C D A



W155-04-01-002



Unit: mm (in)



Standard



Allowable Limit



A



229 (9.02)



149 (5.87)



B



245 (9.65)



－



C



330 (12.99)



－



D



135 (5.32)



－



W4-1-20



Remedy



Replace



FRONT ATTACHMENT / Front Attachment STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION



W1CF-04-01-007



Section B



Section A



Unit: mm (in)



a



370 (14.6)



b



0



c



540 (21.3)



d



520 (20.5)



e



－



f



1430 (56.3)



g



449 (17.7)



h



326 (12.8)



i



80 (3.15)



j



400 (15.7)



k



31 (1.22)



l



433 (17.0)



m



307 (12.1)



n



80 (3.1)



o



90°



p



60°



q



449 (17.7)



W4-1-21



FRONT ATTACHMENT / Front Attachment STANDARD DIMENSIONS FOR ARM AND BOOM CONNECTION



C



W1F3-04-01-004



C



W1F3-04-01-003



Section C W1GL-04-01-010



Unit: mm (in)



s



80 (3.15)



t



307 (12.1)



u



421 (16.6)



W4-1-22



FRONT ATTACHMENT / Cylinder REMOVE AND INSTALL CYLINDER (MONOBLOCK BOOM, 2-PIECE BOOM) 1



Remove Bucket Cylinder CAUTION: Prevent person from injury. Metal fragments may fly when a hammer is used to remove the pins. Be sure to wear necessary protection, such as goggles, hardhat and etc.



3 2 3



1. Insert wooden block (3) between bucket cylinder (1) and arm (2).



W554-04-02-006



4



2. After stopping the engine, push the pressure release button on the air breather to release any remaining pressure from the hydraulic oil tank. Then remove the cap. Release the bucket circuit pressure. (Refer to “Hydraulic Circuit Pressure Release Procedure” on page W4-1-1.) CAUTION: Secure the link with a wire to prevent it from falling before pushing pin (7) out.



5



6



7 1 8



W158-04-02-006



3. Remove nut (6) and bolt (4). Push out pin (7). Remove thrust plate (5). : 30 mm 4. To prevent rod (8) of bucket cylinder (1) from extending, pass wire (9) through the cylinder rod hole and secure wire (9) to the bucket cylinder (1) tube. 9



W4-2-1



W102-04-02-005



FRONT ATTACHMENT / Cylinder 5. Disconnect bucket cylinder hoses (12) (2 used) at the bucket cylinder (1) bottom. Attach caps onto the open ends. : 36 mm



10



CAUTION: Bucket cylinder weight: 125 kg (280 lb)



15



6. Lift bucket cylinder (1) off. Remove nut (13) and bolt (15). Push pin (11) out. Remove thrust plate (10).



11



13



7. Remove bucket cylinder (1). 1



12



W4-2-2



W187-04-02-004



FRONT ATTACHMENT / Cylinder Install Bucket Cylinder IMPORTANT: When pressing the bushing in, if a hammer is used, the bushing may be damaged. Use a press.



10



CAUTION: Prevent person from injury. Metal fragments may fly when a hammer is used to install the pins. Be sure to wear necessary protection, such as goggles, hardhats and etc.



15 14 13



11



CAUTION: Bucket cylinder weight: 125 kg (280 lb) 1. Lift bucket cylinder (1). Align cylinder tube side pin hole with the bucket cylinder mounting hole on arm. Install thrust plate (10) and pin (11).



1



2. Insert bolt (15) into arm stopper (14) and pin (11). Install nut (13). : 180 N⋅m (18.5 kgf⋅m, 133 Ibf⋅ft)



12



3. Connect the bucket cylinder hoses (12) (2 used). : 36 mm : 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)



8



W187-04-02-004



1



4. Remove wire (9) from rod (8) of bucket cylinder (1).



9



W4-2-3



W102-04-02-005



FRONT ATTACHMENT / Cylinder 5. Start the engine and operate the bucket lever to align the cylinder rod side pin hole with those of links (16, 18). Insert thrust plate (5) and pin (7).



16



4



17



7



18



5



6. Insert bolt (4) into stopper (17) and pin (7). Install nut (6). : 30 mm : 550 N⋅m (56 kgf⋅m, 410 Ibf⋅ft) IMPORTANT: In case link (18) has been removed from the arm, never forget to reinsert thrust plate (19). IMPORTANT: Fill the hydraulic oil to the specified level after installation. Start the engine. Fully stroke each cylinder several times to bleed any air remaining in the circuit. Check for any oil leakage.



W158-04-02-006



19



18



W4-2-4



6



19



18



W157-04-01-015



FRONT ATTACHMENT / Cylinder Remove Arm Cylinder 1



CAUTION: Prevent person from injury. Metal fragments may fly when a hammer is used to remove the pins. Be sure to wear necessary protection, such as goggles, hardhat and etc.



2



1. Insert wooden block (3) between arm cylinder (1) and boom (2). 2. After stopping the engine, push the pressure release button on the air breather to release any remaining pressure from the hydraulic oil tank. Then remove the cap. Release the arm circuit pressure. (Refer to “Hydraulic Circuit Pressure Release Procedure” on page W4-1-1.)



3 W187-04-02-005



4



10



5 1



3. Remove nut (8) and bolt (10) from pin (5) at the arm cylinder (1) rod side. : 30 mm 4. Push pin (5) out. Remove thrust plate (4). 8 W187-04-02-006



6



1



5. To prevent arm cylinder (1) rod (6) from extending, pass wire (7) through the cylinder rod hole and secure wire (7) to the arm cylinder (1) tube. 7



W187-04-02-010



W4-2-5



FRONT ATTACHMENT / Cylinder 6. Disconnect hoses (11) (2 used) from the bottom of arm cylinder (1). Attach a cap onto the open ends. In case the hose-rupture safety valve is equipped, refer to the “Remove and Install Hose-Rupture Safety Valve”. : 36 mm



Monoblock Boom 12 1



7. Disconnect grease hose (12) from arm cylinder (1). 11



W1F3-04-01-005



2-Piece Boom 1



11



11



12



W1F3-04-01-007



CAUTION: Arm cylinder weight: 210 kg (460 lb)



1



8. Attach a sling at the arm cylinder (1) center of gravity. Lift arm cylinder (1) off.



9. Remove nuts (15) and bolt (17) from the tube side of arm cylinder (1). Push out pin (14). Remove thrust plates (13) and remove arm cylinder (1). : 30 mm



17



W102-04-02-016



13 14



1



15



W187-04-02-007



W4-2-6



FRONT ATTACHMENT / Cylinder Install Arm Cylinder



13



17



IMPORTANT: When pressing the bushing in, if a hammer is used, the bushing may be damaged. Use a press. CAUTION: Prevent person from injury. Metal fragments may fly when a hammer is used to install the pins. Be sure to wear necessary protection, such as goggles, hardhat and etc. CAUTION: Arm cylinder weight: 210 kg (460 lb)



14



1



16



15



W187-04-02-007



Monoblock Boom 12



1. Attach a sling at arm cylinder (1) where can make the cylinder level. Lift arm cylinder (1). Align the cylinder tube side hole with the arm cylinder mounting hole on boom.



1



2. Install thrust plate (13) and pin (14). Install bolt (17) to pin (14) and stopper (16). Then install nut (15). : 30 mm : 550 N⋅m (56 kgf⋅m, 410 Ibf⋅ft) 3. Connect grease hose (12) and the arm cylinder hoses (11) (2 used). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft) : 41 mm : 205 N⋅m (21 kgf⋅m, 151 Ibf⋅ft)



11



W1F3-04-01-005



2-Piece Boom



IMPORTANT: Fill hydraulic oil to the specified level. Start the engine. Check the connections for any oil leakage.



1



11



11



12



W1F3-04-01-007



W4-2-7



FRONT ATTACHMENT / Cylinder 4. Remove wire (7) from arm cylinder (1) rod (6). Lift arm cylinder (1) off. Start the engine. Operate the arm lever and align the arm cylinder rod side pin hole with the arm cylinder mounting hole on arm (18).



6



1



18



5. Install thrust plate (3) and pin (5). Install bolt (10) to pin (5) and stopper (9), and put nut (8) on bolt (10). : 30 mm : 550 N⋅m (56 kgf⋅m, 410 Ibf⋅ft)



7



W187-04-02-010



10



IMPORTANT: After installation, operate the cylinder several times to stroke end to bleed air from the circuit.



9



4



5



18



8 W187-04-02-006



W4-2-8



FRONT ATTACHMENT / Cylinder Remove Boom Cylinder



Monoblock Boom 1



CAUTION: Prevent person from injury. Metal fragments may fly when a hammer is used to remove the pins. Be sure to wear necessary protection, such as goggles, hardhat and etc. 1. Remove grease hoses (1) from boom cylinder. CAUTION: Boom cylinder weight: 150 kg (330 lb) 2. Attach a wire rope to boom cylinder (2) and lift boom cylinder (2) off.



2-Piece Boom



W1F3-04-01-007



1



4



5



4, 6



2



3. Remove nut (5), bolt (7) and stopper (6) from the boom cylinder (2) rod to push pin (4) out. Remove thrust plate (3). : 27 mm 4. Place boom cylinder (2) on a bracket. Remove boom cylinder at other side by the same method.



W1F3-04-01-008



7



5. Operate the boom lever to retract the boom. To prevent the boom cylinder (2) rod from stretching, pass the wire through the cylinder rod hole and secure the wire to the cylinder tube.



6



6. After stopping the engine, push the pressure release button on the air breather to release any remaining pressure from the hydraulic oil tank. Then remove the cap. Release the boom circuit pressure. (Refer to “Hydraulic Circuit Pressure Release Procedure” on page W4-1-1.)



5



3



4



3



2 W158-04-02-013



Bench



2 W105-04-02-035



W4-2-9



FRONT ATTACHMENT / Cylinder 7. Remove hoses (12) (4 used) from boom cylinder (2) at the boom cylinder bottom. Cover all openings with plug to hoses and with cap to boom cylinder. In case the hose-rupture safety valve is equipped, refer to the “Remove and Install Hose-Rupture Safety Valve”. Plug: 13/16-12UNF : 36 mm 2



8. Loosen nut (10) at the boom cylinder bottom side of the main frame and remove bolt (8). Remove pin (9) completely. Remove thrust plate (11). : 24 mm



11



W105-04-02-036



2 8



9 9 12



10



10 W178-04-02-009



CAUTION: Boom cylinder weight: 150 kg (330 lb) 9. Attach a wire rope at boom cylinder (2) where can make the cylinder level. Lift boom cylinder (2) off. Remove boom cylinder at other side by the same method. 2 W105-04-02-040



W4-2-10



FRONT ATTACHMENT / Cylinder Install Boom Cylinder IMPORTANT: When pressing the bushing in, if a hammer is used, the bushing may be damaged. Use a press. CAUTION: Prevent person from injury. Metal fragments may fly when a hammer is used to install the pins. Be sure to wear necessary protection, such as goggles, hardhat and etc. CAUTION: Boom cylinder weight: 150 kg (330 lb) 2



1. Attach a sling at boom cylinder (2) where can make the cylinder level. Lift boom cylinder (2). Align the cylinder tube side hole with the boom cylinder mounting hole on boom. 2. Insert thrust plate (11) and pin (9). Install bolt (8), then tighten with nut (10). : 24 mm : 270 N⋅m (27.5 kgf⋅m, 200 Ibf⋅ft)



W105-04-02-040



11



2 8



3. Install the boom cylinder at other side by same method. 4. Connect hoses (12) (4 used) on boom cylinders (2) (2 used). : 36 mm : 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft) IMPORTANT: Fill hydraulic oil to the specified level. Start the engine. Check the connections for any oil leakage.



W4-2-11



9 9 12



10



10 W178-04-02-009



FRONT ATTACHMENT / Cylinder 5. Lift boom cylinder (2). Operate the boom lever. Align the pin hole at cylinder rod side with the mounting hole of the boom cylinder. 7



6. Install thrust plate (3) and pin (4). 7. Install bolt (7) to pin (4) and stopper (6). Then install nut (5). : 30 mm : 550 N⋅m (56 kgf⋅m, 410 Ibf⋅ft)



6 5



3



4



3



2 W158-04-02-013



Monoblock Boom 1



8. Connect grease hoses (1). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft) 9. Install the boom cylinder at other side by same method. IMPORTANT: After installation, operate the cylinder several times to stroke end to bleed air from the circuit.



W1F3-04-01-007



2-Piece Boom 4



5, 6



1



2



W1F3-04-01-008



W4-2-12



FRONT ATTACHMENT / Cylinder Remove Positioning Cylinder (2-Piece Boom Only) CAUTION: Prevent person from injury. Metal fragments may fly when a hammer is used to remove the pins. Be sure to wear necessary protection, such as goggles, hardhat and etc.



4



CAUTION: Positioning cylinder weight: 305 kg (670 lb)



2



1. Attach a nylon sling to positioning cylinder (3). Lift and hold positioning cylinder (3). 2. After stopping the engine, push the pressure release button on the air breather to release any remaining pressure from the hydraulic oil tank. Then remove the cap. Release the positioning circuit pressure. (Refer to “Hydraulic Circuit Pressure Release Procedure” on page W4-1-1.) 3. Remove nuts (5) (2 used) and bolt (1) from stopper (4) of the second boom. : 30 mm



1、5 10, 11



3



9



8



W1F3-04-04-003



6



3



4. Drive pin (2) into the second boom at approx. 160 mm (6.3 in) 5. Disconnect hoses (6) (2 used) and hoses (7) (3 used) from positioning cylinder (3). Attach caps onto the open ends. : 19 mm, 36 mm



7



6. Remove nuts (10) (2 used) and bolt (11) from stopper (8) of the first boom. Drive pin (9) in by using a bar and hammer. : 30 mm CAUTION: Positioning cylinder weight: 305 kg (670 lb)



W1F3-04-03-001



7. Lift positioning cylinder (3) off.



W4-2-13



FRONT ATTACHMENT / Cylinder Install Positioning Cylinder CAUTION: Prevent person from injury. Metal fragments may fly when a hammer is used to install the pins. Be sure to wear necessary protection, such as goggles, hardhat and etc.



4



CAUTION: Positioning cylinder weight: 305 kg (670 lb) 2, 13



1. Lift positioning cylinder (3). Align the pin holes on both cylinder bottom side and first boom. Install thrust plate (12) and drive pin (9). 2. Align the pin holes of stopper (8) and pin (9). Install bolt (11) and nuts (10) (2 used). : 30 mm : 550 N⋅m (56.0 kgf⋅m, 406 lb) IMPORTANT: Fill hydraulic oil to the specified level. Start the engine. Check the connections for any oil leakage. 3. Connect hoses (7) (3 used) and (6) (2 used) to positioning cylinder (3). : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 22 lb) : 36 mm : 175 N⋅m (18.0 kgf⋅m, 129 lb) 4. Start the engine, extend positioning cylinder (3). Align the pin holes of the positioning cylinder (3) rod and the second boom. Install thrust plate (13) and drive pin (2).



1, 5 10, 11



3



9, 12



8



W1F3-04-04-003



6



3



7



5. Align the pin holes of stopper (4) and pin (2). Install bolt (1) and nuts (5) (2 used). : 30 mm : 550 N⋅m (56.0 kgf⋅m, 406 lb) IMPORTANT: After installation, operate the cylinder several times to stroke end to bleed air from the circuit.



W4-2-14



W1F3-04-03-001



FRONT ATTACHMENT / Cylinder Remove Blade Cylinder IMPORTANT: Before working, lower the blade onto the ground.



1



CAUTION: Prevent person from injury. Metal fragments may fly when a hammer is used to remove the pins. Be sure to wear necessary protection, such as goggles, hardhat and etc.



2



1. Remove bolts (2) (4 used) to remove protection cover (1). : 19 mm 2. After stopping the engine, push the pressure release button on the air breather to release any remaining pressure from the hydraulic oil tank. Then remove the cap. Release the blade circuit pressure. (Refer to “Hydraulic Circuit Pressure Release Procedure” on page W4-1-1.)



W1GL-04-01-013



3, 4



5



6



7



3. Disconnect hoses (10) (4 used) from blade cylinder (8). Cap the disconnected hose ends. : 19 mm, 27 mm CAUTION: Blade cylinder (8) weight: 70 kg (155 lb) 4. Attach a nylon sling to blade cylinder (8). Lift and hold blade cylinder (8). 5. Remove nuts (6) (8 used) and bolts (5) (2 used). Pull out pins (3) (2 used). Remove thrust plate (4) from the both blade cylinder (8) bottom and rod sides. : 24 mm 6. Lift blade cylinder (8) off.



W4-2-15



8



W1GL-04-02-004



10 3, 4, 5, 6



9



FRONT ATTACHMENT / Cylinder Install Blade Cylinder 3, 4



5



6



7



CAUTION: Prevent person from injury. Metal fragments may fly when a hammer is used to install the pins. Be sure to wear necessary protection, such as goggles, hardhat and etc. CAUTION: Blade cylinder (8) weight: 55 kg (120 lb)



8



1. Lift and hold blade cylinder (8). Align the pin (3) holes of the blade cylinder (8) bottom side and bracket (7) and the rod side and blade (9). Install thrust plate (4) and drive pins (3) (2 used). Install bolts (5) (2 used) and nuts (6) (4 used). : 24 mm : 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft) 2. Connect hoses (10) (4 used) to blade cylinder (8). : 19 mm : 24.5 N⋅m (2.5 kgf⋅m, 18.0 lbf⋅ft) : 27 mm : 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)



W1GL-04-02-004



10 3, 4, 5, 6



9 1



2



3. Install protection cover (1) to blade cylinder (8) with bolts (2) (4 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) IMPORTANT: After installation, operate the cylinder several times to stroke end to bleed air from the circuit. W1GL-04-01-013



W4-2-16



FRONT ATTACHMENT / Cylinder Remove Stabilizer Cylinder In this section, the procedure starts on the premise that the stabilizer operate-check valve has already been removed. For removal and installation of the operate-check valve, refer to “Remove and Install Operate-Check Valve” section.



1, 2, 3, 4



6



5



7



8



9



CAUTION: Prevent person from injury. Metal fragments may fly when a hammer is used to remove the pins. Be sure to wear necessary protection, such as goggles, hardhat and etc.



10, 11 12



1. Remove bolts (9) (3 used) to remove cover (7). : 17 mm Operate-Check Valve



2. After stopping the engine, push the pressure release button on the air breather to release any remaining pressure from the hydraulic oil tank. Then remove the cap. Release the stabilizer circuit pressure. (Refer to “Hydraulic Circuit Pressure Release Procedure” on page W4-1-1.)



W1F3-04-01-011



13 7



9



3. Disconnect hoses (13) (2 used) from stabilizer cylinder (6). Attach caps onto the open ends. : 19 mm, 27 mm 4. Attach a nylon sling to the rod side of the stabilizer cylinder (6) tube. Lift stabilizer cylinder (6) off.



Operate-Check Valve Hose



W1F3-04-01-012



5



5. Remove bolts (12) (3 used), pin (10) and thrust plate (11) from stabilizer (8). : 17 mm



7 9



CAUTION: Stabilizer cylinder weight: 88 kg (195 lb)



10, 11



6. Lift stabilizer cylinder (6) off. Insert the sleeper under the stabilizer cylinder (6) tube.



6



7. Remove ring (2) and lock pin (3) of the stabilizer cylinder (6) bottom side. Pull out pin (1). 8. Pull out stabilizer cylinder (6) from stabilizer beam (5).



W4-2-17



12 Sleeper



8



W1GL-04-02-006



FRONT ATTACHMENT / Cylinder Install Stabilizer Cylinder 5



CAUTION: Prevent person from injury. Metal fragments may fly when a hammer is used to install the pins. Be sure to wear necessary protection, such as goggles, hardhat and etc.



7 9 10, 11



CAUTION: Stabilizer cylinder weight: 88 kg (195 lb) 1. Lift stabilizer cylinder (6). Align the pin (1) holes of the stabilizer cylinder (6) bottom side and stabilizer beam (5). Install thrust plate (4) and drive pin (1).



6



12 Sleeper



8



2. Install lock pin (3) and ring (2) to pin (1).



W1GL-04-02-006



3. Connect hoses (13) (2 used) onto stabilizer cylinder (6). : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft) : 27 mm : 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)



13 7



9



4. Start the engine and extend stabilizer cylinder (6) to align the rod with connecting pin hole. 5. Install thrust plate (11), pin (10) and bolts (12) (3 used) to stabilizer (8). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 6. Install cover (7) with bolts (9) (3 used). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)



Operate-Check Valve Hose



1, 2, 3, 4



IMPORTANT: After installation, operate the cylinder several times to stroke end to bleed air from the circuit.



5



W1F3-04-01-012



6



7



8



9 10, 11 12



W1F3-04-01-011



W4-2-18



FRONT ATTACHMENT / Cylinder (Blank)



W4-2-19



FRONT ATTACHMENT / Cylinder DISASSEMBLE CYLINDER (BOOM (MONOBLOCK/2-PIECE BUCKET)



and



Boom Cylinder (Monoblock/2-Piece Boom)



14



20



16 15



13



19



17



16



18



20



19



11



1



21



22



24



2



4



3



7



5



6



10



9



8



12



23 W158-04-02-016



Bucket Cylinder



11



1



2



3



7



4



5



6



9



10



8



20 19



16 123456-



Wiper Ring Backup Ring U-Ring Buffer Ring Bushing Snap Ring



15



20



17 18



16 78910 11 12 -



19



21



22



24



23



12



Cylinder Head Socket Bolt (12 Used) Backup Ring O-Ring Piston Rod Cylinder Tube



W1F3-04-04-005



13 14 15 16 17 18 -



W4-2-20



Cushion Bearing Cushion Seal Piston Backup Ring (2 Used) Seal Ring O-Ring



19 20 21 22 23 24 -



Slide Ring (2 Used) Slide Ring (2 Used) Shim Set Screw Steel Ball Nut



FRONT ATTACHMENT / Cylinder Disassemble Boom (Monoblock/2-Piece and Bucket Cylinders • Be sure to read “Precautions for Disassembly and Assembly” thoroughly on page W1-1-1 before starting the repair work. The disassembly procedure below starts on the premise that the hydraulic lines and the line securing bands have been removed. CAUTION: Cylinder weight: Boom cylinder (Monoblock): 150 kg (330 lb) Boom cylinder (2-Piece): 160 kg (350 lb) Bucket cylinder: 125 kg (275 lb) 1. Lift and horizontally secure the cylinder on a workbench. Then, drain the hydraulic oil from the cylinder.



5. Remove set screw (22) and steel ball (23). NOTE: Set screw (22) was crimped with a punch in two places after it was tightened. Before loosening set screw (22), cut away the crimped portions. 6. Loosen nut (24) using special tool (ST 5908). Remove piston (15), shim (21) and cushion bearing (13). In case of the boom cylinder remove cushion seal (14). Tools for turning nut: Boom : 85 mm (ST 3304) Bucket : 80 mm (ST 3262) ST 5908



W158-04-02-022



W102-04-02-027



2. Fully extend cylinder rod (11). Hold the rod end. Remove socket bolts (8) from cylinder head (7). 3. Pull out cylinder head (7) from cylinder tube (12) by tapping by using a plastic hammer. IMPORTANT: Be sure to pull out piston rod (11) straight to prevent the sliding surfaces from being damaged. 4. Secure cylinder rod (11) on special tool (ST 5908). Put matching marks between cylinder rod (11) and nut (24).



7. Remove seal ring (17), slide rings (19, 20) (2 used for each), O-ring (18) and backup rings (16) (2 used) from piston (15). 8. Remove cylinder head (7) from cylinder rod (11). 9. Remove O-ring (10) and backup rings (9, 2) from cylinder head (7). Then remove wiper ring (1), U-ring (3), backup ring (4), snap ring (6) and bushing (5). Tools for removing bushing: Boom : 80 mm (ST 8019/ST 1286) Bucket : 75 mm (ST 8018/ST 1285)



ST 5908



W158-04-02-022



W4-2-21



FRONT ATTACHMENT / Cylinder ASSEMBLE CYLINDER (BOOM (MONOBLOCK/2-PIECE BUCKET)



and



Boom Cylinder (Monoblock/2-Piece Boom)



Be sure with the slit facing piston (15).



Hole (1 Place)



1



2



3



4



5



6



7



8



9, 10



11



12 13



14



15



16



17, 18 19



20



21



21 22, 23 24



Be sure with oil groove facing correct direction when assembling



W1F1-04-02-001



Bucket Cylinder



Hole (1 Place)



1



2



3



4 5



6



7



8



9, 10



11



12



13



15



16



17, 18



19 20 21 22, 23 24



Be sure with oil groove facing correct direction when assembling



123456-



Wiper Ring Backup Ring U-Ring Buffer Ring Bushing Snap Ring



78910 11 12 -



Cylinder Head Socket Bolt (12 Used) Backup Ring O-Ring Piston Rod Cylinder Tube



13 14 15 16 17 18 -



W4-2-22



Cushion Bearing Cushion Seal Piston Backup Ring (2 Used) Seal Ring O-Ring



19 20 21 22 23 24 -



W1F1-04-02-002



Slide Ring (2 Used) Slide Ring (2 Used) Shim Set Screw Steel Ball Nut



FRONT ATTACHMENT / Cylinder Assemble Boom Bucket Cylinders



(Monoblock/2-Piece)



and



1. Press bushing (5) into cylinder head (7). Tools for installing bushing: Boom : 80 mm (ST 8019/ST1286) Bucket : 75 mm (ST 8018/ST1285)



8. Install shim (21) to cylinder rod (11). Tighten nut (24) using special tool (ST 5908) while aligning the matching mark on the rod with that on nut (24). ST 5908



IMPORTANT: Be sure to install rings in correct direction. 2. Install U-ring (3), backup ring (2), buffer ring (4), and snap ring (6) to cylinder head (7). 3. Install wiper ring (1) to cylinder head (7) by using a plastic hammer. Tools for installing wiper ring: Boom : ST 8019/1297 Bucket : ST 8018/1296



W158-04-02-022



Tools for tightening nut: Boom : 85 mm (ST 3304) Bucket : 80 mm (ST 3262) Boom cylinder : 3800 N⋅m (390 kgf⋅m, 2800 lbf⋅ft) Bucket cylinder : 4780 N⋅m (490 kgf⋅m, 2800 lbf⋅ft)



4. Install O-ring (10) and backup ring (9) to cylinder head (7). IMPORTANT: When installing slide rings (19) and (20), do not align their split portion. 5. Install O-ring (18), backup rings (16) (2 used), seal ring (17), and slide rings (19, 20) (2 used for each) to piston (15).



9. Align the holes of piston rod (11) and nut (24), then install steel ball (23).



6. Install the cylinder head (7) assembly into piston rod (11). Tools for installing cylinder head: Boom : ST 8019/2345 Bucket : ST 8018/2344



10. Crimp the head of set screw (22) at two places with a punch. : 10 mm : 57±10.5 N⋅m (5.8±1.1 kgf⋅m, 42±7.7 lbf⋅ft)



IMPORTANT: Be sure that the slit in cushion seal (14) is facing piston and that the oil groove in cushion bearing (13) is facing correct direction. 7. Install cushion bearing (13) to piston rod (11). Install the piston (15) assembly to the piston rod (11). In case of the boom cylinder, install cushion seal (14).



IMPORTANT: Take care not to damage rings. Install the piston rod (11) assembly into cylinder tube (12) while aligning it with the center of cylinder tube (12). 11. Horizontally secure cylinder tube (12) on a workbench. Insert the piston rod (11) assembly into cylinder tube (12).



13 Oil Groove Nut Side Head Side



12. Install cylinder head (7) into cylinder tube (12) with socket bolts (8) (12 used). : 10 mm : 171 N⋅m (17.5 kgf⋅m)



Nut Side



W18B-04-02-011



W4-2-23



FRONT ATTACHMENT / Cylinder DISASSEMBLE CYLINDER (Positioning) Positioning Cylinder



1



2



3



4



5



6



7



8



9



10



11



12



13



14



15



17



18 19



22



Hole (1 Place)



16



123456-



Wiper Ring Backup Ring U-Ring Buffer Ring Bushing Retaining Ring



20 21



78910 11 12 -



Cylinder Head Socket Bolt (2 Used) Backup Ring O-Ring Piston Rod Cylinder Tube



13 14 15 16 17 18 -



W4-2-24



Piston Backup Ring (2 Used) Seal Ring O-Ring Slide Ring Slide Ring



W1F3-04-04-007



19 20 21 22 -



Shim Nut Set Screw Steel Ball



FRONT ATTACHMENT / Cylinder Disassemble Positioning Cylinder • Be sure to thoroughly read all “Precautions for Disassembly and Assembly Work” on page W1-1-1 before starting the disassembly work. The disassembly procedure below starts on the premise that the hydraulic line and the line securing bands have been removed. CAUTION: Positioning Cylinder weight: 290 kg (640 lb) 1. Lift and place the cylinder horizontally on a work bench. Drain hydraulic oil from the cylinder.



5. Remove set screw (21) and steel ball (22). NOTE: Set screw (21) was crimped with a punch in two places after it was tightened. Before loosening set screw (21), cut away the crimped portions. 6. Loosen nut (20) using special tool (ST 5908). Remove piston (13) and shim (19) Tool for tightening nut: 135 mm (ST 3283) 7. Remove seal ring (15), slide rings (17, 18), O-ring (18), backup rings (14) (2 used) from piston (13). 8. Remove cylinder head (7) from piston rod (11). 9. Remove O-rings (10), backup rings (9, 2) from cylinder head (7). Then remove wiper ring (1), U-ring (3), buffer ring (4), snap ring (6), and bushing (5). Tool for removing bushing: 120 mm (ST 1374)



W102-04-02-027



2. Fully extend piston rod (11). Secure the rod end. Remove socket bolts (8) from cylinder head (7). IMPORTANT: Be sure to pull out piston rod (11) straight to prevent the sliding surfaces from being damaged. 3. Pull out cylinder head (7) from cylinder tube (12) by tapping by using a plastic hammer. 4. Secure cylinder rod (11) on special tool (ST 5908). Put matching mark between piston rod (11) and nut (20). ST 5908



W158-04-02-022



W4-2-25



FRONT ATTACHMENT / Cylinder ASSEMBLE CYLINDER (Positioning) Positioning Cylinder



1



2



3



4



5



6



7



8



9



10



11



12



13



14



15



17



18 19



22



Hole (1 Place)



16



123456-



Wiper Ring Backup Ring U-Ring Buffer Ring Bushing Retaining Ring



20 21



78910 11 12 -



Cylinder Head Socket Bolt (2 Used) Backup Ring O-Ring Piston Rod Cylinder Tube



13 14 15 16 17 18 -



W4-2-26



Piston Backup Ring (2 Used) Seal Ring O-Ring Slide Ring Slide Ring



W1F3-04-04-007



19 20 21 22 -



Shim Nut Set Screw Steel Ball



FRONT ATTACHMENT / Cylinder Assemble Positioning Cylinder 1. Press bushing (5) into cylinder head (7). Tools for pressing bushing: 120 mm (ST 1374) IMPORTANT: Be sure to install rings in correct direction. 2. Install U-ring (3), backup ring (2), buffer ring (4), and snap ring (6) to cylinder head (7).



8. Install shim (19) to cylinder rod (11). Tighten nut (20) by using special tool (ST 5908) while aligning the matching mark on the rod with that on the nut. Tool for turning nuts:135 mm (ST 3283) : 14700 N⋅m (18 kgf⋅m, 130 Ibf⋅ft) ST 5908



3. Install wiper ring (1) to cylinder head (7) by using a plastic hammer. Wiper ring pressing tool ST 1480 4. Install O-ring (10) and backup ring (9) to cylinder head (7). 5. Install O-ring (16), backup ring (14) (2 used), seal ring (15), slide rings (17, 18) (2 used) to piston (13). 6. Install the cylinder head (7) assembly into piston rod (11). 7. Install the cylinder head (13) assembly into piston rod (11).



W158-04-02-022



9. Align the hole on cylinder rod (11) with that on nut (20). Insert steel ball (23) into the hole and tighten set screw (22). After tightening set screw (22), crimp the head of set screw (22) at two places with a punch. : 14 mm : 96.6±18.2 N⋅m (9.8±1.8 kgf⋅m, 71±13 lbf⋅ft) IMPORTANT: Be sure to keep cylinder rod (11) aligning with the center of cylinder tube (12) when inserting in order to avoid damaging rings. 10. Horizontally secure cylinder tube (12) on a workbench. Insert the piston rod (11) assembly into cylinder tube (12). 11. Install cylinder head (12) into cylinder tube (7) with socket bolts (8) (12 used). : 17 mm : 711 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)



W4-2-27



FRONT ATTACHMENT / Cylinder DISASSEMBLE CYLINDER (ARM) Arm Cylinder



1



11



2



3



4



7



5



6



9



10



8 14



20



19



15



13



16 17



18 19



25



16



20



26



28



27 21 24



22



12



23 W158-04-02-017



1234567-



Wiper Ring Backup Ring U-Ring Buffer Ring Bushing Snap Ring Cylinder Head



8910 11 12 13 14 -



Socket Bolt (12 Used) Backup Ring O-Ring Piston Rod Cylinder Tube Cushion Bearing Cushion Seal



15 16 17 18 19 20 21 -



W4-2-28



Piston Backup Ring (2 Used) Seal Ring O-Ring Slide Ring (2 Used) Slide Ring (2 Used) Shim



22 23 24 25 26 27 28 -



Set Screw Steel Ball Nut Snap Ring Cushion Seal Cushion Bearing Stopper (2 Used)



FRONT ATTACHMENT / Cylinder Disassemble Arm Cylinder • Be sure to read “Precautions for Disassembly and Assembly” thoroughly on page W1-1-1 before starting the repair work. The disassembly procedure below starts on the premise that the hydraulic lines and the line securing bands have been removed. CAUTION: Arm cylinder weight : 220 kg (490 lb)



5. Remove set screw (22) and steel ball (23). NOTE: Set screw (22) was crimped with a punch in two places after it was tightened. Before loosening set screw (22), cut away the crimped portions. 6. Loosen nut (24) using special tool (ST 5908). Remove piston (15), shim (21), cushion bearing (13) and cushion seal (14). Tool for tightening nut: 90 mm (ST 3263) ST 5908



1. Lift and horizontally secure the cylinder on a workbench. Then, drain the hydraulic oil from the cylinder.



W158-04-02-022



W102-04-02-027



2. Fully extend cylinder rod (11). Lift and hold the rod. Remove socket bolts (8) from cylinder head (7). IMPORTANT: Be sure to pull out piston rod (11) straight to prevent the sliding surfaces from being damaged. 3. Pull out cylinder head (7) with piston rod still attached from cylinder tube (12) by using a plastic hammer. 4. Secure cylinder rod (11) on special tool (ST 5908). Put matching mark between cylinder rod (11) and nut (24).



7. Remove seal ring (17), slide rings (19, 20) (2 used), O-ring (18), backup rings (16) (2 used) from piston (15). 8. Remove cylinder head (7) from cylinder rod (11). 9. Remove O-ring (10) and backup rings (9, 2) from cylinder head (7). Then remove wiper ring (1), U-ring (3), backup ring (4), snap ring (6) and bushing (5). Tool for removing bushing: 90 mm (ST 8024/ST 1991) 10. Remove stopper (28) from piston rod (11) with a screwdriver. Remove cushion bearing (27), cushion seal (26) and snap ring (25).



ST 5908



W158-04-02-022



W4-2-29



FRONT ATTACHMENT / Cylinder ASSEMBLE CYLINDER (ARM) Arm Cylinder



Be sure with the slit facing piston.



Hole (1 Place)



2



1



3



4



5



6



7



8



9, 10 11



13



12



14



15



16



17, 18



19



20



21



22, 23 24 25 27



26



28



W1F1-04-02-003



Be sure with oil groove facing correct direction when assembling.



1234567-



Wiper Ring Backup Ring U-Ring Buffer Ring Bushing Retaining Ring Cylinder Head



8910 11 12 13 14 -



Socket Bolt (12 Used) Backup Ring O-Ring Piston Rod Cylinder Tube Cushion Bearing Cushion Seal



15 16 17 18 19 20 21 -



W4-2-30



Piston Backup Ring (2 Used) Seal Ring O-Ring Slide Ring (2 Used) Slide Ring (2 Used) Shim



22 23 24 25 26 27 28 -



Set Screw Steel Ball Nut Retaining Ring Cushion Seal Cushion Bearing Stopper (2 Used)



FRONT ATTACHMENT / Cylinder Assemble Arm Cylinder 1. Press bushing (5) into cylinder head (7). Tools for pressing bushing: ST 8024/ST 1911 IMPORTANT: Be sure to install rings in correct direction. 2. Install U-ring (3), backup ring (2), buffer ring (4), and retaining ring (6) to cylinder head (7).



9. Install shim (21) to cylinder rod (11). Tighten nut (24) using special tool (ST 5908) while aligning the matching mark on the rod with that on the nut. Tool for tightening nut: 90 mm (ST 3263) : 7230 N⋅m (740 kgf⋅m, 5330 Ibf⋅ft) ST 5908



3. Install wiper ring (1) to cylinder head (7) by using a plastic hammer. Tool for pressing wiper ring: ST 8024/ST 1368 4. Install O-ring (10) and backup ring (9) to cylinder head (7). IMPORTANT: When installing slide rings (19) and (20), do not align their split portion. 5. Install seal ring (17), O-ring (18), and slide rings (19, 20) (2 used for each) to piston (15). 6. Install the cylinder head (7) assembly into piston rod (11). Tools for installing cylinder head: ST 8024/ST 2510 IMPORTANT: Be sure that the slit in cushion seal (14) is facing piston and that the oil groove in cushion bearing (13) is facing correct direction. 7. Install cushion seal (14) to cylinder rod (11). Install cushion bearing (13) and the piston (15) assembly to cylinder rod (11)



10. Align the hole of piston rod (11) and nut (24), then install steel ball (23). 11. After tightening set screw (22), crimp the head of set screw (22) at two places with a punch. : 57±10.5 N⋅m (5.8±1.1 kgf⋅m, 42±7.7 lbf⋅ft) CAUTION: Be sure to keep cylinder rod (11) aligning with the center of cylinder tube (12) when inserting in order to avoid damaging rings. 12. Horizontally secure cylinder tube (12) on a workbench. Insert the piston rod (11) assembly into cylinder tube (12). 13. Install cylinder head (7) into cylinder tube (12) with socket bolts (8) (12 used). : 267 N⋅m (27 kgf⋅m, 200 Ibf⋅ft)



13 Oil Groove Nut Side Head Side



W158-04-02-022



Nut Side



W18B-04-02-011



IMPORTANT: Be sure that cushion seal (26) slit is facing piston and that the oil groove in cushion bearing (27) is facing correct direction. 8. Install retaining ring (25) and cushion seal (26) to piston rod (11). Install cushion bearing (27) and stopper (28) to the piston rod.



W4-2-31



FRONT ATTACHMENT / Cylinder DISASSEMBLE CYLINDER (STABILIZER, BLADE) Stabilizer Cylinder



A



W1GL-04-02-001



Blade Cylinder



A



W1GL-04-02-002



Section A Lock Washer



1



3



4



10



11 12



13



14



15



16



15



14



18



Slit Black Green



Hole (1 Place)



19 20



2



5



6



7



8



9 17



12345-



Wiper Ring Cylinder Head O-Ring Buffer Ring U-Ring



13



678910 -



Bushing Retaining Ring Backup Ring O-Ring Piston Rod



11 12 13 14 15 -



W4-2-32



Cylinder Tube Piston Slide Ring (2 Used) Slide Ring (2 Used) Backup Ring (2 Used)



W1GL-04-02-003



16 17 18 19 20 -



Seal Ring O-Ring Nut Set Screw Steel Ball



FRONT ATTACHMENT / Cylinder Disassemble Stabilizer and Blade Cylinders • Be sure to read “Precautions for Disassembly and Assembly” thoroughly on page W1-1-1 before starting the repair work. • The disassembly procedure below starts on the premise that the hydraulic lines and the line securing bands have been removed.



4. Secure piston rod (10) on special tool (ST 5908). Put matching mark between piston rod (10) and nut (18). ST 5908



CAUTION: Stabilizer cylinder weight: 88 kg (195 lb) Blade cylinder weight: 55 kg (120 lb) 1. Lift and horizontally secure the cylinder on a workbench. Then, drain the hydraulic oil from the cylinder.



W102-04-02-027



2. Let the lock washer in cylinder tube (11) bend. By using a hook spanner wrench, loosen cylinder head (2) by 1 to 2 turns. Hook spanner wrench: Stabilizer cylinder: ST 3223 Blade cylinder: ST 3219 NOTE: The lock washer in cylinder head (2) is provided on cylinder tube (11) to from an integral part. IMPORTANT: Be sure to pull out piston rod (10) straight to prevent the sliding surfaces from being damaged. 3. Fully extend piston rod (10). Hold the rod end by crane. Remove cylinder head (2). Pull out the piston rod (10) assembly from cylinder tube (11).



W158-04-02-022



5. Remove set screw (19) and steel ball (20). NOTE: Set screw (19) was crimped with a punch in two places after it was tightened. Before loosening set screw (19), cut away the crimped portions. 6. Loosen and remove nut (18) using special tool (ST 5908). Remove piston (12) from piston rod (10). Tools for turning nut: Stabilizer cylinder: 85 mm (ST 3304) Blade cylinder: 75 mm (ST 3271) 7. Remove cylinder head (2) from cylinder rod (10). IMPORTANT: When removing the seal parts, take care not to damage them. Do not reuse slide rings (13) and (14). When dissembling cylinder, replace them with new ones. 8. Remove slide rings (13, 14) (2 used for each), backup rings (15) (2 used), seal ring (16) and O-ring (17) from piston (15). 9. Remove wiper ring (1), U-ring (5), buffer ring (5), retaining ring (7) and bushing (6) from the cylinder head (1) inside. Tools for removing bushing: Stabilizer cylinder: 70 mm (ST 8017) Blade cylinder: 60 mm (ST 8017) 10. Remove O-rings (3, 9) and backup ring (8) from the cylinder head (2) outside.



W4-2-33



FRONT ATTACHMENT / Cylinder ASSEMBLE CYLINDER (STABILIZER, BLADE)



Stabilizer Cylinder



A



W1GL-04-02-001



Blade Cylinder



A



W1GL-04-02-002



Section A Lock Washer



1



3



4



10



11 12



13



14



15



16



15



14



18



Slit Black Green



Hole (1 Place)



19 20



2



5



6



7



8



9 17



1 2 3 4 5



-



Wiper Ring Cylinder Head O-Ring Buffer Ring U-Ring



13



678910 -



Bushing Retaining Ring Backup Ring O-Ring Piston Rod



11 12 13 14 15 -



W4-2-34



Cylinder Tube Piston Slide Ring (2 Used) Slide Ring (2 Used) Backup Ring (2 Used)



W1GL-04-02-003



16 17 18 19 20 -



Seal Ring O-Ring Nut Set Screw Steel Ball



FRONT ATTACHMENT / Cylinder Assemble Stabilizer and Blade Cylinders • Be sure to read “Precautions for Disassembly and Assembly” thoroughly on page W1-1-1 before starting the repair work. 1. Press bushing (6) into cylinder head (2) by using the special tool. Install retaining ring (7) in cylinder head (4). Tools for pressing bushing: Stabilizer cylinder: 70 mm (ST 8017) Blade cylinder: 60 mm (ST 8017)



8. Install piston (12) to piston rod (10). Tighten nut (18) using special tool (ST 5908) while aligning the matching mark on the rod with that on nut (18). Tools for turning nut: Stabilizer cylinder: 85 mm (ST 3304) : 3560 N⋅m (360 kgf⋅m, 2630 Ibf⋅ft) Blade cylinder: 75 mm (ST 3271) : 2480 N⋅m (250 kgf⋅m, 1830 Ibf⋅ft) ST 5908



IMPORTANT: Install U-ring (5) with the lip facing the bushing (6) side. Install buffer ring (4) with the protrusion part and slit facing the bushing (6) side. 2. Install U-ring (5) and buffer ring (4) to cylinder head (2).



W158-04-02-022



3. Install wiper ring (1) to cylinder head (2) with a plastic hammer. Tools for pressing wiper ring: Stabilizer cylinder: ST 8051 Blade cylinder: ST8049 IMPORTANT: Install backup ring (8) to the piston rod (10) side of O-ring (9). 4. Install O-ring (3), (9) and backup ring (8) to cylinder head (2). 5. Install the cylinder head (2) assembly into piston rod (10). Tools for installing cylinder head: Stabilizer/Blade cylinder: ST 8017 Blade cylinder: ST8012 IMPORTANT: Make sure that O-ring (17) is not twisted after installing it. 6. Install backup rings (15) (2 used), and O-ring (17) and seal ring (16) onto sleeve (12) with a wooden spatula so that they are not installed in the slide ring (13) groove. IMPORTANT: When installing slide rings (13), (14) do not align their split portion. 7. Install slide rings (13), (14) to piston (12).



9. Align the hole on cylinder rod (10) with that on nut (18). Insert steel ball (20) into the hole and tighten set screw (19). After tightening set screw (19), crimp the head of set screw (19) at two places with a punch. Stabilizer cylinder: : 10 mm : 57±10.5 N⋅m (5.8±1.1 kgf⋅m, 42±7.7 lbf⋅ft) Blade cylinder: : 8 mm : 31.5±5.88 N⋅m (3.2±5.88 kgf⋅m, 23±4 lbf⋅ft) IMPORTANT: Be sure to keep piston rod (10) aligning with the center of cylinder tube (11) when inserting in order to avoid damaging the piston rings. IMPORTANT: Apply THREEBOND #1901 onto the thread of cylinder head (2). 10. Securely place cylinder tube (11) on a workbench, insert the piston rod (10) assembly into cylinder tube (11). 11. Tighten cylinder head (2) to cylinder tube (11) using R wrench. Bend the lock washer to prevent cylinder head (2) from loosening. R wrench: Stabilizer cylinder: ST 3223 : 1060 N⋅m (108 kgf⋅m, 780 Ibf⋅ft) Blade cylinder: ST 3219 : 735 N⋅m (75 kgf⋅m, 540 Ibf⋅ft)



W4-2-35



FRONT ATTACHMENT / Cylinder MAITENANCE STANDARD Piston Rod



Rod Bend and Run Out Dial Gauge Piston Rod A



W166-04-02-022



1 m (3.9 in) W105-04-02-094



Cylinder Name



V Block



Unit: mm (in) Recommended Size After Re-manufacturing (A)



Boom



80



Positioning



90



Bucket



75



-0.023 -0.053 -0.029 -0.057 -0.023 -0.053



(3.15 (3.54 (2.95



-0.0009 -0.0021 -0.0011 -0.0022 -0.0009 -0.0021



)



Bend 0.5 (0.020) 1.0 (0.039)



Run out 1.0 (0.039) 2.0 (0.079)



Unit: mm (in) Remedy Repair Replace



) )



Wear to inner Diameter of Rod Bushing Cylinder Name



Standard inner Dimeter (C)



Boom



80



Arm



90



Bucket



75



-0.06 -0.19 -0.06 -0.19 -0.06 -0.19



(3.15 (3.54 (2.95



-0.002 -0.007 -0.002 -0.007 -0.002 -0.007



Unit: mm (in) Allowabl Remedy e Limit +0.3 ) Replace (0.012) +0.3 ) Replace (0.012) +0.3 ) Replace (0.012)



W4-2-36



C



FRONT ATTACHMENT / Hose-Rupture Safety Valve REMOVE AND INSTALL HOSE-RUPTURE SAFETY VALVE Removal of Hose-Rupture Safety Valve for Arm Cylinder



1



2



3, 4



1. After stopping the engine, push the pressure release button on the air breather to release any remaining pressure from the hydraulic oil tank. Then remove the cap. Release the arm circuit pressure. (Refer to “Hydraulic Circuit Pressure Release Procedure” on page W4-1-1.) IMPORTANT: Attach identification tags to the hydraulic hoses and pipes for re-assembly. 2. Disconnect hoses (2) and (5) (2 used) from hose-rupture safety valve (6). Attach a cap onto the open ends. : 17 mm, 19 mm, 27 mm



5



W1GL-04-03-005



6



3. Remove socket bolts (4) (4 used) then remove pipe (3) from hose-rupture safety valve (6). : 10 mm 4. Remove socket bolts (1) (4 used) then remove hose-rupture safety valve (6) from the arm cylinder. : 10 mm Installation of Hose-Rupture Safety Valve for Arm Cylinder 1. Install hose-rupture safety valve (6) onto the arm cylinder with socket bolts (1) (4 used). : 10 mm : 93±2 N⋅m (9.5±0.2 kgf⋅m, 69±1.5 lbf⋅ft) 2. Install pipe (3) onto hose-rupture safety valve (6) with socket bolts (4) (4 used). : 10 mm : 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft) 3. Connect hoses (2) and (5) (2 used). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m,18 lbf⋅ft) : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) IMPORTANT: Fill hydraulic oil to the specified level. Start the engine. Check the connections for any oil leakage.



W4-3-1



FRONT ATTACHMENT / Hose-Rupture Safety Valve Removal of Hose-Rupture Safety Valve for Positioning Cylinder 1. After stopping the engine, push the pressure release button on the air breather to release any remaining pressure from the hydraulic oil tank. Then remove the cap. Release the arm circuit pressure. (Refer to “Hydraulic Circuit Pressure Release Procedure” on page W4-1-1.)



1



8



2



3



IMPORTANT: Attach identification tags to the hydraulic hoses and pipes for re-assembly. 2. Disconnect hoses (1, 2, 3) and (7) from hose-rupture safety valve (5). Attach a cap onto the open ends. : 19 mm, 36 mm 3. Remove the pipe (6) securing bolt (8) and the pipe clamp. : 22 mm 4. Remove socket bolts (4) (4 used) then remove pipe (6) and hose-rupture safety valve (5) from the positioning cylinder. : 10 mm



Installation of Hose-Rupture Safety Valve for Positioning Cylinder 1. Install hose-rupture safety valve (5) and pipe (6) onto the positioning cylinder with socket bolts (4) (4 used). : 10 mm : 93±2 N⋅m (9.5±0.2 kgf⋅m, 69±1.5 lbf⋅ft) 2. Connect hoses (1), (2), (3) and (7). : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft) 3. Secure the pipe clamp with bolt (8). : 22 mm : 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft) IMPORTANT: Fill hydraulic oil to the specified level. Start the engine. Check the connections for any oil leakage.



W4-3-2



6



4



W1F3-04-03-001



7



5



FRONT ATTACHMENT / Hose-Rupture Safety Valve Removal of Hose-Rupture Safety Valve for Boom Cylinder 1. After stopping the engine, push the pressure release button on the air breather to release any remaining pressure from the hydraulic oil tank. Then remove the cap. Release the arm circuit pressure. (Refer to “Hydraulic Circuit Pressure Release Procedure” on page W4-1-1.)



1



2



3



IMPORTANT: Attach identification tags to the hydraulic hoses and pipes for re-assembly. 2. Disconnect hoses (3) (4 used) and (5) (2 used) from hose-rupture safety valve (6). Attach a cap onto the open ends. : 19 mm, 36 mm 3. Remove the pipe (7) securing bolts (1, 2) and the pipe clamp. : 17 mm, 22 mm 4. Remove socket bolts (4) (4 used) then remove pipe (7) and hose-rupture safety valve (6) from the boom cylinder. : 10 mm



Installation of Hose-Rupture Safety Valve for Boom Cylinder 1. Install hose-rupture safety valve (6) and pipe (7) onto the boom cylinder with socket bolts (4) (4 used). : 10 mm : 93±2 N⋅m (9.5±0.2 kgf⋅m, 69±1.5 lbf⋅ft) 2. Connect hoses (3) (4 used) and (5) (2 used). : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft) 3. Secure the pipe clamp with bolts (1, 2). : 17 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) : 22 mm : 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft) IMPORTANT: Fill hydraulic oil to the specified level. Start the engine. Check the connections for any oil leakage.



W4-3-3



7



6



5



4



W1GL-04-03-003



FRONT ATTACHMENT / Hose-Rupture Safety Valve CONSTRUCTION SAFETY VALVE



OF



HOSE-RUPTURE



For Arm Cylinder 1 20



2



21



19



3



18



4



17



5



6



16



15



14



7



13



8 9 10



11



12



W1GL-04-03-002



W4-3-4



FRONT ATTACHMENT / Hose-Rupture Safety Valve



Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21



Part Name Casing Plug O-Ring Spool O-Ring Plug Spring Seat Backup Ring O-Ring Spring Poppet Body O-Ring Seat O-Ring Stopper Set Screw Lock Nut O-Ring Cover Spring



Quantity Wrench Size 1 3 3 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1



W4-3-5



N⋅m



Tightening Torque (kgf⋅m) (lbf⋅ft)



Remark



FRONT ATTACHMENT / Hose-Rupture Safety Valve



For Boom/Positioning Cylinder 3



5



4



2



6



7



8



1 28



29



30



31



9



27



10



26 11 25



12



13 14 15 16 17 24



23



22



21



18



19



20



W1GL-04-03-001



W4-3-6



FRONT ATTACHMENT / Hose-Rupture Safety Valve



Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31



Part Name Pilot Poppet Adapter Plain Washer Lock Nut Set Screw O-Ring Spring O-Ring Casing Backup Ring O-Ring O-Ring Spool Plug Plug Backup Ring O-Ring Spring Poppet Body O-Ring Seat O-Ring Stopper Set Screw Lock Nut O-Ring Cover Spring Plug O-Ring



Quantity 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 3 3



Wrench Size : 24 mm : 17 mm : 5 mm



: 32 mm



: 3 mm : 10 mm : 32 mm : 3 mm



W4-3-7



N⋅m



Tightening Torque (kgf⋅m) (lbf⋅ft)



Remark



FRONT ATTACHMENT / Hose-Rupture Safety Valve (Blank)



W4-3-8



FRONT ATTACHMENT / Operate-Check Valve REMOVE AND INSTALL OPERATE-CHECK VALVE (FOR BLADE/STABILIZER)



1



Removal



2



IMPORTANT: Before working, lower the blade onto the ground. IMPORTANT: Before working, be sure to secure the stabilizer beam and stabilizer with the lock pin. 1. Remove bolts (2) (4 used) then remove protection cover (1). : 19 mm 2. Disconnect hoses (5) (4 used) from operate-check valve (4). Attach a cap onto the open ends. : 17 mm, 19 mm, 22 mm, 27 mm



W1GL-04-01-013



3



3. Remove socket bolts (6) (2 used) then remove bracket (7).



4



4. Remove plug (3) then remove operate-check valve (4). Attach a cap onto the open ends. 6, 7



Installation 1. Install operate-check valve (4) on the blade cylinder with plug (3). : 36 mm : 128±6.4 N⋅m (13±0.7 kgf⋅m, 94±4.7 lbf⋅ft)



W1GL-04-02-004



5



2. Install bracket (7) on the blade cylinder with socket bolts (6) (2 used). : 6 mm : 26.5 N⋅m (2.7 kgf⋅m, 19.5 Ibf⋅ft) 3. Connect hoses (5) (4 used) to operate-check valve (4). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) : 22 mm : 39 N⋅m (4.0 kgf⋅m, 28.5 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 Ibf⋅ft)



Float Stabilizer Beam Lock Pin



4



4. Install protection cover (1) with bolts (2) (4 used). : 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)



W4-4-1



Stabilizer



5 W1F3-04-01-011



FRONT ATTACHMENT / Operate-Check Valve CONSTRUCTION OF OPERATE-CHECK VALVE (FOR BLADE/STABILIZER) 1



2 3



4 5



6



11



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



Part Name Plug O-Ring Casing O-Ring Plug Spring Poppet Check Valve Piston O-Ring Plug



10



Q’ty 1 1 1 1 1 1 1 1 1 1 1



9



Wrench Size



7



8



N⋅m



T1F3-03-10-003



Tightening Torque (kgf⋅m) (lbf⋅ft)



Remark



: 5 mm



1B P11 1B P26 : 36 mm



360±36



(37±3.7)



(265±26.5)



240±24



(24±2.4)



(175±17.5)



φ



1.0×φ8.5×31.0 mm



1B P24 : 36 mm



W4-4-2



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MEMO ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... 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SECTION 5



ENGINE AND ACCESSORY  CONTENTS  General Information General Repair Instructions ........................... 1-2



Engine Assembly 2 (Inspection and Repair)



Notes on the Format of This Manual .............. 1-2



Cylinder Head ................................................ 4-2



Main Data and Specifications......................... 1-6



Valve Guide.................................................... 4-3



Performance Curve........................................ 1-8



Valve Spring ................................................... 4-6



External View ................................................1-11



Tappet ............................................................ 4-7



Tightening Torque Specifications ................. 1-14



Push Rod ....................................................... 4-8



Angular Nut and Bolt Tightening Method...... 1-16



Rocker Arm Shaft and Rocker Arm................. 4-8



Major Parts Fixing Nuts and Bolts ................ 1-18



Idler Gear and Idler Gear Shaft ...................... 4-9



Identifications............................................... 1-26



Camshaft...................................................... 4-10 Cylinder Body and Liner ............................... 4-11



Maintenance Lubricating System ........................................ 2-2 Fuel System................................................... 2-3 Cooling System.............................................. 2-6 Valve Clearance Adjustment .......................... 2-6 Injection Timing.............................................. 2-8 Compression Pressure Measurement .......... 2-12 Turbocharger Inspection .............................. 2-13 Engine Repair Kit ......................................... 2-14



Piston and Piston Ring ................................. 4-17 Piston Pin..................................................... 4-18 Connecting Rod ........................................... 4-19 Crankshaft.................................................... 4-21 Flywheel....................................................... 4-28 Timing Gear Case Cover.............................. 4-28



Engine Assembly 3 (Reassembly) Piston and Connecting Rod



Recommended Lubricants ........................... 2-15



Reassembly Steps........................................ 5-2



Engine Oil Viscosity Chart ........................... 2-15



Cylinder Head Reassembly Steps .................. 5-4 Rocker Arm and Rocker Arm Shaft



Engine Assembly 1 (Disassembly) External Parts Disassembly Steps ................. 3-2 Major Components......................................... 3-6 Rocker Arm and Rocker Arm Shaft Disassembly Steps..................................... 3-10 Cylinder Head Disassembly Steps ................3-11 Piston and Connecting Rod Disassembly Steps..................................... 3-12



Reassembly Steps........................................ 5-7 Major Component Reassembly Steps 1.......... 5-8 Major Component Reassembly Steps 2........ 5-13 External Parts Reassembly Steps (Left-Hand Side) ......................................... 5-18 External Parts Reassembly Steps (Right-Hand Side)....................................... 5-21 Engine Tuning Operation.............................. 5-25



NOTE: Refer to AA-4BG1TCG-01 engine model.



CBBW-5-1



Lubricating System



Troubleshooting



General Description ....................................... 6-2



Hard Starting ................................................ 11-2



Oil Pump ........................................................ 6-3



1) Starter Inoperative ................................. 11-2



Oil Cooler....................................................... 6-5



2) Starter Operates but Engine does not Turn Over .................... 11-3



Cooling System General Description ....................................... 7-2



3) Engine Turns Over but does not Start Fuel is Being Delivered to the



Thermostat..................................................... 7-3



Injection Pump ....................................... 11-4 4) Engine Turns Over but does not Start .... 11-5



Fuel System General Description ....................................... 8-2



Unstable Low Idling ...................................... 11-6



Injection Nozzle ............................................. 8-3



Insufficient Power......................................... 11-8



Injection Pump Calibration Data..................... 8-8



Excessive Fuel Consumption ......................11-11 Excessive Oil Consumption........................ 11-13



Turbocharger



Overheating ............................................... 11-14



General Description ....................................... 9-2



Whity Exhaust Smoke ................................ 11-16



Turbocharger Identification ............................ 9-3



Dark Exhaust Smoke.................................. 11-17



Troubleshooting ............................................. 9-5



Oil Pressure does not Rise......................... 11-18



Inspection and Repair .................................... 9-7



Abnormal Engine Noise.............................. 11-20



Engine Electricals



Special Tool List



Starter Identification ..................................... 10-2



Special Tool List ........................................... 12-2



Starter Main Data and Specifications ........... 10-3 Starter Sectional View.................................. 10-4 Performance ................................................ 10-4 Disassembly ................................................ 10-5 Inspection and Repair .................................. 10-8 Reassembly ............................................... 10-12 Adjustment................................................. 10-13 Performance Test....................................... 10-14 Alternator Identification .............................. 10-15 Main Data and Specifications..................... 10-16 Alternator Sectional View ........................... 10-17 Charging Circuit ......................................... 10-17



Repair Standards Repair Standards ......................................... 13-1



Conversion Table Length .......................................................... 14-1 Area ............................................................. 14-3 Volume ......................................................... 14-3 Mass ............................................................ 14-5 Pressure....................................................... 14-6 Torque .......................................................... 14-7 Temperature ................................................. 14-8



Structure .................................................... 10-18 Disassembly .............................................. 10-19 Inspections ................................................ 10-22 Reassembly ............................................... 10-24



NOTE: Refer to AA-4BG1TCG-01 engine model.



Bench Test ................................................. 10-25 Current Output Test.................................... 10-26 Fault Finding .............................................. 10-27 Specifications............................................. 10-27



CBBW-5-2



MEMO ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... 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MEMO ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... 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....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... .......................................................................................................................................................................



Hitachi Construction Machinery Co. Ltd Attn: Publications, Marketing & Product Support Fax: 81-298-31-1162



Hitachi Ref. No.



SERVICE MANUAL REVISION REQUEST FORM NAME OF COMPANY:



MODEL: PUBLICATION NO.:



YOUR NAME: DATE: FAX:



(Located at the right top corner in the cover page)



PAGE NO.: (Located at the bottom center in the page. If two or more revisions are requested, use the comment column)



YOUR COMMENTS / SUGGESTIONS: Attach photo or sketch if required. If your need more space, please use another sheet.



REPLY:



(Copy this form for usage)



SPECIFICATIONS OPERATING WEIGHT ENGINE OUTPUT BUCKET CAPACITY (PCSA) TRAVEL SPEED



(kg) (kW/min-1) (m3)



15506∼17200 90.2/2300 0.6



(km/h)



32.0/9.0/2.3



WHEEL BASE



(mm)



2550



OVERALL WIDTH



(mm)



2530



ZX160W



ENGINE ENGINE ISUZU AA-4BG1TCG



−1−



OPERATING WEIGHT (Monoblock Boom Type) Unit : kg With, Rear Stabilizer



16300



With, Front & Rear Stabilizer



17300



With, Rear Blade



15800



With, Front Stabilizer & Rear Blade



16900



ENGINE Manufacturer ..........Isuzu Model......................AA-4BG1TCG Rated Output ..........P-Mode : 84.8 kW/1850 min-1 (115 PS/1850 rpm) HP-Mode : 90.2 kW/2300 mim-1 (123 PS/2300 rpm)



−2−



PUMP DEVICE PILOT PUMP



PILOT FILTER STEERING PUMP FUEL FILTER



STEERING FILTER



STEERING PUMP DELIVERY PRESSURE SENSOR (17.2 MPa)



STEERING FILTER



−3−



Pump Device Main Pump Type : Swash-Plate Variable Displacement Tandem Plunger Pump Max Flow : Pump 1 184 L/min-1 (48.5 US gpm) Pump 2 172 L/min-1 (45.4 US gpm) Pilot Pump



N Sensor



Torque Control Solenoid Valve



Pump 1 Control Pressure Sensor



Steering Pump



Pump 2



Pump 1



Pump Delivery Pressure Sensor



Pump 2 Delivery Pressure Sensor



Pilot Pump and Steering Pump Type : Fixed Displacement Type Gear Pump Max Flow : 27.8 L/min (7.34 us gpm)



−4−



Pump 2 Control Pressure Sensor



3-UNIT SOLENOID VALVE MAX. PUMP 2 FLOW RATE SHIFT SOLENOID VALVE MAX. PUMP 1 FLOW RATE LIMIT SOLENOID VALVE



MAX. PUMP 1 FLOW RATE LIMIT SOLENOID VALVE



N SENSOR (ENGINE SPEED)



TORQUE CONTROL SOLENOID VALVE



−5−



−6−



MAIN PUMP DELIVERY PRESSURE SENSORS



PUMP 1 DELIVERY PRESSURE SENSOR



PUMP 2 DELIVERY PRESSURE SENSOR



HYDRAULIC OIL TANK TANK CAPACITY…205 L



DRAIN PLUG



HYDRAULIC OIL TEMPERATURE SENSOR (-20 °C – 16.2 kΩ) ( 0 °C – 5.88 kΩ) ( 20 °C – 2.45 kΩ) −7−



DRAIN PLUG FOR OIL TANK SUMP



• Drain Hydraulic Oil Tank Sump every 250 hours



−8−



HYDRAULIC OIL TANK CAPACITY…205 liters (54 us gal)



COVER FOR OIL FILTER



COVER FOR SUCTION FILTER



CONTROL VALVE / SWING MOTOR CONTROL VALVE



SIGNAL CONTROL VALVE



PILOT RELIEF VALVE



SWING MOTOR



−9−



HYDRAULIC OIL TANK Hydraulic Oil Change Interval…Every 4000 hours



Control Valve Main Relief Set-Pressure................................ Normal : 34.3 MPa (350 kgf/cm2, 4980 psi) Overload Relief Set-Pressure ......................... 37.3 MPa (380 kgf/cm2, 5420 psi) for Boom, Arm Roll-in, BKT. Roll-in 39.2 MPa (400 kgf/cm2, 5690 psi) for Arm Roll-out, BKT. Roll-out Pressure Sensor (Arm Roll-In)



Main Relief Valve



Pressure Sensor (Boom Raise)



Swing Motor Type…Swash-plate Type, Fixed Displacement Axial Plunger Motor Relief Set Pressure...30.4 MPa (310 kgf/cm2, 4420 psi)



Swing Parking Brake



Release Pressure…1.9∼2.8 MPa (19∼28 kgf/cm2, 284∼384 psi)



−10−



SIGNAL CONTROL VALVE



POSITION OF PRESSURE SENSOR (AUXILIARY)



PRESSURE SENSOR (SWING)



4-UNIT SOLENOID VALVE



ARM REGENERATIVE (SC)



AXLE LOCK TRAVEL MOTOR CAPACITY (SE) CONTROL (SI)



−11−



BRAKE VALVE CONTROL (SG)



−12−



PILOT RELIEF VALVE PILOT RELIEF VALVE 3.7 MPa



ACCUMULATOR (PILOT CIRCUIT)



SWING DEVICE



RELIEF PRESSURE SETTING(30.4 MPa)



SWING MOTOR (PARKING RELEASE PRESSURE 1.9∼2.8 MPa)



SWING REDUCTION GEAR



−13−



SWING DEVICE • Swing Motor…Swash-Plate Type, Fixed Displacement Axial Plunger Motor.



−14−



FUEL TANK CAPACITY…280 liters



FUEL SENSOR



BLADE / STABILIZER SIGNAL SHIFT VALVE



PROVIDED TO CONTROL THE BYPASS SHUT-OFF VALVE



−15−



−16−



LEFT SIDE VIEW



COOLANT RESERVOIR INTERCOOLER AIR CLEANER



AIR CONDITIONER CONDENSER



TRAVEL SHOCKLESS VALVE / ACCUMULATOR CHARGING VALVE PRESSURE SENSOR FOR BRAKE OIL PRESSURE GAUGE



TRAVEL SHOCKLESS VALVE



ACCUMULATOR CHARGING VALVE



PI CUT SOLENOID VALVES FOR TRAVEL FORWARD/REVERSE



−17−



• Air Cleaner Element Clean Interval…Every 250 Hours. • Clean Radiator, Oil Cooler Core and Intercooler…Every 500 Hours. • Clean Air Conditioner Condenser…Every 500 Hours.



Travel Shockless Valve / Accumulator Charging Valve Type…Slow Return Valve (with the 2-Unit Solenoid Valve)



−18−



STEERING COLUMN STEERING WHEEL



COMBINATION SWITCH



STEERING COLUMN CONSOLE



STEERING COLUMN WIPER / WASHIER SWITCH



SHIFT LEVER



BRAKE SWITCH



HORN SWITCH MONITOR PANEL ATTACHMENT PEDAL (OPTION)



BRAKE PEDAL −19−



FORWARD / REVERSE TRAVEL PEDAL



−20−



RIGHT CONTROL LEVER & SWITCH PANEL RIGHT CONTROL LEVER



CLOCKWISE SWITCH



COUNTER CLOCKWISE SWITCH SWITCH PANEL



POWER BOOST SWITCH



LEFT CONTROL LEVER ATTACHMENT SELECTION SWITCH



ATTACHMENT SELECTION SWITCH



HORN SWITCH



LEFT CONTROL LEVER



−21−



−22−



SWING LOCK LEVER



OFF



ON



SWING LOCK LEVER



SWING LOCK BRACKET



SWING LOCK BRAＣKET



−23−



−24−



UNDER OPERATOR’S CAB BRAKE VALVE



STEERING VALVE



TRAVEL PILOT VALVE



SERVICE BRAKE PRESS. SWITCH



ACCUMULATOR ACCUMULATORS (BRAKE CIRCUIT) BRAKE ACCUMULATOR PRESSURE : (4.0 MPa)



BRAKE REMAINING PRESSURE SWITCH ON : 5.2 MPa or lower OFF : 5.2 to 6.4 MPa −25−



−26−



AXLE (REAR)



OIL LEVEL PLUG



AXLE (FRONT)



FRONT AXLE



OIL LEVEL PLUG



−27−



AXLE (REAR) Type…Rear : Rigid Axle with Hub Reduction. Reduction Gear Ratio…13.8 kg



AXLE (FRONT) Type…Steering Drive Axle with Hub Reduction.



−28−



SERVICE BRAKE



TRANSMISSION



−29−



TRANSMISSION Type…Two-speed Powershift Transmission. Gear Ratio… High Speed Side : 1.39 Low Speed Side : 5.35



−30−



TRAVEL DEVICE



TRAVEL MOTOR



TRANSMISSION



CENTER JOINT & SLIP RING



−31−



TRAVEL MOTOR Type…Bent-Axis Type Variable Displacement Plunger Motor.



−32−



2-UNIT SOLENOID VALVE (BLADE / STABILIZER)



PROPELLER SHAFT OIL CAPACITY 3.2 L (0.85 us gal) TRANSMISSION



PROPELLER SHAFT



−33−



−34−



TRANSMISSION CONTROL VALVE



TRANSMISSION CHANGE OVER SOLENOID VALVE



PARKING BRAKE SOLENOID VALVE ACCUMULATOR (TRANSMISSION CIRCUIT)



TRANSMISSION CONTROL VALVE REDUCING VALVE PRESSURE ... 3.4 MPa RELIEF PRESSURE....................... 1.3 MPa



AXLE LOCK CYLINDER AXLE LOCK CYLINDER



−35−



PARKING BRAKE PRESSURE SWITCH



−36−



BLADE



BLADE



BLADE CYLINDER



STABILIZER



STABILIZER LOCK PINS



−37−



−38−



FRONT AND REAR HUB REDUCTION DEVICE



PLUG (CHECK OIL LEVEL & DRAIN OIL) FRONT SIDE : 2.1 L REAR SIDE : 1.0 L



−39−



* OIL LEVEL CHECK EVERY ONE MONTH * REPLACE GEAR OIL EVERY 1000 HOURS (FIRST TIME AT 500HR)



−40−



INTRODUCTION TO THE READER • This manual is written for an experienced technician



to provide technical information needed to maintain and repair this machine. • Be sure to thoroughly read this manual for correct product information and service procedures.



• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.): Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-298-32-7173 FAX: 81-298-31-1162



ADDITIONAL REFERENCES • Please refer to the materials listed below in addition to this manual.



• The Operator’s Manual • The Parts Catalog



• Operation Manual of the Engine • Parts Catalog of the Engine • Hitachi Training Material



MANUAL COMPOSITION • This manual consists of three portions: the Techni-



• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.



• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.



• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/disassemble procedures.



cal Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.



IN-01



INTRODUCTION PAGE NUMBER • Each page has a number, located on the center



lower part of the page, and each number contains the following information: Example : T 1-3-5 Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual



W: Workshop Manual



SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.



•



CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.



• IMPORTANT:



Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.



•



IN-02



NOTE: Indicates supplementary technical information or know-how.



INTRODUCTION UNITS USED 



Example : 24.5 MPa (250 kgf/cm2, 3560 psi)



• SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units.



Quantity Length Volume



Weight Force Torque



To Convert From mm mm L L m3 kg N N N⋅m N⋅m



Into in ft US gal US qt yd3 lb kgf lbf kgf⋅m lbf⋅ft



A table for conversion from SI units to other system units is shown below for reference purposees.



Quantity



Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 1.0197 0.7375



Pressure Power Temperature Velocity Flow rate



IN-03



To Convert From MPa MPa kW kW °C km/h min-1 L/min mL/rev



Into kgf/cm2 psi PS HP °F mph rpm US gpm cc/rev



Multiply By 10.197 145.0 1.360 1.341 °C×1.8+32 0.6214 1.0 0.2642 1.0



INTRODUCTION (Blank)



IN-04



















SECTION AND GROUP CONTENTS



SECTION 1 GENERAL Group 1 Specification Group 2 Component Layout Group 3 Component Specifications











SECTION 2 SYSTEM Group 1 Control System Group 2 Hydraulic System Group 3 Electrical System



 TECHNICAL MANUAL (Operational Principle)



Group 1 Pump Device Group 2 Swing Device Group 3 Control Valve Group 4 Pilot Valve Group 5 Travel Device Group 6 Signal Control Valve Group 7 Steering Valve Group 8 Brake Valve Group 9 Transmission Control Valve Group 10 Others (Upperstructure) Group 11 Others (Undercarriage)



     



All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.



  COPYRIGHT(C)2003 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved











SECTION 3 COMPONENT OPERATION



















TECHNICAL MANUAL (Troubleshooting) SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Excavator Test Group 5 Component Test Group 6 Adjustment







SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Component Layout Group 3 Troubleshooting A Group 4 Troubleshooting B Group 5 Troubleshooting C Group 6 Electrical System Inspection Group 7 ICX











WORKSHOP MANUAL SECTION 1 GENERAL INFORMATION SECTION 3 UNDERCARRIAGE Group 1 Precautions for DisassemGroup 1 Swing Bearing bling and Assembling Group 2 Travel Motor Group 2 Tightening Torque Group 3 Center Joint Group 3 Painting Group 4 Transmission Group 4 Bleeding Air from HydrauGroup 5 Axle lic Oil Tank Group 6 Axle Lock Cylinder Group 7 Check Valve SECTION 2 UPPERSTRUCTURE (Axle Lock Cylinder) Group 1 Cab Group 8 Propeller Shaft Group 2 Counterweight Group 3 Main Frame SECTION 4 FRONT ATTACHMENT Group 4 Pump Device Group 1 Front Attachment Group 5 Control Valve Group 2 Cylinder Group 6 Swing Device Group 3 Hose-Rupture Safety Valve Group 7 Pilot Valve Group 4 Check Valve Group 8 Pilot Shut-Off Valve (Blade/Stabilizer) Group 9 Signal Control Valve SECTION 5 ENGINE Group 10 Travel Shockless Valve  Group 11 Solenoid Valve Group 12 Pilot Relief Valve Group 13 Steering Valve Group 14 Brake Valve Group 15 Accumulator Charging Valve Group 16 Transmission Control Valve 



SECTION 1



GENERAL ̆CONTENTS̆ Group 1 Specifications



Group 3 Component Specifications



Specifications............................................ T1-1-1



Engine.......................................................T1-3-1



Working Ranges ....................................... T1-1-6



Engine Accessories ...................................T1-3-4 Hydraulic Component................................T1-3-5



Group 2 Component Layout Main Component Layout ........................... T1-2-1



Electrical Component ..............................T1-3-10



Electrical Component Layout .................... T1-2-4 (Overview) Electrical System (Relays) ....................... T-1-2-5 Electrical System ................................... T-1-2-7 (Monitors and Switches) Electrical System (Column Box)............... T-1-2-8 Pump Device ............................................ T1-2-9 Swing Device ............................................ T1-2-9 Signal Control Valve.................................. T1-2-9 Control Valve .......................................... T1-2-10 Auxiliary control Valve............................. T1-2-10 4-Unit Solenoid Valve Unit ...................... T1-2-10 3-Unit Solenoid Valve Unit ...................... T1-2-10 Travel Shockless Valve / Accumulator Chrging Valve ...................................... T1-2-11 Transmission Control Valve .................... T1-2-11 Travel Device .......................................... T1-2-11 Filter ....................................................... T1-2-11



CBBT-1-1



(Blank)



CBBT-1-2



GENERAL / SPECIFICATIONS SPECIFICATIONS Standard GAUGE, REAR BLADE C H



D



B G P



F



N



E K



J Q



I



O R



L A



 MCBB-12-001



Type of Front-End Attachment Type of Arm Bucket Capacity (Heaped) Operating Weight Basic Machine Weight Engine Type Engine DIN 6271 net SAE J1349 net ISO 9249 net ECE-R24 A: Overall Width (Excluding Rearview Mirrors) B: Cab Height C: Rear End Swing Radius D: Rear End Length E: Minimum Ground Clearance F: Counterweight Clearance G: Engine Cover Height H: Overall Width of Upperstructure I: Wheelbase J: Swing-center to Rear Axle K: Front Wheel Tread L: Rear Wheel Tread M: Stabilizer Spread N: Max.Raising Height O: Max.Digging Depth P: Blade Height Q: Front Axle to Front of Chassis R: Rear Axle to Rear of Chassis Tire Size Swing Speed Travel Speed (fast/low/creeper) Gradeability



㧙 m3 (yd3) kg (lb) kg (lb) 㧙 -1 kW/min (PS/rpm) kW/min-1(PS/rpm) kW/min-1(PS/rpm) kW/min-1(PS/rpm) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) 㧙 min-1(rpm) km/h(mph) degree(%)



NOTE: ̪ Working mode



T1-1-1



Monoblock boom 2-piece boom 2.58m (8 ft 6 in) 2.50m (8 ft 2 in) PCSA 0.60m3 (0.78yd3), CECE 0.55m3 15800 (34800) 16400 (36200) 12400 (27300) 12400 (27300) ISUZU AA-4BG1TC 90.2(123)/2300 ̪84.8(115)/1850 90.2(123)/2300 ̪84.8(115)/1850 90.2(123)/2300 ̪84.8(115)/1850 90.2(123)/2300 2530 (8’ 4”) 3045 (10' 0") 2190 (7' 2") 2190 (7' 2") 360 (1’ 2”) 1215 (4' 0") 2345 (7' 8") 2465 (8' 1") 2550 (8' 4") 1000 (3' 3") 1915 (6' 3") 1915 (6' 3") 440 (1’ 5”) 150 (6") 590 (1' 6") 1015 (3' 4") 1025 (3’ 4”) 10.00-20 14PR 13.3 32.0㧛9.0㧛2.3 (19.9㧛5.6㧛1.4) 35(70)



GENERAL / SPECIFICATIONS Standard GAUGE, REAR STABILIZER C H



D



B G F E K A



J I



Q



L R



M



 MCBB-12-002



Type of Front-End Attachment Type of Arm Bucket Capacity (Heaped) Operating Weight Basic Machine Weight Engine Type Engine DIN 6271 net SAE J1349 net ISO 9249 net ECE-R24 A: Overall Width (Excluding Rearview Mirrors) B: Cab Height C: Rear End Swing Radius D: Rear End Length E: Minimum Ground Clearance F: Counterweight Clearance G: Engine Cover Height H: Overall Width of Upperstructure I: Wheelbase J: Swing-center to Rear Axle K: Front Wheel Tread L: Rear Wheel Tread M: Stabilizer Spread N: Max.Raising Height O: Max.Digging Depth P: Blade Height Q: Front Axle to Front of Chassis R: Rear Axle to Rear of Chassis Tire Size Swing Speed Travel Speed (fast/low/creeper) Gradeability



㧙 m (yd3) kg (lb) kg (lb) 㧙 kW/min-1(PS/rpm) kW/min-1(PS/rpm) kW/min-1(PS/rpm) kW/min-1(PS/rpm) 3



mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) 㧙 min-1(rpm) km/h(mph) degree(%)



NOTE: ̪ Working mode



T1-1-2



Monoblock boom 2-piece boom 2.58m(8 ft 6 in) 2.50m (8 ft 2 in) PCSA 0.60m3 (0.80yd3), CECE 0.55m3 16300 (35900) 16800 (37000) 12800 (28200) 12800 (28200) ISUZU AA-4BG1TC 90.2(123)/2300 ̪84.8(115)/1850 90.2(123)/2300 ̪84.8(115)/1850 90.2(123)/2300 ̪84.8(115)/1850 90.2(123)/2300 2530 (8’ 4”) 3045 (10' 0") 2190 (7’ 2”) 2190 (7’ 2”) 360 (1’ 2”) 1215 (4’ 0”) 2345 (7’ 8”) 2465 (8’ 1”) 2550 (8’ 4”) 1000 (3’ 3”) 1915 (6’ 3”) 1915 (6’ 3”) 3570 (11’ 9”) 㧙 㧙 㧙 1015 (3’ 4”) 1030 (3’ 5”) 10.00-20 14PR 13.3 32.0㧛9.0㧛2.3 (19.9㧛5.6㧛1.4) 35 (70)



GENERAL / SPECIFICATIONS Standard GAUGE, FRONT BLADE REAR STABILIZER C H



D



B G P



F



N K



E J



O



A



Q



I



L R



M



 MCBB-12-003



Type of Front-End Attachment Type of Arm Bucket Capacity (Heaped) Operating Weight Basic Machine Weight Engine Type Engine DIN 6271 net SAE J1349 net ISO 9249 net ECE-R24 A: Overall Width (Excluding Rearview Mirrors) B: Cab Height C: Rear End Swing Radius D: Rear End Length E: Minimum Ground Clearance F: Counterweight Clearance G: Engine Cover Height H: Overall Width of Upperstructure I: Wheelbase J: Swing-center to Rear Axle K: Front Wheel Tread L: Rear Wheel Tread M: Stabilizer Spread N: Max.Raising Height O: Max.Digging Depth P: Blade Height Q: Front Axle to Front of Chassis R: Rear Axle to Rear of Chassis Tire Size Swing Speed Travel Speed (fast/low/creeper) Gradeability



㧙 m3 (yd3) kg (lb) kg (lb) 㧙 -1 kW/min (PS/rpm) kW/min-1(PS/rpm) kW/min-1(PS/rpm) kW/min-1(PS/rpm) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) 㧙 min-1(rpm) km/h(mph) degree(%)



NOTE: ̪ Working mode



T1-1-3



Monoblock boom 2-piece boom 2.58m(8 ft 6 in) 2.50m (8 ft 2 in) PCSA 0.60m3 (0.80yd3), CECE 0.55m3 16900 (37300) 17400 (38400) 13500 (29800) 13500 (29800) ISUZU AA-4BG1TC 90.2(123)/2300 ̪84.8(115)/1850 90.2(123)/2300 ̪84.8(115)/1850 90.2(123)/2300 ̪84.8(115)/1850 90.2(123)/2300 2530 (8’ 4”) 3045 (10’ 0”) 2190 (7' 2") 2190 (7’ 2”) 360 (1’ 2”) 1215 (4’ 0”) 2345 (7’ 8”) 2465 (8’ 1”) 2550 (8’ 4”) 1000 (3’ 3”) 1915 (6’ 3”) 1915 (6’ 3”) 3570 (11’ 9”) 440 (1’ 5”) 150 (6") 590 (1' 6") 1315 (4’ 4”) 1030 (3’ 5”) 10.00-20 14PR 13.3 32.0㧛9.0㧛2.3 (19.9㧛5.6㧛1.4) 35 (70)



GENERAL / SPECIFICATIONS Standard GAUGE, FRONT STABILIZER REAR BLADE C H



D



B G P E



F



N



K M



J Q



I



O R



L A



 MCBB-12-004



Type of Front-End Attachment Type of Arm Bucket Capacity (Heaped) Operating Weight Basic Machine Weight Engine Type Engine DIN 6271 net SAE J1349 net ISO 9249 net ECE-R24 A: Overall Width (Excluding Rearview Mirrors) B: Cab Height C: Rear End Swing Radius D: Rear End Length E: Minimum Ground Clearance F: Counterweight Clearance G: Engine Cover Height H: Overall Width of Upperstructure I: Wheelbase J: Swing-center to Rear Axle K: Front Wheel Tread L: Rear Wheel Tread M: Stabilizer Spread N: Max.Raising Height O: Max.Digging Depth P: Blade Height Q: Front Axle to Front of Chassis R: Rear Axle to Rear of Chassis Tire Size Swing Speed Travel Speed (fast/low/creeper) Gradeability



㧙 m3 (yd3) kg (lb) kg (lb) 㧙 -1 kW/min (PS/rpm) kW/min-1(PS/rpm) kW/min-1(PS/rpm) kW/min-1(PS/rpm) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) 㧙 min-1(rpm) km/h(mph) degree(%)



NOTE: ̪ Working mode



T1-1-4



Monoblock boom 2-piece boom 2.58m (8 ft 6 in) 2.50m (8 ft 2 in) PCSA 0.60m3 (0.80yd3), CECE 0.55m3 16900 (37300) 17400 (38400) 13500 (29800) 13500 (29800) ISUZU AA-4BG1TC 90.2(123)/2300 ̪84.8(115)/1850 90.2(123)/2300 ̪84.8(115)/1850 90.2(123)/2300 ̪84.8(115)/1850 90.2(123)/2300 2530 (8’ 4”) 3045 (10’ 0”) 2190 (7' 2") 2190 (7’ 2”) 360 (1’ 2”) 1215 (4’ 0”) 2345 (7’ 8”) 2465 (8’ 1”) 2550 (8’ 4”) 1000 (3’ 3”) 1915 (6’ 3”) 1915 (6’ 3”) 3570 (11’ 9”) 440 (1’ 5”) 150 (6”) 590 (1' 6") 1320 (4’ 4”) 1025 (3’ 4”) 10.00-20 14PR 13.3 32.0㧛9.0㧛2.3 (19.9㧛5.6㧛1.4) 35 (70)



GENERAL / SPECIFICATIONS Standard GAUGE, FRONT REAR STABILIZER C H



D



B G F E J



K A



Q



I



L R



M



 MCBB-12-005



Type of Front-End Attachment Type of Arm Bucket Capacity (Heaped) Operating Weight Basic Machine Weight Engine Type Engine DIN 6271 net SAE J1349 net ISO 9249 net ECE-R24 A: Overall Width (Excluding Rearview Mirrors) B: Cab Height C: Rear End Swing Radius D: Rear End Length E: Minimum Ground Clearance F: Counterweight Clearance G: Engine Cover Height H: Overall Width of Upperstructure I: Wheelbase J: Swing-center to Rear Axle K: Front Wheel Tread L: Rear Wheel Tread M: Stabilizer Spread N: Max.Raising Height O: Max.Digging Depth P: Blade Height Q: Front Axle to Front of Chassis R: Rear Axle to Rear of Chassis Tire Size Swing Speed Travel Speed (fast/low/creeper) Gradeability



㧙 m3 (yd3) kg (lb) kg (lb) 㧙 kW/min-1(PS/rpm) kW/min-1(PS/rpm) kW/min-1(PS/rpm) kW/min-1(PS/rpm) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) 㧙 min-1(rpm) km/h(mph) degree(%)



NOTE: ̪ Working mode



T1-1-5



Monoblock boom 2-piece boom 2.58m(8 ft 6 in) 2.50m (8 ft 2 in) PCSA 0.60m3 (0.80yd3), CECE 0.55m3 17300 (38100) 17900 (39500) 13900 (30600) 13900 (30600) ISUZU AA-4BG1TC 90.2(123)/2300 ̪84.8(115)/1850 90.2(123)/2300 ̪84.8(115)/1850 90.2(123)/2300 ̪84.8(115)/1850 90.2(123)/2300 2530 (8’ 4”) 3045 (10' 0") 2190 (7’ 2”) 2190 (7’ 2”) 360 (1’ 2”) 1215 (4’ 0”) 2345 (7’ 8”) 2465 (8’ 1”) 2550 (8' 4") 1000 (3' 3") 1915 (6’ 3”) 1915 (6’ 3”) 3570 (11’ 9”) 㧙 㧙 㧙 1320 (4’ 4”) 1030 (3’ 5”) 10.00-20 14PR 13.3 32.0㧛9.0㧛2.3 (19.9㧛5.6㧛1.4) 35 (70)



GENERAL / SPECIFICATIONS WORKING RANGES MONOBLOCK BOOM



G



C



D



E



F A B



 MCBB-12-006



Type of Front-End Attachment Category Item A: Maximum Digging Reach B: Maximum Digging Depth C: Maximum Cutting Height D: Maximum Dumping Height E: Transport Height



Monoblock Boom 2.22 m (7 ft 3 in) Arm



2.58 m (8 ft 6 in) Arm



3.10 m (10 ft 2 in) Arm



Backhoe



Backhoe



Backhoe



mm



8650



9000



9460



(ftxin)



(28′ 5″)



(29′ 6″)



(31′ 0″)



mm



4970



5340



5840



(ftxin)



(16′ 4″)



(17′ 6″)



(19′ 2″)



mm



8810



9090



9340



(ftxin)



(28′ 11″)



(29′ 10″)



(30′ 8″)



mm



6110



6350



6600



(ftxin)



(20′ 0″)



(20′ 10″)



(21′ 8″)



mm



3210



3045



3120



(ftxin)



(10′ 6″)



(10′ 0″)



(10′ 3″)



Standard Gauge, Rear Blade/Stabilizer F: Overall Transport



mm



8510



Length (Max)



(ftxin)



(27′ 11″)



Standard Gauge,



Radius



Standard Gauge, Rear Blade/Stabilizer



8820 (28′ 11″)



Standard Gauge,



Front Blade, Rear Stabilizer



9090



Front Blade, Rear Stabilizer



9120



Front Stabilizer, Rear Blade



(29′ 10″)



Front Stabilizer, Rear Blade



(29′ 11″)



Front Rear Stabilizer G: Minimum Swing



8790 (28′ 10″)



Front Rear Stabilizer



mm



3340



2900



2920



(ftxin)



(10′ 11″)



(9′ 6″)



(9′ 7″)



T1-1-6



GENERAL / SPECIFICATIONS 2-PIECE BOOM



G



C D E



F A B



 MCBB-12-007



Type of Front-End Attachment Category



2.21 m (7 ft 3 in) Arm



2.50 m (8 ft 2 in) Arm



3.10 m (10 ft 2 in) Arm



Backhoe



Backhoe



Backhoe



mm



9020



9280



9800



(ftxin)



(29′ 7″)



(30′ 5″)



(32′ 2″)



Item A: Maximum Digging Reach B: Maximum Digging Depth C: Maximum Cutting Height D: Maximum Dumping Height E: Transport Height



2-piece Boom



mm



5440



5730



6300



(ftxin)



(17′ 10″)



(18′ 10″)



(20′ 8″)



mm



9650



9800



10090



(ftxin)



(31′ 8″)



(32′ 2″)



(33′ 1″)



mm



6810



6970



7260



(ftxin)



(22′ 4″)



(22′ 10″)



(23′ 10″)



mm



3300



3340



3610



(ftxin)



(10′ 10″)



(10′ 11″)



(11′ 10″)



Standard Gauge, Rear Blade/Stabilizer F: Overall Transport



mm



8550



Length (Max)



(ftxin)



(28′ 1″)



Standard Gauge,



Radius



Standard Gauge, Rear Blade/Stabilizer



8880 (29′ 2″)



Standard Gauge,



Front Blade, Rear Stabilizer



9220



Front Blade, Rear Stabilizer



9180



Front Stabilizer, Rear Blade



(30′ 3″)



Front Stabilizer, Rear Blade



(30′ 1″)



Front Rear Stabilizer G: Minimum Swing



8920 (29′ 3″)



Front Rear Stabilizer



mm



3070



3030



3430



(ftxin)



(10′ 1″)



(9′ 11″)



(11′ 3″)



T1-1-7



GENERAL / SPECIFICATIONS (Blank)



T1-1-8



GENERAL / Component Layout MAIN COMPONENT LAYOUT Upperstructure 2



3



4



5



6



7



8



9



10



12



11



1



13 14 15 16 17 29 18 19



28 27



20 26 25



24







23



22



1 - Pilot Valve (Left)



9 - Center Joint



16 - Accumulator (Pilot Circuit)



2 - Positioning/Auxiliary Pilot Valve 3 - Steering Valve 4 - Brake Valve



10 - Signal Control Valve



17 - 4-Unit Solenoid Valve Unit



11 - Swing Device 12 - Control Valve



18 - 3-Unit Solenoid Valve Unit 19 - Pilot Filter



13 - Accumulator (Transmission Circuit) 14 - Transmission Control Valve



20 - Steering Filter 21 - Pump Device



15 - Pilot Relief Valve



22 - Engine



5 - Travel Pilot Valve 6 - Pilot Valve (Right) 7 - Blade/Stabilizer Pilot Valve 8 - Auxiliary Control Valve



T1-2-1



21



T1F3-01-02-001



23 - Shuttle Valve (Swing Parking Brake Release Circuit) 24 - Accumulator Charging Valve 25 - Travel Shockless Valve 26 - Shuttle Valve (Blade/Stabilizer Circuit) 27 - Blade/Stabilizer Signal Shift Valve 28 - Accumulator (Brake Circuit) 29 - Pilot Shut-Off Valve



GENERAL / Component Layout Undercarriage   



2



1



3



4



5



8 7



6



 T1F3-01-02-002



  1 - Blade Cylinder 2 - Rear Axle



3-



2-Unit Solenoid Valve (Blade/Stabilizer) 4 - Axle Lock Cylinder



5-



Front Axle



7-



Transmission



6-



Stabilizer Cylinder



8-



Travel Motor



 



T1-2-2



GENERAL / Component Layout Front Attachment 2-Piece Boom



Monoblock Boom 1



2



2



3 4 7



7 4



1 5



6



6







 T1F3-01-02-004



T1F3-01-02-003



1 - Bucket Cylinder



3-



Positioning Cylinder



2 - Arm Cylinder



4-



Boom Cylinder



5-



Hose-Rupture Safety Valve (Positioning) 6 - Hose-Rupture Safety Valve (Boom)



NOTE: Hose-rupture safety valves (5), (6), (7) are optional.



T1-2-3



7㩷



Hose-Rupture Safety Valve (Arm)



GENERAL / Component Layout ELECTRICAL COMPONENT LAYOUT (Overview)



1



2



Refer to the Transmission Control Valve. (T1-2-11)



Refer to the Signal Control Valve. (T1-2-9)



Refer to the Swing Device.㩷 (T1-2-9)



3



Refer to the Control Valve. (T1-2-10)



4



15



5



14



Refer to the Pump Device. (T1-2-9)



13



6 Refer to the Travel Shockless Valve and Accumulator Charging Valve. (T1-2-11)



Refer to the Filter. (T1-2-11)



12



7



 T1F3-01-02-011



11



10



9



8



1 - Service Brake Pressure Switch 2 - Fuel Sensor



5 - EC Motor/EC Sensor 6 - 3-Unit Solenoid Valve Unit



9 - Coolant Temperature Sensor 10 - Battery Relay



3 - 4-Unit Solenoid Valve Unit 4 - Hydraulic Oil Temperature Sensor



7 - Engine Oil Pressure Switch 8 - Overheat Switch



11 - Glow Plug Relay 12 - Battery



T1-2-4



13 - Air Cleaner Restriction Switch 14 - Brake Remaining Pressure Switch 15 - Slip Ring



GENERAL / Component Layout ELECTRICAL SYSTEM (RELAYS)



1



2



5



4



3



6



7



8 9



Relay Position (T1-2-6)



10



T1F3-01-02-012



1 - QOS Controller 2 - Transistor Unit 2



45-



Transistor Unit 1 Fuse Box



78-



3 - Flasher Relay



6-



Dr. ZX Connector to MC



∗Transister Unit 3 is available for additional attachment



T1-2-5



Learning Switch ICX (Information Controller)



9 - MC (Main Controller) 10 - Dr. ZX Connector to ICX



GENERAL / Component Layout Relay Position 



A



1 2



 T1F3-01-02-012







3



View A







4 5 6 7 8 9



30 29 28 27 26



10 11 12



25 24 23



13 14 15



22 21



16







20



T1F3-01-02-013



19 18 1 - Head Lamp Relay (Left-Lower) (R29) 2 - Parking Brake Relay 3 (R30) 3 - Parking Brake Relay 2 (R11) 4 - Work Light Relay (R4) 5 - High Beam Relay (R14)



17



9-



Head Lamp Relay (Right-Lower) (R13) 10 - Wiper Relay A (R6) 11 - Wiper Relay B-3 (R9) 12 - Washer Relay (R2)



6 - Wiper Relay B-1 (R7)



13 - Right Clearance Light Relay (R12) 14 - Horn Relay (R5)



7 - Starter Relay (R10)



15 - Wiper Relay B-2 (R8)



8 - Work Light Relay (R3)



16 - Load Damp Relay (R1)



17 - Left Turn Signal Relay (R15) 18 - Work Brake Indicator Relay (R18) 19 - Neutral Signal Relay (R21) 20 - Right Turn Signal Relay (R16) 21 - Travel Forward Pi Cut Relay (R24) 22 - Axle Lock Relay (R19) 23 - Travel Motor Alarm Relay (R22)







T1-2-6



24 - Stop Lamp Relay (R17) 25 - Travel Reverse Pi Cut Relay (R25) 26 - Parking Brake Alarm Relay (R23) 27 - Transmission Changeover Relay (R20) 28 - Auto-Acceleration Cancel Relay (R26) 29 - Parking Brake Relay 1 (R27) 30 - Left Clearance Light Relay (R28)



GENERAL / Component Layout ELECTRICAL SYSTEM (Monitors and Switches)



 







1 2







19



18 3



17 16







4



15



MCBB-01-022



5



 14







6 7 13



20



8



12 11



21







10



MCBB-01-012



22







9







23



24



25



26











M216-01-021



MCBB-01-014



 1 - Coolant Temperature Gauge 2 - Fuel Gauge



9-



3 - Display Selection Switch



10 -



4 - Set Switch



11 -



5 - Work Mode Switch



12 -



6 - Fuel Level Indicator



13 - Air Filter Restriction Indicator 14 - Overheat Indicator



7 - Alternator Indicator



8-



Blade/Stabilizer Operation Indicator Overload Alarm Indicator (Optional) Hydraulic Oil Filter Restriction Indicator Engine Oil Pressure Indicator Preheat Indicator



15 - Digging Mode Indicator



22 - Work Light Switch



16 - Attachment Mode Indicator 17 - Liquid Crystal Display (LCD) 18 - Auto-Idle Indicator



23 - Power Mode Switch



19 - Auto-Acceleration Indicator 20 - Engine Control Dial 21 - Engine Speed Control Mode Selection Switch



T1-2-7



24 - Auto-Idle/Acceleration Selector 25 - Brake Selection Switch 26 - Shift Lever



GENERAL / Component Layout ELECTRICAL SYSTEM (Column Box)  



1, 2, 3, 4



5



 8 6



9



10



12



11







 13



12 MCBB-01-004



  



14



15



16



17



18



19



20







MCBB-01-005



7











22



21







MCBB-01-006



  1 - Turn Signal Switch 2 - Light Switch 3 - Dimmer Switch



789-



4 - Passing Switch 5 - Hazard Light Switch



Horn Switch Turn Signal Indicator Abnormal Travel Motor Indicator 10 - Work Light Indicator 11 - Travel Mode Indicator



6 - Wiper Switch



12 - Auxiliary 2



13 - Auxiliary 1 14 - Brake Oil Pressure Gauge 15 - Speed Meter



18 - Clearance Light Indicator 19 - Parking Brake Indicator 20 - Work Brake Indicator



16 - Hazard Light Indicator 17 - High-Beam Indicator



21 - Axle Lock Indicator 22 - Brake Oil Pressure Indicator



㩷







T1-2-8



8



GENERAL / Component Layout PUMP DEVICE 















2



1







6



5







 4











T1F3-01-02-008



3



10







9



8











SWING DEVICE



SIGNAL CONTROL VALVE











7



T1F3-01-02-007



12



13



11



 T1F3-03-06-003











T178-03-02-001



 1 - Steering Pump



5-



2 - Pilot Pump



6-



3 - Pump 1



N sensor (Engine)



8-



Torque Control Solenoid Valve 7 - Pump 2 Control Pressure Sensor



Pump 2 Delivery Pressure Sensor 9 - Pump 1 Control Pressure Sensor 10 - Pump 1 Delivery Pressure Sensor



4 - Pump 2







T1-2-9



11 - Pressure Sensor (Front Attachment) 12 - Pressure Sensor (Auxiliary) 13 - Pressure Sensor (Swing)



GENERAL / Component Layout CONTROL VALVE



AUXILIARY CONTROL VALVE FOR BLADE & OUTRIGGER 4 (39.2 MPa)



1



2



T1F3-03-03-018 T176-01-02-003



3



4-UNIT SOLENOID VALVE UNIT



3-UNIT SOLENOID VALVE UNIT 9



5



6



7



8



10



11



T178-01-02-003



T1F3-01-02-010



1 - Pressure Sensor (Arm Roll-In) 2 - Main Relief Valve (34.3 MPa) 3 - Pressure Sensor (Boom Raise) SC SE SG SI



4-



Overload Relief Valve (Auxiliary Control Valve) 5 - Solenoid Valve Unit (SC)



7-



Solenoid Valve Unit (SI)



8-



Solenoid Valve Unit (SG)



6-



9-



Max. Pump 1 Flow Rate Limit Solenoid Valve



Solenoid Valve Unit (SE)



: Arm Regenerative : For Axle Lock : Brake Valve Control : Travel Motor Capasity Control



T1-2-10



10 - Max. Pump 2 Flow Rate Limit Solenoid Valve 11 - Max. Pump 1 Flow Rate Shift Solenoid Valve Increase Max. Flow Rate from 75 cc/rev. to 80 cc/rev.



GENERAL / Component Layout TRAVEL SHOCKLESS VALVE/ ACCUMULATOR CHARGING VALVE



TRANSMISSION CONTROL VALVE 9



Pressure (Cut-in) : 12.3 MPa (Cut-out) : 15.0 MPa



10 8 11



1



2



3



4



5



12 T1F3-01-02-006



Reducing Valve Press. Setting : 3.4 MPa Relief Press. Setting : 1.3 MPa 7



6 T1F3-01-02-005



FILTER TRAVEL DEVICE 17 13 14



18 19



15



16 MCBB-07-026 T1F3-01-02-009



1 - Travel Shockless Valve 2 - Pressure Sensor (Travel Forward) 3 - Travel Forward Pi Cut Solenoid Valve 4 - Pressure Sensor (Brake Oil Pressure Gauge) 5 - Accumulator Charging Valve



6-



Travel Reverse Pi Cut Solenoid Valve 7 - Pressure Sensor (Travel Reverse) 8 - Transmission Control Valve



11 - Accumulator (Transmission Circuit) 12 - Parking Brake Pressure Switch 13 - N sensor (Travel)



9-



14 - Transmission



Transmission Changeover Solenoid Valve 10 - Parking Brake Solenoid Valve



15 - Travel Motor



T1-2-11



16 - Travel Motor Drain Pressure Switch 17 - Pilot Filter 18 - Steering Pump Delivery Pressure Sensor 19 - Steering Filter



GENERAL / Component Layout (Blank)                         



T1-2-12



GENERAL / Component Specifications ENGINE Manufacturer.................................................. ISUZU Model ............................................................. AA-4BG1TCG Type ............................................................... Diesel, 4-Cycle, Water-cooled, Inline, Direct Injection Cyl. No.- Bore × Stroke .................................. 4-105 mm×125 mm (4.13 in×4.92 in) Piston Displacement ...................................... 4329 cm3 (264 in3) Rated Output.................................................. 84.8 kW/1850 min-1 (115 PS/1850 rpm) HP Mode: 90.2 kW/2300 min-1 (123 PS/2300 rpm) Compression Ratio ........................................ 18:1 Dry Weight ..................................................... 362 kg (800 lb) Firing Order.................................................... 1-3-4-2 Rotation Direction .......................................... Clockwise (Viewed from fan side) COOLING SYSTEM Cooling Fan ................................................... Dia. 600 mm (23.6 in), 7 Blades (N-Type Blade, Unequal Pitch), Draw-in Type Fan Pulley Ratio............................................. Engine rpm × 0.84 Thermostat ..................................................... Cracking Temperature at Atmospheric Pressure: 82 °C (180 °F) Full Open (Stroke: 10 mm or more) Temperature: 95 °C (203 °F) Water Pump ................................................... Centrifugal Belt Driven Type LUBRICATION SYSTEM Lubrication Pump Type .................................. Gear Pump Oil Filter.......................................................... Full-Flow Paper Element Type with Bypass Oil Cooler ....................................................... Water Cooled Integral Type STARTING SYSTEM Motor ..............................................................Magnetic Pinion Shift Reduction Type Voltage / Output .............................................24 V / 4.5 kW PREHEAT SYSTEM Preheating Method.........................................Glow Plug (QOS Type) ENGINE STOP SYSTEM Stop Method................................................... Fuel Shut-Off



T1-3-1



GENERAL / Component Specifications ALTERNATOR Type................................................................Regulator Integrated AC Type Voltage / Output..............................................24 V / 50 A (Brushless)  SUPERCHARGING SYSTEM Type................................................................Exhaust-Turbocharger Type TD04HL  FUEL SYSTEM Type............................................................... BOSCH Type (ADS Type) Governor ....................................................... Centrifugal All Speed Control RSV Type Injection Nozzle ............................................. Multi-Hole Type PERFORMANCE IMPORTANT: This list shows design specifications, which are not servicing standards. Fuel Consumption Ratio (Digging) .................Less than 211±14 g/kW/h (155±10 g/PS⋅h) at 84.8 kW/1850 min-1 (at Working Load (P Mode)) (Traveling) ...............Less than 238±14 g/kW/h (175±10 g/PS⋅h) at 90.2 kW/2300 min-1 (at Full Load (Pedal Mode)) Injection Timing ..............................................9 ° before T.D.C. Maximum Output Torque ................................More than 449±39 N⋅m (45.8±4 kgf⋅m) at approx. 1800 min-1 Injection Pressure...........................................18.14 MPa (185 kgf/cm2) Compression Pressure...................................3.04 MPa (31 kgf/cm2) Valve Clearance (Inlet / Exhaust)...................0.4 / 0.4 mm (when cool) No Load Speed (Digging)...............................Slow: (at Full Load: 950+500 min-1) Fast: (at Full Load: 2530±25 min-1) (at Working Load: 2150±50 min-1) (Traveling) ............................Fast: (at Full Load: 2530±25 min-1)



T1-3-2



GENERAL / Component Specifications Engine Performance Curve (AA-4BG1TCG) Test Condition: 1. In conformity with JIS D1005 (Performance Test Method for Diesel Engine Used for Construction Machinery) under standard atmospheric pressure. 2. Equipped with the fan and alternator. Traveling at HP Mode



Torque N⋅m



Digging at P Mode



Output kW Traveling at HP Mode



Digging at P Mode



Fuel Consumption Ratio g/kW⋅h



-1



Engine Speed min (rpm) ×100



T1-3-3



T1F3-01-03-002



GENERAL / Component Specifications ENGINE ACCESSORIES  RADIATOR ASSEMBLY Type............................................................. Radiator/Oil Cooler Tandem Type Assembly Weight ......................................................... 73 kg (160 lb)   Radiator  Oil Cooler Capacity....................................................... 7.8 L (2.1 US gal) 18.0 L (1.7 US gal) Air-Tight Test Pressure................................ 100 kPa (1.0 kgf/cm2, 14.5 psi) 1500 kPa (15 kgf/cm2, 217 psi) Cap Opening Pressure................................ 49 kPa (0.5 kgf/cm2, 7 psi) −   Intercooler Capacity....................................................... 7.2 L (1.7 US gal) Air-Tight Test Pressure................................ 250 kPa (2.5 kgf/cm2, 36 psi) Cap Opening Pressure................................ −  BATTERY Capacity....................................................... 55 Ah (5-Hour Rate) Voltage......................................................... 12 V Weight ......................................................... 17.7 kg (39 lb) × 2 



T1-3-4



GENERAL / Component Specifications HYDRAULIC COMPONENT • Upperstructure



PUMP DEVICE Drive Gear Ratio.............................................Main Pump: 1, Pilot Pump: 1, Steering Pump: 1  MAIN PUMP Type................................................................Swash-Plate Type, Variable Displacement Tandem Plunger Pump Maximum Flow (Theoretical Value)................Pump 1: 184 L/min (48.5 US gpm) Pump 2: 172 L/min (45.4 US gpm)  REGULATOR Type................................................................Hydraulic Pressure Operated Type  PILOT PUMP, STEERING PUMP Type................................................................Fixed Displacement Type Gear Pump Maximum Flow (Theoretical Value)................27.8 L/min (7.34 US gpm) CONTROL VALVE Model..............................................................HCV06EH-101 Type................................................................Pilot Pressure Operated Type (4-Spools + 5-Spools) Main Relief Set-Pressure Normal: 34.3 MPa (350 kgf/cm2, 4980 psi) Overload Relief Set-Pressure ........................37.3 MPa (380 kgf/cm2, 5420 psi) at 50 L/min (13.2 US gpm) (Boom, Arm Roll-In, Bucket Roll-In) 39.2 MPa (400 kgf/cm2, 5690 psi) at 50 L/min (13.2 US gpm) (Arm Roll-Out, Bucket Roll-Out)  AUXILIARY CONTROL VALVE Type  Pilot Pressure Operated Type Overload Relief Set-Pressure  28.0+0.980 MPa (285+100 kgf/cm2, 4070+1420) at 80 L/min SWING DEVICE Type................................................................Two-Stage Reduction Planetary Gear Reduction Gear Ratio.....................................14.9  SWING MOTOR Model..............................................................M5X130C Type................................................................Swash-Plate Type, Fixed Displacement Axial Plunger Motor  VALVE UNIT Type................................................................Non Counterbalance Valve Type Relief Set-Pressure ........................................30.4+1.40 MPa (310+140 kgf/cm2, 4420+2040 psi) at 90 L/min SWING PARKING BRAKE Type................................................................Multi-Disc-Wet Negative Type Release Pressure...........................................1.9 to 2.8 MPa (19 to 28 kgf/cm2, 284 to 384 psi) 



T1-3-5



GENERAL / Component Specifications  SOLENOID VALVE UNIT Function..........................................................⋅SC  ⋅SE  ⋅SG  ⋅SI



: Arm Regenerative Control : Check Valve (Axle Lock) Control : Brake Valve Control : Travel Motor Swash Angle Control



3-UNIT SOLENOID VALVE Function..........................................................⋅Maximum Pump 1 Flow Rate Control  ⋅Pump 1 Flow Rate Limit Control  ⋅Pump 2 Flow Rate Limit Control 2-UNIT SOLENOID VALVE (AUXILIARY FLOW RATE CONTROL) (OPTIONAL) Function..........................................................⋅Auxiliary Flow Rate Control 2-UNIT SOLENOID VALVE (BLADE/STABILIZER) (OPTIONAL) Function..........................................................⋅Check Valve (Blade/Stabilizer) Control  SIGNAL CONTROL VALVE Function..........................................................⋅Shock Reducing (Boom Raise)  ⋅Pump Flow Rate Control  ⋅Bucket Flow Rate Control  ⋅Swing Parking Brake Release  PILOT SHUT-OFF VALVE Type................................................................Rotary Type PILOT RELIEF VALVE Relief Set-Pressure  3.7+0.2−0.1 MPa (37.7+2−1 kgf/cm2, 538+29−15 psi) at 13 L/min STEERING VALVE Relief Set-Pressure  17.2 MPa (175 kgf/cm2, 2500 psi) at 23 L/min Overload Relief Set-Pressure  22.6 MPa (230 kgf/cm2, 3286 psi) at 1 L/min BRAKE VALVE Brake Pressure 7.0 MPa (71 kgf/cm2, 1018 psi) ACCUMULATOR CHARGING VALVE Charging (Cut-in) Pressure 12.3 MPa (125 kgf/cm2, 1788 psi) Stopping to Charge (Cut-out) Pressure  15.0 MPa (153 kgf/cm2, 2181 psi)



T1-3-6



GENERAL / Component Specifications TRAVEL SHOCKLESS VALVE Type  Slow Return Valve (With the 2-Unit Solenoid Valve) TRANSMISSION CONTROL VALVE Type  With the2-Unit Solenoid Valve Reducing Valve Set-Pressure  3.4 MPa (35 kgf/cm2, 494 psi) Relief Set-Pressure  1.3 MPa (13 kgf/cm2, 189 psi) at 4 L/min OVERLOAD RELIEF VALVE (OUTSIDE) Overload Relief Set-Pressure  39.2+0.940 MPa (400+9.60 kgf/cm2, 5700+1370 psi) at 50 L/min  OIL COOLER BYPASS CHECK VALVE Cracking Pressure  600 kPa (6 kgf/cm2, 87 psi) at 5 L/min



T1-3-7



GENERAL / Component Specifications • Undercarriage  TRAVEL MOTOR Type........................................................ Bent-Axis Type Variable Displacement Axial Plunger Motor  TRAVEL BRAKE VALVE Type........................................................ Counter Balance Valve Type Relief Set Pressure ................................ 40±0.2 MPa (408 kgf/cm2, 5820±30 psi)  TRANSMISSION (DIRECT CONNECTION TO REAR AXLE) Type........................................................ Two-Speed Powershift Transmission Relief Gear Ratio.................................... High Speed Side : 1.39 Low Speed Side : 5.35 AXLE (FRONT, REAR) Type........................................................ Front : Steering Drive Axle with Hub Reduction Rear : Rigid Axle with Hub Reduction Final Reduction Gear Ratio.................... 13.848 AXLE LOCK CYLINDER Rod Diameter ......................................... 90 mm (3.54”) Stroke ..................................................... 96 mm (3.78”) Fully Retracted Length ........................... 83 mm (3.27”) Plating Thickness ................................... 30 µm (1.18 µin)



T1-3-8



GENERAL / Component Specifications • Front Attachment CYLINDER • Monoblock Boom:  Boom Rod Diameter ......................................... 80 mm (3.15”) Cylinder Bore.......................................... 110 mm (4.33”) Stroke ..................................................... 1005 mm (3’3”) Fully Retracted Length ........................... 1655 mm (5’5”) Plating Thickness ................................... 30 µm (1.18 µin)



Arm 90 mm (3.54”) 120 mm (4.72”) 1365 mm (4’5”) 1905 mm (6’3”) 30 µm (1.18 µin)







Boom Rod Diameter ......................................... 80 mm (3.15”) Cylinder Bore.......................................... 110 mm (4.33”) Stroke ..................................................... 940 mm (3’1”) Fully Retracted Length ........................... 1680 mm (5’6”) Plating Thickness ................................... 30 µm (1.18 µin)



Arm 90 mm (3.54”) 120 mm (4.72”) 1365 mm (4’5”) 1905 mm (6’3”) 30 µm (1.18 µin)







Bucket Rod Diameter ......................................... 75 mm (2.95”) Cylinder Bore.......................................... 105 mm (4.13”) Stroke ..................................................... 935 mm (3’0”) Fully Retracted Length ........................... 1460 mm (4’9”) Plating Thickness ................................... 30 µm (1.18 µin)



Positioning 120 mm (4.72”) 170 mm (6.69”) 648 mm (2’2”) 1290 mm (4’3”) 30 µm (1.18 µin)



Bucket Rod Diameter ......................................... 75 mm (2.95”) Cylinder Bore.......................................... 105 mm (4.13”) Stroke ..................................................... 935 mm (3’0”) Fully Retracted Length ........................... 1460 mm (4’9”) Plating Thickness ................................... 30 µm (1.18 µin)



• 2-Piece Boom: 



• Optional: 



Blade Rod Diameter ......................................... 60 mm (2.36”) Cylinder Bore.......................................... 105 mm (4.13”) Stroke ..................................................... 195 mm (7.68”) Fully Retracted Length ........................... 615 mm (2’0”) Plating Thickness ................................... 30 µm (1.18 µin) 



T1-3-9



Stabilizer 70 mm (2.76”) 120 mm (4.73”) 381 mm (1’3”) 854 mm (3’0”) 30 µm (1.18 µin)



GENERAL / Component Specifications ELECTRICAL COMPONENT BATTERY RELAY Voltage / Current   GLOW RELAY Voltage   HORN Voltage / Current  Sound Pressure   ILLUMINATION Specifications 



24 V / 100 A 24 V 24 V⋅1.5±0.5 A 113±5 dB (A) Work Light Halogen 24 V, 70 W Cab Light 24 V, 10 W Head Light: Halogen 24 V, 75 / 70 W Turn Signal Light : 24 V, 21 W Clearance Light : 24 V, 4 W License Plate : 24 V, 10 W Tail Light : 24 V, 10 W Stop Light : 24 V, 21 W



AIR CONDITIONER Refrigerant......................................................134 a Cooling Ability.................................................19.3 MJ/h (4600 kcal/h) Cool Air Volume..............................................550 m3/h or More Heating Ability.................................................21.0 MJ/h (5000 kcal/h) or More Warm Air Volume............................................400 m3/h or More Temperature Adjusting System ......................Electronic Type Refrigerant Quantity .......................................1000±50 g Compressor Oil Quantity................................180 cm3



T1-3-10



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SECTION 2



SYSTEM —CONTENTS— Group 1 Control System



Group 3 Electrical System



Outline ...................................................... T2-1-1



Outline ......................................................T2-3-1



Engine Control .......................................... T2-1-2



Main Circuit ...............................................T2-3-2



Pump Control .......................................... T2-1-27



Electric Power Circuit ................................T2-3-3



Valve Control .......................................... T2-1-40



Indicator Light Check Circuit .....................T2-3-4



Other Controls ........................................ T2-1-53



Accessory Circuit ......................................T2-3-5



Electric and Hydraulic



Preheat Circuit ..........................................T2-3-6



Composite Circuit Control ..................... T2-1-71



Starting Circuit...........................................T2-3-8 Charging Circuit ......................................T2-3-12



Group 2 Hydraulic System Outline ...................................................... T2-2-1 Pilot Circuit ............................................... T2-2-2 Service Brake Circuit .............................. T2-2-12



Parking Brake Circuit ..............................T2-3-16 Serge Voltage Prevention Circuit.............T2-3-18 Engine Stop Circuit..................................T2-3-19



Steering Circuit ....................................... T2-2-13 Main Circuit............................................. T2-2-14



CBBT-2-1



 (Blank)



CBBT-2-2



SYSTEM / Control System ENGINE CONTROL The engine control has the following functions:



• • • • • • • • • • • •



Engine Control Dial Control Forward/Reverse Travel Pedal Control Engine Slowdown Control HP Mode Control E Mode Control Auto-Idle Control Auto-Acceleration Control Auto-Warming Up Control Slow Idle Speed-Up Control *Attachment Operation Speed Increase Control *Attachment Operation Speed Limit Control Engine Learning Control



ZX160W (Actual Engine RPM) Pedal Mode with Travel Relief Pedal Mode with Digging HP-Mode with Arm-in Relief P-Mode with No ECO Mode P-Mode with ECO Mode P-Mode with Arm-in Relief E-Mode with No Load A/A, P-Mode with No Load A/I Warm-up Low Idle 950 1150 1200



1600 1750 1850 1900 2000 2050 22002300



ZX210W (Actual Engine RPM) Pedal Mode with Travel Relief Pedal Mode with Digging HP-Mode with Arm-in Relief P-Mode with No ECO Mode P-Mode with Arm-in Relief P-Mode with ECO Mode E-Mode with No Load A/A, P-Mode with No Load Warm-up A/I Pedal Mode (Low Idle) Low Idle



950 1150



T2-1-2



1300



1400 1650 1800



1950 1900 2000 2050 2120 2250



SYSTEM / Control System



Engine Control System Layout



Parking Brake Pressure Switch







N Sensor (Travel)



Column Box Learning Switch Pressure Sensor Travel Forward Travel Reverse Front Attachment Swing Boom Raise Arm Roll-In Auxiliary (Optional)



Key Switch



Engine Control Dial



Travel Motor Drain Pressure Sensor



Pump 1 Delivery Pressure Sensor



Pump 2 Delivery Pressure Sensor



EC Sensor Auto-Idle/Acceleration Selector Auto-Idle EC Motor



Auto-Acc eleration



Pump 1 Control Pressure Sensor Pump 2 Control Pressure Sensor



Power Mode Switch HP Mode E Mode P Mode



Hydraulic Oil TemAuxiliary Mode Switch (Optional) perature Sensor



Work Mode Switch Digging Mode Attachment Mode



Engine Speed Control Mode Selection Switch



Shift Lever



Brake Switch



Pedal



Neutral



Dial



D Mode



Creeper



L Mode



Work Brake Parking Brake Axle Lock OFF



 T1GL-02-01-001



NOTE: OP: Optional *Control system available only on the machine equipped with the optional parts.



T2-1-3



SYSTEM / Control System Engine Control Dial Control Function: Controls the engine speed in response to the rotation angle of the engine control dial -1 and reduces the engine speed by 100 min to reduce fuel consumption and noise level when all control levers are in neutral.



    



Operation: The MC drives the governor lever in response to the rotation angle of the engine control dial to regulate the engine speed.







NOTE: Even if the control dial is rotated to the full speed position, the governor lever doesn’t come in contact with the full speed stopper. (Refer to the HP mode control.)







When all control levers are turned to neutral (the travel and front attachment sensors are OFF), the MC drives the EC motor so that the engine speed is reduced from -1 the maximum speed by 100 min .







Engine speed is reduced by 100 min-1 when the control levers are in neutral.



Control Range



    



Slow Idle



Fast Idle



Engine Control Dial Position



 NOTE: The engine speed is reduced from the -1 maximum speed by 100 min . Therefore, when the engine speed set by the engine control dial is already slower than the -1 maximum speed by 100 min , the engine speed remains unchanged. This engine speed reduction control is activated regardless of whether the auto-idle and/or auto-acceleration control is activated or not.



-1



Engine speed reduction (100 min ) requirements: • Engine Speed Control Mode Selection Switch: Dial or Creeper Position • Auto-Idle / Auto-Acceleration Selector: Auto-Idle or OFF Position • Power Mode Switch: HP or P Position NOTE: When the engine speed control mode selection switch is not in the pedal or creeper position, the MC recognizes that the engine speed control mode selection switch is in the dial position. When the power mode switch is not in the HP or E mode position, the MC recognizes that the power mode switch is in the P mode position.



Engine Speed







NOTE: The signals from N sensor (travel) are sent to the MC via the column box. When the shift lever is not in either the N or L position, the MC recognizes that the shift lever is in the D position. NOTE: The engine governor stopper position is adjusted so as to match the travel pedal control. Accordingly, the governor lever doesn’t come in contact with the stopper in the normal mode.



T2-1-4



SYSTEM / Control System   Parking Brake Pressure Switch Pressure Sensor Travel Forward Travel Reverse Front Attachment



Engine Control Dial EC Sensor Auto-Idle/Acceleration Selector Auto-Idle EC Motor



Auto-Acc eleration Power Mode Switch HP Mode E Mode



Engine Speed Control Mode Selection Switch



Brake Switch



Shift Lever



P Mode Pedal



Neutral



Dial



D Mode



Creeper



L Mode



Work Brake Parking Brake Axle Lock OFF







T1GL-02-01-002



   NOTE: The illustration indicates system operation when each switch is placed in the following position. Engine Speed Control Mode Selection Switch: Dial Position Shift Lever: L Position Brake Switch: Work Position Auto-Idle/Auto-Acceleration Selector: Auto-Idle Position Power Mode Switch: P Position



x When P mode is selected, H/P & E are grounded. x When D mode is selected, N & L are grounded.



T2-1-5



SYSTEM / Control System Forward/Reverse Travel Pedal Control



• When driving the machine Function: When driving the machine, the MC controls the engine speed corresponding to the accelerator pedal stroke and/or pump loads so that travel operation at an economical engine speed can be achieved. Operation: Detection signals from the travel forward or reverse pilot pressure sensor and from the pump 1 delivery pressure sensor, and set-signal (D or L) of the shift lever are sent to the MC. After processing these information, the MC drives the EC motor so that the most proper engine speed is selected. Requirements: • Brake Switch: OFF or Axle Lock Position • Engine Speed Control Mode Selection Switch: Pedal Position • Shift Lever: D or L Position NOTE: When the brake switch is not in the work brake position and the parking brake pressure switch is OFF, the MC recognizes that the brake switch is in either the Axle lock or OFF position.



STATUS OF PARKING BRAKE LINE PARKING BRAKE PRESSURE SWITCH



PARKING ON



PARKING OFF



NOT PRESSURIZED



PRESSURIZED



CLOSE (ON)



OPEN (OFF)



T2-1-6



SYSTEM / Control System



  Parking Brake Pressure Switch Pressure Sensor Travel Forward Travel Reverse



Pump 1 Delivery Pressure Sensor EC Sensor



EC Motor



Engine Speed Control Mode Selection Switch



Shift Lever



Brake Switch



Pedal



Neutral



Work Brake



Dial



D Mode



Parking Brake



Creeper



L Mode



Axle Lock OFF



   NOTE: The illustration indicates system operation when each switch is placed in the following position. Engine Speed Control Mode Selection Switch: Pedal Position Shift Lever: L Position or D Position Brake Switch: Axle Lock or OFF Position (S is grounded)



T2-1-7



SYSTEM / Control System • When excavating operation Function: The engine speed is allowed to control with the forward/reverse travel pedal in addition to the engine control dial during excavation operation. Operation: When the following conditions are satisfied, the MC drives the EC motor in proportion to the forward/reverse travel pedal stroke (due to the sensing pressure signals from the travel forward pilot pressure sensor) so that the engine speed is controlled. NOTE: The engine speed range to be controlled with the forward/reverse travel pedal is up to the P mode maximum engine speed in the engine control dial control mode plus 250 min-1. Conditions: • Brake Switch: Work Brake Position • Shift Lever: N Position • Engine Speed Control Mode Selection Switch: Pedal Position



T2-1-8



SYSTEM / Control System



Parking Brake Pressure Switch Pressure Sensor Travel Forward Travel Reverse



EC Sensor



EC Motor



Engine Speed Control Mode Selection Switch



Shift Lever



Brake Switch



Pedal



Neutral



Dial



D Mode



Creeper



L Mode



Service Brake Parking Brake Axle Lock OFF T1GL-02-01-005



NOTE: The illustration indicates system operation when each switch is placed in the following position. Engine Speed Control Mode Selection Switch: Pedal Position Shift Lever: N Position Brake Switch: Work Brake Position



T2-1-9



SYSTEM / Control System Engine Slowdown Control Function: When reducing travel speed (when the travel pilot valve is returned to neutral), the engine speed is gradually reduced, preventing cavitation from occurring in the travel motor. Operation: 1. When the following conditions are satisfied and the travel speed is slower than approximately 20 km/h, the MC drives the EC motor, causing the engine speed to gradually reduce to the travel idle speed. 2. When the travel speed is faster than approximately 20 km/h, the engine speed is gradually reduced to 1700 min-1 and is once held to run at that speed. 3. After the travel speed is reduced to slower than approximately 20 km/h, the engine speed is again reduced gradually to the minimum speed.



The travel pilot valve is in neutral (the engine slowdown starts). Engine Speed Maximum Speed 1700 min



Conditions: • Engine Speed Control Mode Selection Switch: Pedal Position • Forward/Reverse Travel Pedal: After the pedal is fully pressed for longer than 4 seconds during travel operation (forward or reverse), when the accelerator pedal is returned to neutral. NOTE: When the brake switch is not in the work brake position and the parking brake pressure switch is OFF, the MC recognizes that the brake switch is in either the acceleration lock or OFF position. NOTE: When the Shift Lever is not in either the N or L position, the MC recognizes that the shift lever is in the D position. ∗ When N-sensor malfunctions, this protection is not performed. ∗ When N-sensor does not function, this protection system is not available.



T2-1-10



Travel Speed: Approximately 20 km/h



-1



Minimum Speed Travel Speed (Fast)



Travel Speed (Slow)



Travel Speed



SYSTEM / Control System  



Parking Brake Pressure Switch Pressure Sensor Travel Forward Travel Reverse



EC Sensor



EC Motor



Engine Speed Control Mode Selection Switch



Shift Lever



Brake Switch



Pedal



Neutral



Work Brake



Dial



D Mode



Parking Brake



Creeper



L Mode



Axle Lock OFF



   NOTE: The illustration indicates system operation when each switch is placed in the following position. Engine Speed Control Mode Selection Switch: Pedal Position Shift Lever: D Position Brake Switch: Axle Lock or OFF Position (S is grounded)



T2-1-11



SYSTEM / Control System HP Mode Control Function: Slightly increases digging power such as arm roll-in operation while excavating deeply.



Engine Speed



Operation: The MC drives the EC motor to slightly increase the engine speed set by the engine control dial when all the following conditions exist with the power mode switch is in the HP position. • Engine Control Dial: Set at 1600 min-1 or faster. • Boom Raise and/or Arm Roll-In Control: In Operation • Average Delivery Pressure of Pumps 1 and 2: High ( > 250 kgf/cm2) NOTE: The engine governor stopper position is adjusted in the HP mode. Accordingly, the governor lever doesn’t come in contact with the stopper in the normal mode.



T2-1-12



Maximum speed increases by 200 -1 min 1600 min



Slow Idle



-1



Fast Idle



Engine Control Dial Position



SYSTEM / Control System



  



PILOT PRESS. SENSOR Boom Raise Arm Roll-In



Pump 1 Delivery Pressure Sensor



Pump 2 Delivery Pressure Sensor



Engine Control Dial EC Sensor



EC Motor



Power Mode Switch HP Mode E Mode P Mode



 T1GL-02-01-006



 



T2-1-13



SYSTEM / Control System E Mode Control







 Function: Reduce the engine speed by the constant specified ratio.







Engine Speed



 Operation: The MC drives the EC motor to reduce the engine speed set by the engine control dial when the power mode switch is in the E mode position. The engine speed is reduced in proportion to the rotation angle of the engine control dial.



Engine speed is reduced at the constant specified ratio.



Slow Idle







Fast Idle



Engine Control Dial







EC Motor



Power Mode Switch



E Mode



  



T2-1-14



Engine Control Dial Position



SYSTEM / Control System (Blank)



T2-1-15



SYSTEM / Control System Auto-Idle Control  Function: Reduces the engine speed when all control levers are in neutral to reduce fuel consumption and noise level.







 Operation: Approx. 4 seconds after all control levers are return to neutral, the MC drives the EC motor so that the engine speed is reduced to the auto-idle speed. As soon as a control lever is operated (the travel and/or front attachment pressure sensor is turned ON), the MC drives the EC motor so that the engine speed is increased to the original engine speed (set by the engine control dial).







Auto-Idle System Deactivation Requirements: • Control Levers: Being operated (either travel or front attachment control levers with pilot sensor ON) • Power Mode Switch: When the E mode is changed to P mode or the P mode is changed to the E mode. • Engine Control Dial: When engine speed is changed.







    



Engine speed is reduced to the auto-idle speed 4 seconds later.



Engine Speed



 



Fast Speed



  Auto-Idle Speed      



T2-1-16



Slow Idle



Fast Idle



Engine Control Dial Position



SYSTEM / Control System



   Pressure Sensor Travel Forward Travel Reverse Front Attachment Engine Control Dial EC Sensor Auto-Idle/Acceleration Selector Auto-Idle EC Motor



Auto-Acceleration Power Mode Switch HP Mode E Mode P Mode



 T1GL-02-01-008



   



T2-1-17



SYSTEM / Control System Auto Acceleration Control Function: Automatically regulates the engine speed to meet the machine operating conditions. When all the control levers are in neutral, the engine speed is reduced to reduce fuel consumption and noise level. Operation: When a control lever is operated with the auto-idle/acceleration selector in auto acceleration position, the MC calculates the most proper engine operating speed corresponding to the signals from pressure sensors (travel, swing, boom raise, and arm roll-in), the pump control pressure sensors, and the pump delivery pressure sensors. Then, the MC drives the EC motor so that the engine speed is set to the rotation speed calculated by the MC. When all control levers are returned to neutral, the engine speed is reduced by 450 min-1 from the maximum speed first. Then, 4 seconds later, the engine speed is further reduced to the auto-idle speed. Conditions: • Engine Speed Control Mode Selection Switch: Dial or Creeper Position • Auto-Idle/Auto-Acceleration Selector: Auto-Acceleration Position • Power Mode Switch: HP or P Position



Engine Speed VS. Control Lever Operations: Engine Speed Engine speed is reduced from the maximum speed -1 by 400 min .



Fast Speed AutoAcceleration Speed



Engine speed is reduced to the auto-idle speed 4 seconds later.



Auto-Idle Speed Slow Speed



Slow Idle



Fast Idle



Engine Control Dial Position



Operating Time Progress VS. Engine Speed Change Control Lever Stroke Full Stroke



Neutral Position Time



NOTE: When the engine speed control mode selection switch is not in either the pedal or creeper position, the MC recognizes that the engine speed control mode selection switch is in the dial position. When the power mode switch is not in either the HP or E mode position, the MC recognizes that the power mode switch is in the P mode position. NOTE: When all control levers are returned to neutral, the engine speed is reduced by 450 min-1 from the maximum speed. In case the engine speed is set by the engine control dial and is running at a speed slower than the maximum speed by 100 min-1, the engine speed will be reduced by 300 min-1.



Engine Speed Fast Idle Speed (P Mode)



In response to the control lever stroke and the pump delivery pressure, the optimum engine speed is selected.



Auto Acceleration Control



Auto-Idle Engine Speed



T2-1-18



Time



SYSTEM / Control System



Pressure Sensor Travel Forward Travel Reverse Swing Boom Raise Engine Control Dial



Pump 1 Delivery Pressure Sensor



Pump 2 Delivery Pressure Sensor



Arm Roll-In EC Sensor



Auto-Idle/Acceleration Selector AutoIdle Auto-Acc eleration



EC Motor



Pump 1 Control Pressure Sensor



Power Mode Switch HP Mode E Mode P Mode



Engine Speed Control Mode Selection Switch



Pump 2 Control Pressure Sensor



Pedal Dial Creeper T1GL-02-01-009



NOTE: The illustration indicates system operation when each switch is placed in the following position. Auto-Idle/Auto-Acceleration Selector: Auto-Acceleration Position Power Mode Switch: P Position (H/P & E are grounded) Engine Speed Control Mode Selection Switch: Dial Position (Creeper is grounded at Pedal mode) ∗ Pedal and creeper shall be grounded at Dial mode.



T2-1-19



SYSTEM / Control System Auto Warming Up Control







 Function: Automatically warms up the hydraulic system (similar to the auto choke on automobiles).







 Operation: When the hydraulic oil temperature is below 0 qC (32 qF), the MC drives the EC motor in response to signals from the key switch and the hydraulic oil temperature sensor to run the engine at the auto warming up speed for 15 minutes after starting the engine.







  



Fast Speed



  Auto



Warming



Increasing Speed



 Up Speed  Slow 



IMPORTANT: When adjusting the auto-idle speed deactivate the auto warming up control function using Dr. ZX, or wait to adjust until 15 minutes after starting the engine.



Engine Speed



Speed







Fast Idle



Slow Idle







Engine Control Dial Position



ZX160W : 1150 r 100 rpm ZX210W : 1400 + 140 rmp  100 rmp



  



Key Switch



EC Motor







Hydraulic Oil Temperature Sensor







T2-1-20



T1GL-02-01-010



SYSTEM / Control System Slow Idle Speed-Up Control







 Function: Prevents the engine from hunting when running the engine at slow speed.







 Operation: When the travel or front attachment function is operated while the engine is running at a speed between the minimum speed and the Slow Idle Speed-Up Speed, the MC drives the EC motor so that the engine speed is increased to the Slow Idle Speed-Up Speed.











Engine Speed



   Idle



Speed-Up



Speed



Increasing Speed







Engine Control Dial Position



  



Slow Idle



Fast Idle



  Pressure Sensor Travel Forward Travel Reverse Front Attachment



Engine Control Dial



EC Motor



 T1GL-02-01-046







T2-1-21



SYSTEM / Control System Attachment Operation Speed Increase Control (Only on the machines equipped with the auxiliary mode switch (Optional).)  Function: Increases the maximum engine speed to the attachment (hydraulic breaker, secondary crusher, primary crusher or vibrating hammer) operating engine speed set by Dr. ZX when the attachment is operated. Operation: When the following conditions exist, the MC drives the EC motor so that the engine maximum speed is increased to the attachment operating speed set by Dr. ZX when the attachment is operated.  Operating Conditions: Dr. ZX: Resets the maximum engine speed to a faster (+) attachment (hydraulic breaker, secondary crusher, primary crusher, or vibrating hammer) operating speed in the service mode. Engine Control Dial: Maximum Speed Position Power Mode Switch: HP Mode Auxiliary: In Operation Work Mode Switch: Attachment Mode Auxiliary Mode Switch (Optional): Attachment position (hydraulic breaker, secondary crusher, primary crusher, or vibrating hammer) reset by Dr. ZX.



   



When all conditions exist, the maximum engine speed is increased to the speed set by Dr. ZX.



Engine Speed



         



Slow Idle



Fast Idle



Engine Control Dial Position



  NOTE: When the P mode engine speed is preset to a slower speed in the Dr. ZX service mode, the maximum engine speed won’t be increased when operating the attachment. 







T2-1-22



SYSTEM / Control System



  



PILOT PRESS. SENSOR



Engine Control Dial



Auxiliary (Optional) EC Sensor



EC Motor Power Mode Switch HP Mode E Mode P Mode Auxiliary Mode Switch (Optional) Work Mode Switch Digging Mode Attachment Mode







 



T2-1-23



SYSTEM / Control System Attachment Operation Speed Limit Control (Only on the machines equipped with the auxiliary mode switch (Optional).)







 Function: Decreases the maximum engine speed to the attachment (hydraulic breaker, secondary crusher, primary crusher or vibrating hammer) operating engine speed set by Dr. ZX when the attachment mode is selected.







Operation: When the following conditions exists, the MC drives the EC motor so that the engine maximum speed is reduced to the attachment operating speed set by Dr. ZX when the attachment mode is selected.







 Operating Conditions: Dr. ZX: Resets the maximum engine speed to a slower () attachment (hydraulic breaker, secondary crusher, primary crusher, or vibrator) operating speed in the service mode. Work Mode Switch: Attachment Mode Auxiliary Mode Switch (Optional): Attachment position (hydraulic breaker, secondary crusher, primary crusher, or vibrating hammer) set by Dr. ZX.







  



Engine Speed When all conditions exist, the maximum engine speed is reduced to the speed set by Dr. ZX.



 



   



Slow Idle



Fast Idle



 



  Engine Control Dial EC Sensor



EC Motor



Work Mode Switch Digging Mode Attachment Mode



 Auxiliary Mode Switch (Optional)



 NOTE: OP: Optional  



T2-1-24



T1GL-02-01-012



SYSTEM / Control System Engine Learning Control Function: Inputs the governor lever stopper positions on both the STOP and FULL sides as the standard data to control the engine. Operation:When the learning switch in the rear console is turned to the engine learning position, the EC motor is driven by the signals from the MC. The EC motor moves the governor lever from the IDLE to FULL and to STOP positions in this order. The EC sensor detects the stopper positions of the governor lever on both the FULL and STOP sides and sends each stopper position signal to the MC. The MC stores these signals in its memory.



IMPORTANT: Be sure to perform the engine learning if the following repair work is done. (Refer to the Troubleshooting Section in T/M.) After performing the engine learning, check that the engine learning has been performed correctly using Dr. ZX. • After the engine, engine control cable, or EC motor has been removed or replaced. • After the MC has been replaced. NOTE: The engine learning is not required when the batteries are replaced.



Learning Switch



Key Switch EC Sensor



EC Motor T1GL-02-01-014



T2-1-25



SYSTEM / Control System (Blank)



T2-1-26



SYSTEM / Control System Pump Control This system performs the following controls. • Speed Sensing Control (Normal) • Travel Speed Sensing Control • Travel Pump1 Flow Rate Shift Control • Flow Rate Limit Control (When Combined Operation of the Travel and Front Attachment) • *Pump1 Flow Rate Limit Control • *Pump2 Flow Rate Limit Control • Steering Pump Torque Reduction Control



NOTE: OP: Optional *Control system available only on the machine equipped with the optional parts.



Pump Control System Layout Column Box



Parking Brake Pressure Switch N Sensor (Travel)



Pressure Sensor Travel Forward



Travel Reverse N Sensor (Engine) Pump2 Delivery Pressure Sensor Front Attachment Pump1 Delivery Steering Pump Pressure Sensor Delivery Pressure Auxiliary (OP) Sensor



Engine Control Dial



Engine Speed Control Mode Selection Switch Pedal Dial Creeper Shift Lever Neutral D Mode L Mode Brake Switch Work Brake Parking Brake Axle Lock



Torque Control Solenoid Valve



Maximum Pump 1 Flow Rate Limit Solenoid Valve



Maximum Pump 1 Flow Rate Shift Solenoid Valve



Maximum Pump 2 Flow Rate Limit Solenoid Valve



OFF



 T1F3-02-01-001



T2-1-27



SYSTEM / Control System Speed Sensing Control Function: Controls the pump flow rate in response to engine speed changes due to variations in load so that the engine output can be utilized more efficiently. (Engine stall is prevented when the machine operates under adverse conditions such as operating at high altitude.)



Q Flow Rate



Operation: 1. The target engine operating speed is set by controlling the engine control dial. 2. The MC calculates the difference in speed between the target operating speed and the actual operating speed monitored by the N sensor. Then, the MC sends signals to the torque control solenoid valve. 3. The torque control solenoid valve delivers pilot pressure oil in response to the signals received from the MC to the pump regulator, controlling the pump flow rate. 4. If the engine load increases and the actual engine operating speed becomes slower than the target operating speed, the pump swash angle is reduced so that pump flow rate will be reduced. Therefore, the engine load is reduced, preventing engine stall. 5. If the actual engine operating speed becomes faster than the target operating speed, the pump swash angle is increased so that the pump flow rate will increase, by which the engine output can be utilized more efficiently.



T2-1-28



Normal Pump P-Q Curve



Pressure



P



SYSTEM / Control System



N Sensor (Engine) Engine Control Dial



Torque Control Solenoid Valve



 T1F3-02-01-002



T2-1-29



SYSTEM / Control System Travel Speed Sensing Control Function: The pump flow rate is controlled in response to variations in engine speed due to travel load changes, allowing to use the engine power effectively. Conditions: • Travel Forward or Reverse Operation • Shift Lever: D or L Position • Brake Switch: Axle Lock or OFF Position



Q



NOTE: When the brake switch is not in the brake position and the parking brake pressure switch is OFF position, the MC recognizes that the brake switch is in either the axle lock or OFF position.



Flow Rate



Operation: 1. The MC determines the engine target running speed corresponding to sensing signals detected by the EC dial or the pilot pressure sensor (travel forward or reverse). 2. The MC computes the difference between the engine target running speed and actual engine operating speed detected by the N sensor (engine) and outputs signals to the torque control solenoid valve. 3. In response to the signals from the MC, the torque control solenoid valve sends the pilot pressure to the pump regulators to control the pump flow rate. 4. When the actual engine operating speed becomes slower than the engine target running speed as the load to the engine increases, the pump displacement angle is reduced to reduce the delivery flow rate. Therefore, the load to the engine is reduced, preventing the engine from stalling. 5. If the actual engine operating speed becomes faster than the engine target running speed, the pump displacement angle is increased to effectively utilize the engine power.



T2-1-30



Pump P-Q Curve



Pressure



P



SYSTEM / Control System



Parking Brake Pressure Switch Pressure Sensor Travel Forward Travel Reverse



N Sensor (Engine) Pump1 Delivery Pump2 Delivery Pressure Sensor Pressure Sensor



Engine Control Dial



Engine Speed Control Mode Selection Switch Pedal Dial Torque Control Solenoid Valve



Creeper Shift Lever Neutral D Mode L Mode



Brake Switch Work Brake Parking Brake Axle Lock OFF



 T1F3-02-01-003



NOTE: The illustration indicates system operation when each switch is placed in the following position. Engine Speed Control Mode Selection Switch: Pedal Position Shift Lever: L Position Brake Switch: Axle Lock or OFF Position



T2-1-31



SYSTEM / Control System Travel Pump 1 Flow Rate Shift Control Function: The maximum flow rate of pump 1 is increased to increase travel speed during travel operation. Operation: 1. The MC recognizes that travel operation is being performed when the following conditions are arranged. 2. The MC activates the pump 1 maximum flow rate shift solenoid valve to increase the displacement angle so that the pump 1 delivers the maximum oil flow.



Q



Maximum flow rate is increased.



Flow Rate



NOTE: While traveling at slow speed, when the front attachment is operated, too much oil may be supplied to the front attachment actuators. To prevent this operation, when input signals (travel motor speed) from the N sensor (travel) match speed (A) described below, this control system is deactivated.



Normal Pump P-Q curve



Speed A: During travel acceleration → 800 min−1 or slower During travel deceleration → 500 min−1 or slower



Pressure



Conditions: • Engine Speed Control Mode Selection Switch: Pedal or Dial Position • Travel Pilot Pressure (Forward or Reverse): Output is present. • N sensor (Travel): Output is present. • Front Attachment Pilot Pressure Sensor: No output is present. NOTE: When the brake switch is not in the work brake position and the parking brake pressure switch is OFF position, the MC recognizes that the brake switch is in either the axle lock or OFF position. NOTE: The signals from N sensor (travel) are sent to the MC via the column box. When the shift lever is not in either the N or L position, the MC recognizes that the shift lever is in the D position. NOTE: The signals from the N sensor (travel) is sent to the MC via the column box.



P



ZX160W ONLY • INCREASE OF MAX. OIL FLOW (FOR TRAVEL OPERATION) PUMP1



3



80 cm /rev 3



75 cm /rev



30 K



PUMP2 3



75 cm /rev



T2-1-32



SYSTEM / Control System



Column Box Parking Brake Pressure Switch Pressure Sensor



N Sensor (Travel)



Travel Forward Travel Reverse Front Attachment



Engine Speed Control Mode Selection Switch Pedal Dial Creeper Maximum Pump 1 Flow Rate Shift Solenoid Valve



Shift Lever Neutral D Mode L Mode



Brake Switch Work Brake Parking Brake Axle Lock OFF



 T1F3-02-01-004



NOTE: The illustration indicates system operation when the front attachment is operated while traveling the machine forward with each switch in the following position. Engine Speed Control Mode Selection Switch: Pedal Position Shift Lever: D Position Brake Switch: Axle Lock or OFF Position



T2-1-33



SYSTEM / Control System Flow Rate Limit Control (When combined operation of the travel and front attachment) Function: The maximum engine speed for travel operation is set faster than that for excavation operation. Therefore, when the front attachment and/or swing system is operated together with the travel system when the engine is running at the travel maximum speed, the increased oil flow is supplied to the front attachment and/or swing actuators so that each actuator may be overloaded. To prevent this overloading, when combined operation of the travel and front attachment and/or swing functions is made, the maximum pump 2 flow rate is reduced.



Q Flow Rate



Operation: 1. The MC recognizes that combined operation of the travel and front attachment functions is being made when the following condition is established. 2. When the MC recognizes that the current engine -1 target running speed is 2050 min (engine target running speed in the HP mode) during travel operation, the MC activates the maximum pump 2 flow rate limit control solenoid valve to reduce the pump 2 maximum flow rate. Conditions: • Shift Lever: Pedal or Dial Position • Travel Pilot Pressure (Forward or Reverse): Output is present. • N Sensor (Travel): Output is present. • Front Attachment Pilot Pressure Sensor: Output is present. NOTE: When the brake switch is not in the work brake position and the parking brake pressure switch is OFF position, the MC recognizes that the brake switch is in either the axle lock or OFF position. NOTE: The signals from N sensor (travel) are sent to the MC via the column box. When the shift lever is not in either the N or L position, the MC recognizes that the shift lever is in the D position.



T2-1-34



Maximum flow rate is reduced.



Normal Pump P-Q Curve



Pressure 2



SYSTEM / Control System



Parking Brake Pressure Switch Pressure Sensor



N Sensor (Engine)



Travel Forward Travel Reverse Front Attachment



Engine Speed Control Mode Selection Switch Pedal Dial Creeper



Shift Lever Neutral Maximum Pump 2 Flow Rate Limit Solenoid Valve



D Mode L Mode



PUMP CONTROL PRESS. SENSOR Brake Switch Work Brake Parking Brake Axle Lock OFF



 T1F3-02-01-005



NOTE: The illustration indicates system operation when the front attachment is operated while traveling the machine forward with each switch in the following position. Engine Speed Control Mode Selection Switch: Pedal Position Shift Lever: D Position Brake Switch: Axle Lock or OFF Position



T2-1-35



SYSTEM / Control System Pump 1 Flow Rate Limit Control (Only on the machines with the auxiliary sensors (Optional))



Pump 2 Flow Rate Limit Control (Only on the machines with the auxiliary sensor (Optional))



Function: Limits the maximum pump 1 flow rate when operating a front attachment such as a vibration hammer requiring a large flow rate of hydraulic oil.



Function: Limits the maximum pump 2 flow rate when operating a front attachment such as a hydraulic breaker that doesn’t require a large flow rate of hydraulic oil.



NOTE: When a front attachment, such as a vibration hammer requiring a large flow rate of hydraulic oil is operated, the pressure oil from pumps 1 and 2 is jointly supplied to the auxiliary spool in the control valve. Since pump 2 delivers the maximum flow rate at this time, the vibration hammer doesn’t need the maximum flow rate from pump 1 so that the maximum pump 1 flow rate is limited. (Optional flow combining system: ON)



NOTE: When operating a front attachment such as a hydraulic breaker that doesn’t require a large flow rate of hydraulic oil, the auxiliary flow combiner valve is not shifted. Then, only the pressure from pump 2 flows to the auxiliary spool in the control valve. Since a hydraulic breaker doesn’t need a large flow rate of hydraulic oil, the maximum pump 2 flow rate is limited. (Optional flow combining system: OFF)



Operation: 1. When a front attachment is used, the MC receives signals from the pressure sensor (auxiliary). 2. In response to the signals arriving from the pressure sensor, the MC drives the maximum pump 1 flow rate limit solenoid valve (optional) to reduce the maximum pump flow rate.



Operation: 1. When a front attachment is used, the MC receives signals from the pressure sensor (auxiliary). 2. In response to the signals arriving from the pressure sensor, the MC drives the maximum pump 2 flow rate limit solenoid valve to reduce the maximum pump flow rate.



NOTE: In proportion to the attachment control pedal stroke, the maximum pump flow rated is reduced. The minimum pump swash set-angle for a front attachment (hydraulic breaker, secondary crusher, primary crusher or vibrating hammer) can be set in the service mode of Dr. ZX. Flow Rate Q



Maximum flow rate is reduced.



NOTE: In proportion to the attachment control pedal stroke, the maximum pump flow rated is reduced. The minimum pump swash set-angle for a front attachment (hydraulic breaker, secondary crusher, primary crusher or vibrating hammer) can be set in the service mode of Dr. ZX.



Flow Rate Q



Maximum flow rate is reduced.



Normal Pump P-Q Curve



0



Pressure P



T2-1-36



Pump Control Pressure



Pi



SYSTEM / Control System



Auxiliary (OP)



Control Valve (Right)



Control Valve (Left)



Maximum Pump 1 Flow Rate Limit Solenoid Valve



Maximum Pump 2 Flow Rate Limit Solenoid Valve



T1F3-02-01-006



T2-1-37



SYSTEM / Control System Steering Pump Torque Reduction Control Function: When load to the steering pump increases, loads to pump-1 and 2 are reduced so that engine stall is prevented, allowing the engine power to be used efficiently.



Q Flow Rate



Operation: When the MC receives signals from the steering pump delivery pressure sensor, the MC activates the torque control solenoid valve so that the pumps-1 and 2 delivery flow rate is reduced. Accordingly, the total driving power of pumps-1 and 2, and the steering pump is controlled so that it doesn’t exceed the engine output power, allowing the engine power to be used efficiently. ∗ (Steering Relief Press. Setting : 17.2 MPa)



Pump P-Q Curve is reduced in proportion to the steering pump delivery pressure.



Normal Pump P-Q Curve



Pressure P



Steering Pump Delivery Pressure Sensor



Torque Control Solenoid Valve



T1F3-02-01-007



T2-1-38



SYSTEM / Control System (Blank)



T2-1-39



SYSTEM / Control System Valve Control The valve control has the following functions.



• • • • •



Arm Regenerative Control Superfine Travel Speed Control Travel Motor Excessive Rotation Control Work Brake Control Auxiliary Flow Rate Control



NOTE: OP: Optional *Control system available only on the machine equipped with the optional parts.



T2-1-40



SYSTEM / Control System Valve Control System Layout



Parking Brake Pressure Switch



Column Box







N Sensor (Travel)



Learning Switch Pressure Switch Travel Forward Travel Reverse Front Attachment Swing Boom Raise



Key Switch



Arm Roll-In Arm Roll-Out (OP) Auxiliary (OP)



Engine Control Dial



Engine Speed Control Mode Selection Switch



Travel Motor



Displacement Angle Control Valve



Pump 1 De- Pump 2 Delivery Pres- livery Pressure Sensor sure Sensor



Hydraulic Oil Temperature Sensor



Pedal Dial



Pump 2 Control Pressure Sensor



Creeper



Pump 1 Control Pressure Sensor



Solenoid Valve Unit SG SC SE SI



Shift Lever Neutral D Mode L Mode



Brake Switch



Auxiliary Flow Rate Control Solenoid Valve (OP)



Work Brake Parking Brake Axle Lock



Brake Valve



Auxiliary Flow Rate Control Valve



OFF



Brake (Front)



Brake (Rear) Arm Regenerative Valve



 T1F3-02-01-022



T2-1-41



SYSTEM / Control System Arm Regenerative Control Function: Accelerates the arm roll-in speed to prevent arm hesitation during arm roll-in operation. Operation: The MC activates the solenoid valve unit (SC) so that solenoid valve delivers the pilot pressure oil to shift the arm regenerative valve when signals from the pump 2 delivery pressure sensor, swing pressure sensor, arm roll-in pressure sensor, and boom raise pressure sensor meet the following conditions. When the arm regenerative valve is shifted, the return circuit from the arm cylinder rod side to the hydraulic oil tank is closed. Then, the return oil from the cylinder rod side is combined with the pressure oil from the pump and is routed to the cylinder bottom, accelerating the arm roll-in speed and preventing arm hesitation. (Refer to the COMPONENT OPERATION / Control Valve group.) Operating Conditions: Pump 2 Delivery Pressure Sensor: Low pressure. (The arm doesn’t need much power.) Arm Roll-In Pressure Sensor: High output. (The arm control lever stroke is large.) Swing or Boom raise Sensor: Outputting signal. NOTE: To improve arm leveling performance, the MC gradually activates solenoid valve unit (SC) when the hydraulic oil temperature is at 0 to 10 qC (32 to 50 qF).  



T2-1-42



SYSTEM / Control System    Swing Boom Raise Arm Roll-In



Pump 1 Delivery Pump 2 Delivery Pressure Sensor Pressure Sensor



Hydraulic Oil Temperature Sensor



Solenoid Valve Unit SG SC SE SI



Auxiliary Flow Rate Control Valve



Arm Regenerative Valve



 T1F3-02-01-025







T2-1-43



SYSTEM / Control System Superfine Travel Speed Control Function: The machine is driven in the superfine travel speed mode. Operation: 1. When the following conditions are established, the MC activates solenoid valve unit (SI). 2. When solenoid valve unit (SI) is activated, the pilot oil pressure is routed to the travel motor displacement angle control valve, causing the motor to rotate at a large displacement angle so that the machine travels at the superfine speed.  Conditions: • Engine Speed Control Mode Selection Switch: Creeper Position • Shift Lever: D or L Position • N sensor (Travel): Output signal (travel motor -1 speed) is under 1500 min .  NOTE: When the output signal from N sensor -1 (travel) is 1500 min and up, the MC doesn’t operate this system to prevent cavitation from occurring in the travel motor. NOTE: The signals from N sensor (travel) are sent to the MC via the column box. When the shift lever is not in either the N or L position, the MC recognizes that the shift lever is in the D position.



T2-1-44



SYSTEM / Control System     N Sensor (Travel)



Column Box



Engine Speed Control Mode Selection Switch



Displacement Angle Control Valve Travel Motor



Pedal Dial Creeper Shift Lever Neutral D Mode L Mode



Solenoid Valve Unit SG SC SE SI



 T1F3-02-01-026







T2-1-45



SYSTEM / Control System Travel Motor Excessive Rotation Control Function: The machine is prevented from running away while descending slopes, protecting the travel motor from damage.  Operation: 1. The output signal from N sensor (travel) is sent to the MC. NOTE: The output signals from N sensor (travel) are sent to the MC via the column box.  2. When the signal value from N sensor (travel) exceeds the specified value, The MC activates solenoid valve unit (SI). 3. When solenoid valve unit (SI) is activated, the pilot oil pressure is routed to the travel motor displacement angle control valve so that the travel motor displacement angle increases. NOTE: When the travel motor displacement angle is suddenly increased, cavitation may occur in the travel motor. Therefore, the MC activates solenoid valve unit (SI) slowly so that the travel motor displacement angle changes slowly, preventing the occurrence of cavitation.  4. As the travel motor displacement angle increases, the motor displacement increases, creating braking force to the travel motor. 5. Thereby, the excessive rotation of the travel motor is prevented, reducing travel speed. 



T2-1-46



SYSTEM / Control System



    N Sensor (Travel)



Column Box Displacement Angle Control Valve Travel Motor



Solenoid Valve Unit SG SC SE SI



 T1F3-02-01-027



   AUTI-OVERSPINNING OF TRAVEL MOTOR  



140



  



CAPACITY (cm 3/rev)



 



57.8



 



16-18 26.4



32.1



DELIVERY PRESS (MPa)



 



1.39



1.69



PRESS TO X-PORT OF TRAVEL MOTOR (MPa)



  



While traveling on down slop then the machine speed exceeds more than 39 km/h, MC energizes solenoid valve SI and sends pressure of 1.4–1.5 MPa to X-port of the travel motor as to increase the motor capacity slightly. 



T2-1-47



SYSTEM / Control System Work Brake Control Function: The front and rear brakes are applied during excavation work to stabilize the machine vehicle.  Operation: 1. When the MC receives the signal from the brake switch, the MC recognizes that the brake switch is in the work brake position. 2. Then, the MC activates solenoid valve unit (SG). 3. When solenoid valve unit (SG) is activated, the pilot oil pressure is routed to the brake valve so that the brake valve is shifted. 4. When the brake valve is shifted, the pilot pressure from the brake valves routed to the front and rear brakes, causing the brakes to be applied.  NOTE: A slight time-lag will occur due to difference in operation start time of solenoid valves when the brake switch is shifted from the work brake to the parking brake. Therefore, the MC activates solenoid valve unit (SG) one second after the brake switch has been shifted to the parking brake position from the work brake position to allow the work brake to be released. (1 second) 



T2-1-48



SYSTEM / Control System    



Brake Switch Work Brake Parking Brake Axle Lock Solenoid Valve Unit



OFF



SG SC SE SI Brake Valve



Brake (Front)



Brake (Rear)



 T1F3-02-01-028



   



T2-1-49



SYSTEM / Control System Auxiliary Flow Rate Control (Only on the machines equipped with the auxiliary pressure sensor and auxiliary flow rate control solenoid valve) Function: Restricts the oil flow to the auxiliary spool when the combined operation of the swing, boom raise, and arm roll-in is made while operating a front attachment using the auxiliary spool to maintain controllability of the combined operation. Operation: The MC activates the auxiliary flow rate control solenoid valve (optional) so that the oil flow to the auxiliary spool is restricted under the following conditions. Operating Conditions: Auxiliary Pressure Sensor: ON Swing, Boom Raise, Arm Roll-In Pressure Sensors: ON NOTE: OP: Optional



T2-1-50



SYSTEM / Control System     Swing Boom Raise Arm Roll-Out (OP) Auxiliary (OP)



Auxiliary Flow Rate Control Solenoid Valve (OP)



Auxiliary Flow Rate Control Valve



  



T2-1-51



SYSTEM / Control System (Blank)



T2-1-52



SYSTEM / Control System Other Controls Other control systems consist of the following systems.



• • • • • • • •



Parking Brake Alarm Control Brake Dragging Prevention Control Travel Motor Alarm Control Forward/Reverse Shifting Restriction Control Work Mode Control Overload Alarm Control Swing Alarm Control Travel Alarm Control



T2-1-53



SYSTEM / Control System Parking Brake Alarm Control Function: The buzzer sounds when the front attachment is operated with the parking brake applied to protect the transmission.  Operation: 1. The MC recognizes that the parking brake is applied when signals from the parking brake pressure switch arrive at the MC. 2. When signals from pilot pressure sensors (front attachment, boom raise, arm roll-in, and swing) are sent to the MC while the parking brake is applied, the MC connects the circuit from terminal #7 on transistor unit 1 to the ground in the MC. NOTE: Even if the same operation is made, the sensing pressure may differ depending on oil temperature. The MC Judges that the front attachment is being operated when the oil temperature and the pilot pressure match the values shown in the following table.  Oil Temperature 10 qC or more



Pilot Pressure 0.7 MPa



0 qC up to 10 qC



1 MPa



Below 0 qC



1.5 MPa



Input Sensor Front Attachment Boom Raise Arm Roll-In Swing n



 3. As terminal #7 is connected to the ground, transistors (a and b) in transistor unit 1 operate so that terminal #4 is connected to the ground. [The emitter on transistor (a) is connected to terminal #3 on transistor unit 1.] 4. Since terminal #4 is connected to the ground, the parking brake alarm relay, which is connected to terminal #4, is magnetized. 5. Then, the buzzer in the column box is grounded through the parking brake alarm relay. 6. As the buzzer is connected to the ground, the buzzer sounds. 



T2-1-54



NOTE: When the brake switch is not in the brake position and the parking brake pressure switch is OFF position, the MC recognizes that the brake switch is in either the axle lock or OFF position.



SYSTEM / Control System



Parking Brake Pressure Switch Pressure Sensor Front Attachment Swing Boom Raise Arm Roll-In



Brake Switch Work Brake Parking Brake Axle Lock OFF



Column Box Transistor unit 1 a b



From Fuse #27



Hydraulic Oil Temperature Sensor



Parking Brake Alarm Relay



Travel Motor Alarm Relay



From Fuse #20



 T1GL-02-01-031



 NOTE: This illustration indicates the system operation when the front attachment is operated with the brake switch in the parking brake position.



T2-1-55



SYSTEM / Control System Brake Dragging Prevention Control Function: When the parking brake or the work brake are applied, travel system is deactivated. Operation: 1. The MC recognizes that both the parking brake or the work brake is applied when the MC receives signals from the brake switch and the parking brake pressure switch. 2. Then，the MC grounds the circuits connecting to terminals #6 and #7 on transistor unit 2 in the MC. 3. As terminals #6 and #7 are grounded, transistors (a and a’, and b and b’) in transistor unit 2 operate. Then, terminals #1 and #4 on transistor unit 2 are connected to the ground circuit (terminal 5). [The emitters on transistors (a and a’) are connected to terminal #3 on transistor unit 2.] 4. Since terminals #1 and #4 are grounded, the travel reverse Pi cut relay, which is connected to terminal #1, and the travel forward Pi cut relay, which is connected to terminal #4, become magnetized. 5. Accordingly, the current from fuse #20 flows through each relay and energizes the travel forward Pi cut solenoid valve and the travel reverse Pi cut solenoid valve. 6. Therefore, the pilot oil pressure from the travel pilot valve is interrupted with the solenoid valves, deactivating the travel operation system.



T2-1-56



SYSTEM / Control System



Parking Brake Pressure Switch



Brake Switch Work Brake Parking Brake Axle Lock OFF



From Fuse #20



Transistor Unit 2 a



b



a’



b’



Travel Forward Pi Cut Relay



Travel Reverse Pi Cut Relay



Travel Pilot Valve



Travel Reverse Pi Cut Solenoid Valve



Travel Forward Pi Cut Solenoid Valve T1GL-02-01-032



NOTE: The illustration indicates the system operation when the brake switch is placed in the work brake position.



T2-1-57



SYSTEM / Control System Travel Motor Alarm Control Function: In case any abnormality occurs in the travel motor, the engine running speed is reduced and held at the minimum, causing the buzzer to sound and the alarm indicator to light. Operation: 1. The signals from the travel motor drain pressure sensor are sent to the MC. 2. If any abnormality occurs in the travel motor during travel operation, the drain pressure from the travel motor will increase. 3. Then, when the MC judges that the travel motor is abnormal, the MC activates the EC motor so that the engine running speed is reduced and held at the minimum.



7. At the same time, the travel motor alarm relay, which is connected to terminal #1, is also magnetized. 8. Therefore, the current from fuse #20 flows through the travel motor alarm relay, turning the warning indicator in the column box ON.



NOTE: When the travel motor drain pressure is kept at more than 1.5 MPa (15 kgf/cm2) for 50 ms, the MC judges that the travel motor is abnormal. NOTE: The MC judges that the travel motor is not abnormal when the machine is under the following conditions: • When hydraulic oil temperature is –5 °C or below: • When the shift lever is in neutral: • When the front attachment is operated, or during the period of 3.5 seconds after the front attachment operation is stopped: 4. At the same time, the MC grounds the circuit from terminal #6 on transistor unit 1 in the MC. 5. Thereby, transistors (a’ and b’) operate, connecting terminal #1 to the ground. [The emitter on transistor (a’) is connected to terminal #3 on transistor unit 1.] 6. As terminal #1 is grounded, the buzzer is grounded via terminal #1 so that the buzzer sounds.



T2-1-58



NOTE: This operation continues to be performed until the key switch is turned OFF then ON, or until the fault codes are cleared with Dr. ZX. However, when the system operation is deactivated with the key switch (OFF→ON), only engine control system can be recovered. (The buzzer and the warning indicator are not deactivated ON.)



SYSTEM / Control System







Shift Lever



Neutral



Pressure Sensor Front Attachment Swing Boom Raise Arm Roll-In



D Mode L Mode



Travel Motor Drain Pressure Sensor



Brake Switch Work Brake Parking Brake



EC Motor



Axle Lock OFF



Column Box



Buzzer Indicator



Transistor unit 1



a㵭



From Fuse #27



Hydraulic Oil Temperature Sensor b㵭



Parking Brake Alarm Relay



Travel Motor Alarm Relay



From Fuse #20



 T1GL-02-01-033







T2-1-59



SYSTEM / Control System Forward/Reverse Shifting Restriction Control Function:



If the travel direction is changed to the opposite direction while traveling, adverse effects may occur in the travel circuit and components. To protect the circuit and components from being damaged, the opposite travel direction side pilot pressure is temporarily interrupted so that the opposite direction system is deactivated during travel operation.



Conditions: Shift Lever: D or L Position N Sensor (Travel): Output is present (during travel operation). Either Travel Forward or Reverse Pilot pressure: 0.7 MPa or more



NOTE: When the Shift Lever is not in either the N or L position, the MC recognizes that the shift lever is in the D position. Operation: The MC judges that the machine is traveling forward or reverse when the above conditions are established.



x When traveling forward (travel reverse pilot pressure



is temporarily interrupted): 1. When signals from the travel forward pilot pressure sensor arrives at the MC, the MC judges that the machine is traveling forward, and grounds the circuit connecting to terminal #6 on transistor unit 2 in the MC. 2. Thereby, transistors (a’ and b’) operate, connecting terminal #1 to the ground. [The emitter on transistor (a’) is connected to terminal #3 on transistor unit 2.] 3. As terminal #1 is grounded, the travel reverse Pi cut relay, which is connected to terminal #1, is magnetized. 4. When the travel reverse Pi cut relay is magnetized, the current from fuse #20 flows to the travel reverse Pi cut solenoid valve via the travel reverse Pi cut relay. 5. Then the travel reverse Pi cut solenoid valve operates, deactivating the travel reverse operation circuit.



x When traveling reverse (travel forward pilot pressure



is interrupted): 6. When signals from the travel reverse pilot pressure sensor arrive at the MC, the MC judges that the machine is traveling in reverse, and grounds the circuit connecting to terminal #7 on transistor unit 2 in the MC. 7. Thereby, transistors (a and b) operate, connecting terminal #4 to the ground. [The emitter on transistor (a) is connected to terminal #3 on transistor unit 2.] 8. As terminal #4 is grounded, the travel forward Pi cut relay, which is connected to terminal #4, is magnetized. 9. When the travel forward Pi cut relay is magnetized, the current from fuse #20 flows to the travel forward Pi cut solenoid valve via the travel forward Pi cut relay. 10. Then the travel forward Pi cut solenoid valve operates, deactivating the travel forward operation circuit.



T2-1-60



SYSTEM / Control System



N Sensor (Travel) Shift Lever Travel Motor Drain Pressure Sensor



Pressure Sensor



Neutral



Travel Forward D Mode



Travel Reverse



L Mode



Brake Switch Work Brake Parking Brake Axle Lock OFF



From Fuse #20



Transistor Unit 2



a’



Travel Forward Pi Cut Solenoid Valve



b’



Travel Reverse Pi Cut Relay



Travel Pilot Valve



Travel Reverse Pi Cut Solenoid Valve



NOTE: The illustration indicates the system operation when travel forward operation is made with the travel mode switch in the D position.



T2-1-61



Travel Forward Pi Cut Solenoid Valve



CUT OUT



: more than 10 km/h



CHANGEOVER



: less than 7km/h



T1GL-02-01-034



SYSTEM / Control System Work Mode Control Two work modes, digging and front attachment, are available by operating the work mode switch.



• Digging Mode: Normal control is performed.



• Front Attachment Mode: Functions only when a front attachment in the optional kit is operated. The engine speed (see T2-1-22 and 24) and pump flow rate (see T2-1-34) are controlled so as to match the installed front attachment operation in response to the movement of the auxiliary valve spool. The engine speed and pump flow rate control settings are made by using Dr. ZX.



T2-1-62



SYSTEM / Control System (Blank)



T2-1-63



SYSTEM / Control System Overload Alarm Control (Available only on machines equipped with optional parts) Function:



When more than set-load is lifted, the buzzer sounds and the warning indicator lights.



 Operation: 1. The MC receives sensing signals from the boom bottom pressure sensor (OP). When the MC judges that the front attachment is overloaded, the MC grounds the circuit from terminal #7 on the transistor unit (OP) in the MC. 2. Thereby, transistors (a and b) operate so that terminal #4 is grounded. 3. Then, the load alarm relay (OP), which is connected to terminal #4, is magnetized. [The emitter on transistor (a) is connected to terminal #3 on the transistor unit (OP).] 4. When the load alarm relay is magnetized, the circuit from the buzzer and the load alarm indicator are grounded via the load alarm relay and the deactivation switch. 5. Then, the buzzer and the alarm indicator operate.  NOTE: The buzzer and the alarm indicator can be deactivated with the deactivation switch (OP). OP: Optional 



T2-1-64



SYSTEM / Control System  



Boom Bottom Pressure Sensor (OP)



Monitor Panel From Fuse #1or #5



Transistor Unit (OP) a b



Load Alarm Relay (OP) From Fuse #18



From Fuse #18



 Deactivation Switch (OP) T1GL-02-01-035







T2-1-65



SYSTEM / Control System Swing Alarm Control (Available only on machines equipped with optional parts) Function: When swing operation is made, the buzzer (OP) sounds and the rotating light turns.  Operation: 1. When the MC receives sensing signals from the pilot pressure sensor (swing), the MC judges that swing operation is being made. Then, the MC grounds the circuit from terminal #7 on the transistor unit (OP) in the MC. 2. Thereby, transistors (a and b) operate so that terminal #4 is grounded. 3. Then, the swing alarm relay (OP), which is connected to terminal #4, is magnetized. [The emitter on transistor (a) is connected to terminal #3 on the transistor unit (OP).] 4. When the swing alarm relay is magnetized, the circuit from the fuse (OP) flows to the buzzer and the rotating light via the swing alarm relay.  NOTE: The buzzer can be deactivated with the deactivation switch (OP). OP: Optional  



T2-1-66



SYSTEM / Control System  Pressure Sensor







Swing



Transistor Unit (OP)



Swing Alarm Relay (OP) From Fuse (OP)



Buzzer



From Fuse (OP) Deactivation Switch (OP)



 Rotating (OP)



  



T2-1-67



T1GL-02-01-037



SYSTEM / Control System Travel Alarm Control (Only on the machines equipped with the travel alarm device (Optional)) Function: Sounds the buzzer while traveling. Operation: As long as the MC receives signals from the travel pressure sensor when travel operation is made, the MC sends out signals to the travel alarm device to sound the buzzer (optional). NOTE: After traveling continuously for more than 13 seconds, the buzzer can be stopped with the buzzer deactivation switch (Optional). NOTE: To prevent the buzzer from sounding when operation other than traveling (such as work pedal operation) is made, the MC doesn’t activate the buzzer when one of the following condition is established: Shift Lever: N Position Brake Switch: S (work brake) or P (parking brake) Position



T2-1-68



SYSTEM / Control System   Shift Lever



Pressure Sensor Travel Forward



Neutral



Parking Brake Pressure Switch



Travel Reverse



D Mode L Mode



Brake Switch Work Brake Parking Brake Travel Alarm Device (OP)



Axle Lock



Buzzer Deactivation Swing (OP)



OFF



 Buzzer (OP)



 NOTE: OP: Optional



T2-1-69



T1GL-02-01-038



SYSTEM / Control System (Blank)



T2-1-70



SYSTEM / Control System ELECTRIC AND HYDRAULIC COMPOSITE CIRCUIT CONTROL The electric and hydraulic composite circuit performs the following controls. 



• • • • •



Axle Lock Release Control Travel Pilot Pressure Cut Control Blade/Stabilizer Control Parking Brake Control Travel Mode Control



T2-1-71



SYSTEM / Control System Axle Lock Release Control Function: When the operate check valves for axle lock cylinders are shifted with the brake switch, the axle lock cylinder circuits are opened to the hydraulic oil tank, allowing the oil in the axle lock cylinders to freely flow in and out of the hydraulic oil tank so that machine vibration is reduced during traveling.  Operation: 1. When the brake switch is turned OFF, the current from fuse #28 is grounded via the brake switch. 2. Then, the axle lock relay is magnetized. 3. When the axle lock relay is turned ON, the current from fuse #28 flows to the axle lock solenoid valve >solenoid valve unit (SE)@ via the axle lock relay, energizing the axle lock solenoid valve >solenoid valve unit (SE)@.



4. Thereby, the axle lock solenoid valve >solenoid valve unit (SE)@ is shifted, causing the pressure oil from the pilot pump to act on check valves (axle lock) through the axle lock solenoid valve >solenoid valve unit (SE)@. 5. Therefore, the check valves (axle lock) are released so that the axle lock cylinders are opened to the hydraulic oil tank.



  



Axle Lock Relay



Brake Switch (OFF position)



From fuse #28



Check Valve (Axle Lock)



Axle Lock Solenoid Valve [Solenoid Valve Unit (SE)]



Axle Lock Cylinder Pilot Pump



 T1GL-02-01-039







T2-1-72



SYSTEM / Control System Travel Pilot Pressure Cut Control Function: When the shift lever is in neutral, the travel forward and reverse pilot pressure is cut so that the travel function becomes inoperable even if the travel pilot valve is operated.  Operation: 1. When the shift lever is in neutral, the current from fuse #20 flow to the ground via the shift lever. 2. Thereby, both the travel forward and reverse Pi cut relays are magnetized, turning the relays ON. 3. As the relays are turned ON, the current from fuse #20 magnetizes both the travel forward and reverse Pi cut solenoid valves via each relay, shifting the solenoid valves. 4. When the solenoid valves are shifted, the pilot pressure circuit from the pilot valve is blocked.  



Shift Lever From Fuse #20



Travel Forward Pi Cut Relay



Travel Reverse Pi Cut Relay



Travel Pilot Valve



Travel Reverse Pi Cut Solenoid Valve



Travel Forward Pi Cut Solenoid Valve



To Control Valve Travel Spool







T2-1-73



 T1GL-02-01-040



SYSTEM / Control System Blade/Stabilizer Control Function: When solenoid valves are activated, the operate check valves are operated, making each blade/stabilizer cylinder operable. Operation: Independent circuits operate each cylinder and are similar. Therefore, the front-right stabilizer cylinder operation is explained here as an example. 1. Each switch is operated to connect each terminal as shown in the table below. Switch Connected Switch Position Terminals Blade/Stabilizer ON #1 to #2 Selection Switch Right and Left Right #4 to #5 Selection Switch Front and Rear #1 to #2 and Front Selection Switch #4 to#5 2. Terminal #2 on the blade/stabilizer relay (front-right) is grounded via terminals #1 to #2 on the front and rear selection switch, terminals #4 and #5 on the right and left selection switch, and terminals #1 to #2 on the blade/stabilizer selection switch. 3. Then, the current from fuse #29 magnetizes the blade/stabilizer relay (front-right).



5. When 2-unit solenoid valve (front-right stabilizer) is shifted, pressure oil from the pilot pump routed to the check valves via the solenoid valve, opening the check valves. 6. Then, the stabilizer cylinder (front-right) becomes operable. 7. When the blade/stabilizer pilot valve is operated under this condition, the stabilizer cylinder (front-right) is operated with pressure oil from the auxiliary control valve. NOTE: When the optional blade is used, right and left circuit operation is always interlocked. Operation circuit to match the operation specification and the type of optional attachment can be arranged by changing connections of optional connectors (A, B, C, D, and E). Cylinder Connector



FrontLeft



FrontRight



Rear-Left



NOTE: The monitor panel circuit is also grounded at the same time so that the indicator in the monitor panel comes ON.



A



Independent



Interlocked



Independent



Interlocked



B



Interlocked



Independent



Interlocked



Independent



4. When the blade/stabilizer relay (front-right) is magnetized, the current from fuse #29 flows to the 2-unit solenoid valve (front-rear stabilizer) via the blade/stabilizer relay (front-right), shifting the 2-unit solenoid valve (front-rear stabilizer).



C



Interlocked



Interlocked



Independent



Independent



D



Independent



Independent



Interlocked



Interlocked



Interlocked*



Interlocked**



Interlocked**



E



Interlocked*



RearRight



NOTE: Both cylinders marked with * and ** are interlocked to operate simultaneously.



T2-1-74



SYSTEM / Control System Front and Rear Selection Switch



Right and Left Selection Switch



Optional Connector E Optional Connector A Optional Connector C



Optional Connector B THOSE CONNECTORS ARE STORED AT THE REAR TRAY



Optional Connector D



Blade/Stabilizer Relay (Front-Right)



Blade/Stabilizer Relay (Front-Left)



Monitor Panel



Blade/Stabilizer Pilot Valve Blade/Stabilizer Relay (Rear-Right)



2-Unit Solenoid Valve [Stabilizer (Front-Right)] Blade Signal Shift Control Valve



Blade/Stabilizer Relay (Rear-Left) From fuse #29



Setting : 0.7 MPa



To Auxiliary Control Valve Pilot Pump



Front Side of Base Machine Stabilizer Cylinder (Front-Right) Check Valve (Stabilizer)



From Auxiliary Control Valve



T2-1-75



T1GL-02-01-041



SYSTEM / Control System Parking Brake Control Function: The parking brake in the transmission is applied or released by operating the brake switch. Operation: 1. When the travel system is operable after the engine is started and once the current from terminal ST on the key switch magnetizes parking brake relay 3, the current from fuse #6 magnetizes parking brake relay 1. Then, the current from fuse #20 is routed to parking brake relay 2 via parking brake relay 1. Accordingly, the parking brake solenoid valve is shifted depending on whether the parking brake relay 2 is turned ON or OFF as far as the engine is running. (Refer to the SYSTEM / Electric System group.) 2. When the parking brake switch is turned to the parking position, the current from fuse #20 is grounded through the parking brake switch, magnetizing parking brake relay 2. 3. Thereby, parking brake relay 2 cuts the current from #20 to the parking brake solenoid valve. 4. Then, the parking brake solenoid valve is demagnetized, shifting the parking brake solenoid valve spool. 5. When the solenoid valve spool is shifted, the pressure oil flow from the pilot pump is blocked at the solenoid valve. 6. When the pressure oil flow from the pilot pump is blocked, no pressure oil is supplied to the transmission so that the disc brake and the disc clutch are engaged. 7. Therefore, the transmission output shaft is locked, causing the parking brake to be applied. 



T2-1-76



SYSTEM / Control System



Key Switch



From Alternator Terminal L



From Battery



Monitor Controller



A2 Fuse #6



C5 C4



B14



From Alternator Brake Switch: Parking Position Fuse #20 Parking Brake Relay 3



Parking Brake Relay 1



Parking Brake Relay 2



Parking Brake Solenoid Valve Pilot Pump



Output Shaft Transmission



T1GL-02-01-044



Disc Clutch



Disc Brake



T2-1-77



SYSTEM / Control System Parking Brake Holding System Function: When the parking is released, this system holds the parking brake ON for 1 seconds until each operating system is shifted to other mode. Operation: 1. When the travel system is operable after the engine is started and once the current from terminal ST on the key switch magnetizes parking brake relay 3, the current from fuse #6 magnetizes parking brake relay 1. Then, the current from fuse #20 is routed to parking brake relay 2 via parking brake relay 1. Accordingly, the parking brake solenoid valve is shifted depending on whether the parking brake relay 2 is turned ON or OFF as far as the engine is running. (Refer to the SYSTEM / Electric System group.) 2. The monitor controller recognizes that the brake switch is shifted to other position from the parking position by change in the input signal to terminal B14 on the monitor controller from the brake switch. 3. Then the monitor controller ground the circuit connected to terminal C4 in the monitor controller for 1 second. 4. Thereby, parking brake relay 2 is magnetized. 5. As long as parking brake relay 2 is kept magnetized, the current from fuse #29 doesn’t flow to the parking brake solenoid valve. 6. Therefore, the parking brake solenoid valve is kept demagnetized, holding the parking brake ON for one second.



T2-1-78



SYSTEM / Control System



C5 : Grounded while the engine is running B14 : Timer (1 second)



Key Switch



Signal : the engine is running



From Alternator Terminal L



From Battery



Monitor Controller



A2 Fuse #6



Timer circuit built-in



C5 C4



B14



From Alternator Brake Switch: Parking Position Fuse #20 Parking Brake Relay 3



Parking Brake Relay 1



Relay 1 : The parking is kept on for 3 seconds after the engine is running.



Parking Brake Relay 2



Accumulator for Pilot Press. Back-up Enclosed Press. 0.8 ± 0.1 MPa



Relay 2 : The parking is kept on for 1 second after shifting the Parking Selection from parking to service brake.



Parking Brake Solenoid Valve



Relay 3 : The parking is kept on continueusly if there is no “START” signal.



Pilot Pump



Output Shaft Transmission



Disc Clutch



Disc Brake



T2-1-79



When the Brake Selection switch is shifted to Parking position, the parking is applied gradually.



HOW TO RELEASE PARKING BRAKE • Energize the parking brake solenoid valve with a jump cable (self evacuation) • Mechanically release by a shift lever at the transmission (Towing)



T1GL-02-01-045



SYSTEM / Control System Travel Mode Control







Function: Operating the shift lever shifts the transmission changeover solenoid valve, causing the transmission to select the fast or slow (D or L) mode, and turning the indicator ON in the column box.







 Operation: Shift Lever: N Position 1. When the shift lever is turned to neutral (N), the current from fuse #28 magnetizes the neutral relay and is grounded via the shift lever. 2. As the neutral relay is magnetized, the current from fuse #28 flows through the neutral relay and turns indicator (N) ON in the column box.







 Shift Lever: D Position 1. When the shift lever switch is turned to the D position, the neutral relay and the Hi/Low selection relay are demagnetized. 2. Therefore, the current from fuse #28 flows through the neutral relay and the Hi/Low selection relay and turns indicator (D) ON in the column box. 3. The pressure oil from the pilot pump is routed to the Hi port on the transmission via the transmission changeover solenoid valve. 4. Then, the oil pressure releases the disc brake in the transmission, allowing the transmission to shift to the Hi (D) side.



    Shift Lever: L Position 1. When the shift lever is turned to the L position, the current from fuse #28 magnetizes the Hi/Low selection relay and is grounded via the shift lever. In addition, the current turns indicator (L) ON in the column box. 2. When the Hi/Low selection relay is magnetized, the current from fuse #28 flows through the neutral relay and the Hi/Low selection relay and magnetizes the transmission changeover solenoid valve. 3. When the transmission changeover solenoid valve is magnetized, the pressure oil from the pilot pump is routed to the Low port on the transmission via the transmission changeover solenoid valve. 4. Then, the oil pressure releases the disc clutch in the transmission, allowing the transmission to shift to the Low (L) side.  







T2-1-80



SYSTEM / Control System



 



Column Box (Indicator)







N D



Shift Lever



L



Energized at “N“ position Hi/Low Selection Relay



Neutral Relay



From fuse #28



Transmission Control Valve



Pilot Pump



Transmission Changeover Solenoid Valve Energized for “Low“ speed Low Hi



 



Disc Clutch



T1GL-02-01-043



Disc Brake



 NOTE: The illustration indicates the system operation when the brake switch is not in the P position and the shift lever is in the L position.



T2-1-81



SYSTEM / Control System (Blank)



T2-1-82



SYSTEM / Hydraulic System OUTLINE The hydraulic system is broadly divided into four circuits, the pilot circuit, the service brake circuit, the main circuit and the steering circuit. Pilot Circuit: Power Source →



Pilot Pumps 



Controller Pilot  Valves Pump   Regulator



Pilot Circuit →



Pump Control Circuit



Solenoid Valve Unit   Max.   Pump 1 Flow Rate Limit



 



Swing Parking Brake Release Circuit Valve Control Circuit



 Solenoid Valve



  



Front Attachment Operation Control Circuit



Hydraulic Oil Heat Circuit



Max. Pump 2 Flow Rate Limit



Travel Operation Control Circuit



Valve  Solenoid  Torque Control Solenoid Valve



Travel Motor Displacement Angle Control



Max. Pump 1 Flow Rate Shift



Work Brake Circuit



Circuit



Solenoid Valve



Blade/Stabilizer Operation Control Circuit



Blade/Stabilizer Signal Shift Valve  Signal Control Valve Service Brake Circuit: Power Source Pilot Pumps



Controller →



Actuator →



Accumulator Charging







Valves







Brake Valve



Front Brake Rear Brake







 Main Circuit: Power Source Main Pumps



Controller →



Actuator →



Control Valves



Motors















Cylinders















Front Attachments (Optional)



 Steering Circuit: Power Source Steering Pumps→



Controller Steering Valves



Actuator →



Steering Cylinders































T2-2-1



SYSTEM / Hydraulic System PILOT CIRCUIT Outline: Pressure oil from the pilot pump is used to operate as follows. • Operation Control Circuit (Front Attachment, Travel, Blade/Stabilizer) Left Pilot Valve



Travel Pilot Valve



• Travel Motor Displacement Angle Control Circuit • Work Brake Circuit



Positioning / Auxiliary Pilot Valve



Right Pilot Valve



Blade/Stabilizer Pilot Valve



Swing Motor



Travel Shockless Valve Shuttle Valve Pilot Shut-Off Valve



To Auxiliary Control Valve Spools



Signal Control Valve



SA To Control Valve Spools



Blade/Stabilizer Solenoid Valve (Rear)



Blade/Stabilizer Signal Shift Valve



Max. Pump 1 Flow Rate Limit Control Solenoid Valve



1



2



Regulator



Blade/Stabilizer Solenoid Valve (Front)



Bypass Shut-Out Valve Work Brake Circuit



Brake Valve



Control Valve



SG SC SE



Hydraulic Oil Tank



SI Solenoid Valve Unit Travel Motor Displacement Angle Control Circuit



Suction Filter



Travel Motor



Pilot Pump Relief Valve Accumulator Charging Valve



Pilot Filter



 T1F3-02-02-015



T2-2-2



SYSTEM / Hydraulic System • Swing Parking Brake Release Circuit • Hydraulic Oil Heat Circuit



Left Pilot Valve



Travel Pilot Valve



• Pump Control Circuit • Valve Control Circuit



Right Pilot Valve



Positioning/ Auxiliary Pilot Valve



Swing Motor Max. Pump 1 Flow Rate Limit Control Solenoid Valve Pump Control Circuit Max. Pump 2 Flow Rate Limit Control Solenoid Valve



Pilot Shut-Off Valve



Torque Control Solenoid Valve



Signal Control Valve



To Control Valve Spools



1 Max. Pump 1 Flow Rate Shift Control Solenoid Valve



Hydraulic Oil Heat Circuit



Regulator



Bucket Flow Rate Control Valve Boom Anti-Drift Valve



Hose-Rupture Safety Valve (Positioning)



Arm Anti-Drift Valve SG



Bypass Shut-Out Valve



SC



Arm Regenerative Valve



2



Hose-Rupture Safety Valve (Arm) Hose-Rupture Safety Valve (Boom)



SE Control Valve SI



Hydraulic Oil Tank



Solenoid Valve Unit



Valve Control Circuit



Suction Filter



Pilot Pump Relief Valve Accumulator Charging Valve



Pilot Filter



 T1F3-02-02-014



T2-2-3



SYSTEM / Hydraulic System Front Attachment, Travel, Blade/Stabilizer Operation Control Circuit • Each pilot valve controls the pressure oil from the pilot pump to operate the spools in the control valve. • A signal control valve is located in the circuit between the front attachment and travel pilot valves and the control valve. The shockless valve built in the boom raise circuit in the signal control valve buffers the movement of the spool in the control valve. (Refer to the COMPONENT OPERATION / Signal Control Valve group.) • A travel shockless valve is located in the travel operation circuit to buffer the movement of the travel spools in the control valve. • An auxiliary solenoid valve is located in the positioning operation circuit between the signal control valve and the control valve. One auxiliary pilot valve can operate two kinds of the attachments by shifting the auxiliary solenoid.



T2-2-4



SYSTEM / Hydraulic System Travel Pilot Valve







Pilot Valve (Left)



Pilot Valve (Right)



Positioning /Auxiliary



Travel Shockless Valve



Blade/ Stabilizer



61



60



Shockless Valve



Signal Control Valve



11



12 4 1



3 2



Auxiliary Solenoid Valve



7 6 5



8



14 13 10 9



10



9



12



8



14



13



11



7 2



1



1 Auxiliary Control Valve 4



3



3



60 5



61



6 Control Valve



Pilot Pump



 T1F3-02-02-005



1234-



Boom Raise Boom Lower Arm Roll-Out Arm Roll-In



5678-



Swing Left Swing Right Bucket Roll-In Bucket Roll-Out



910 11 12 -



T2-2-5



Positioning Raise Positioning Lower Travel Reverse Travel Forward



13 14 60 61 -



Auxiliary Auxiliary Blade/Stabilizer Raise Blade/Stabilizer Lower



SYSTEM / Hydraulic System Travel Motor Displacement Angle Control Circuit (Refer to the COMPONENT OPERATION / Travel Device group.) • The pilot pressure oil from solenoid valve unit (SI) regulates the travel motor displacement angle control valve. Work Brake Circuit • The pilot pressure oil from the solenoid valve unit (SG) shifts the brake valve.



• Then, the pressure oil from the accumulator charging valve is routed to the front and rear brakes via the brake valve, operating both brakes. Swing Parking Brake Release Circuit (Refer to the COMPONENT OPERATION / Swing Device group.) • When the front attachment and/or swing function is operated, the pilot pressure oil selected by the shuttle valves in the signal control valve shifts the swing parking brake release spool. • Consequently, the release signal pressure oil is routed to the swing motor, releasing the swing parking brake. Hydraulic Oil Heat Circuit (Refer to the COMPONENT OPERATION / Others (Upperstructure) group.) • When the pilot shut-off valve is closed, the pilot pressure oil is routed to the signal control valve so that hydraulic oil is warmed while passing through the orifice in the signal control valve. • The warmed pilot pressure oil flows to the signal control valve and pilot valves so that the pilot system components are warmed.



T2-2-6



SYSTEM / Hydraulic System Arm RollIn



Swing RollOut Right Left



Boom



Bucket



Roll- RollLower Raise In Out



Positioning /Auxiliary



Blade/ Stabilizer



Pilot Shut-Off Valve Shuttle Valve



Swing Parking Brake Release Spool



Shuttle Valve



Solenoid Valve Unit



SG



SI



Travel Motor



Displacement Angle Control Valve



Swing Motor



Brake Valve Front Brake



Accumulator Charging Valve



Rear Brake



 T1F3-02-02-008



T2-2-7



SYSTEM / Hydraulic System Pump Control Circuit (Refer to the COMPOMENT OPERATION / Pump Device group.)



x Pump Flow Rate Control by Flow Rate Control Pressure Pi • Pressure oil from the pilot valve is selected by the shuttle valves in the signal control valve. Then, the selected pressure oil is routed further to either the pump 1 flow rate control valve or the pump 2 flow rate control valve in the same signal control valve, shifting either of the flow rate control valves. • The selected pilot pressure oil flow from the blade/stabilizer pilot valve by the separately installed shuttle valve shifts the pump 1 flow rate control valve in the signal control valve. • When either the pump 1 flow rate control valve or the pump 2 flow rate control valve is shifted, the pilot pressure oil from the pilot pump is routed to either main pump 1 or main pump 2 as flow rate control pressure Pi. NOTE: When the boom (raise/lower), arm (roll-in/out), bucket (roll-in/out), travel (forward/reverse), positioning/auxiliary and/or blade/stabilizer function is operated, flow rate control pressure Pi is routed to main pump 1. When the boom (raise), arm (roll-in/out), swing (right/left), and/or positioning/auxiliary function is operated, flow rate control pressure Pi is routed to main pump 2.



x Torque Control (Speed Sensing) by Torque Control Solenoid Valve • After the pilot pressure oil from the pilot pump is regulated by the torque control solenoid valve, the regulated pilot pressure oil is routed to main pump 1 and 2 as speed sensing pressure Ppc.



x Maximum Pump Flow Rate Control by Maximum Pump 1 Flow Rate Solenoid Valve • The pilot oil pressure from the pilot pump is routed to pump 1 as the maximum pump 1 flow rate shift pressure after being regulated by the maximum pump 1 flow rate solenoid valve.



T2-2-8



SYSTEM / Hydraulic System Travel



Arm



Boom



Swing



Bucket



Positioning/ Auxiliary



Blade/ Stabilizer



Shuttle Valve



Pump 1 Flow Rate Control Valve



Pump 2 Flow Rate Control Valve



Control Valve Pi



Pi



Maximum Pump 2 Flow Rate Limit Solenoid Valve Torque Control Solenoid Valve Pump 1 Pump 2



Maximum Pump 1 Flow Rate Limit Solenoid Valve Maximum Pump 1 Flow Rate Shift Solenoid Valve



T2-2-9



Pic T1F3-02-02-006



SYSTEM / Hydraulic System Valve Control Circuit (Refer to the COMPONENT OPERATION / Control Valve and Travel Device groups.) x The following valves are controlled by pressure oil from the pilot valves, solenoid valve unit (SC) and the bucket flow rate control valve control spool.



• Boom Lower Pilot Pressure: Boom Anti-Drift Valve, Hose-Rupture Safety Valve (Boom)



• Arm Roll-In Pilot Pressure: Arm Anti-Drift Valve, Hose-Rupture Safety Valve (Arm), Bucket Flow Rate Control Valve Control Spool



• Blade/Stabilizer Pilot Pressure: Blade/Stabilizer Signal Shift Valve, Bypass Shut-Out Valve



• Positioning Lower Pilot Pressure: Hose-Rupture Safety Valve (Positioning)



• Solenoid Valve SC: Arm Regenerative Valve • Bucket Flow Rate Control Valve Control Spool: Bucket Flow Rate Control Valve



T2-2-10



SYSTEM / Hydraulic System 



Travel







Reverse Forward



Hose-Rupture Safety Valve (Positioning)



Arm Roll- RollIn Out



Boom



Swing



Bucket Roll- Roll- Positioning Right Left Lower Raise In Out /Auxiliary



Blade/ Stabilizer



4 9



2



Blade/Stabilizer Signal Shift Valve Bucket Flow Rate Control Valve Control Spool



Hose-Rupture Safety Valve (Arm)



9



Bucket Flow Rate Control Valve



2



Solenoid Valve



4 Boom Anti-Drift Valve



SC



Hose-Rupture Safety Valve (Boom) Arm Anti-Drift Valve



Bypass Shut-Out Valve Arm Regenerative Valve



 T1F3-02-02-007







T2-2-11



SYSTEM / Hydraulic System SERVICE BRAKE CIRCUIT • Pressure oil from the pilot pump is routed to the brake valve via the accumulator charging valve.



• When the brake pedal is operated, the pressure oil from the accumulator charging valve is supplied to the front and rear brakes, operating the brakes. NOTE: The accumulator charging valve is located in the circuit between the pilot pump and the pilot relief valve so that the pressure oil has priority to flow to the brake circuit than the priority circuit. (Refer to the COMPONENT OPERATION / Others (Upperstructure) group.) NOTE: Even if the engine stalls, the oil pressure in the service brake is kept maintained for a specified period of time due to functions of the accumulators and check valves.



Brake Valve Enclosed Pressure : 4.0 ± 0.2 MPa Front Brake



To the pilot relief valve



Rear Brake Check Valve Accumulator Charging Valve Priority to Brake Circuit Chaege starts at 12.3 MPa Charge cut out at 15 MPa Pilot Pump



Completion of charging : 1-2 seconds after the engine starts



T2-2-12



T1GL-02-02-014



SYSTEM / Hydraulic System STEERING CIRCUIT The pressure oil from the steering pump flows into the steering valve via the steering filter. The steering valve is actuated by the rotation of the steering wheel to make the pressure oil flow to the steering cylinder, so that the front wheels change their directions. Steering Cylinder



Steering Valve



17.2 MPa 22.6 MPa



Steering Filter



Pressure Sensor



Steering Pump



T1GL-02-02-009



T2-2-13



SYSTEM / Hydraulic System MAIN CIRCUIT Outline • Main pumps (1 and 2) draw hydraulic oil from the hydraulic oil tank. Main pump 1 and main pump 2 deliver pressure oil to the 4-spool control valve and the 5-spool control valve respectively.



• The pressure oil from the main circuit in 4-spool control valve is routed to the auxiliary control valve. • Delivered pressure oil is routed to the motor(s) or cylinder(s) in response to operation(s) of the spool(s) in the control valve(s). • The return oil from the motor(s) and/or cylinder(s) flows back to the hydraulic oil tank via the control valve and/or the oil cooler. • When the oil temperature is low (high viscosity), the oil flow resistance increases in the oil cooler, which opens the bypass check valve, allowing hydraulic oil to return directly to the hydraulic oil tank without passing through the oil cooler. 



T2-2-14



SYSTEM / Hydraulic System



Positioning Cylinder



A6VM140HA (140 / 57.8 cc/rev) Relief Setting (40 MPa)



Travel Motor



Bucket Cylinder Front Attachment (s)



Overload (39.2MPa)



Main Relief : 34.3 MPa Overload Relief : 37.3 MPa 39.2 MPa Control Valve



Boom Cylinder 4-Spool Side



Arm Cylinder Positioning



Travel



Auxiliary



Bucket



Boom 2



Boom 1



Arm 1



Arm 2



Auxiliary Control Valve



Swing



Blade/ 5-Spool Side



Stabilizer



Bypass Check Valve (600 kPa) Swing Motor M5X130C 99.1 cc/rev Relief Setting : 31.9 MPa



75 cc/rev 172 ℓ/min



Main Pump 2



Main Pump 1



K5V80DTP173R 80 cc/rev 184 ℓ/min



Oil Cooler



Suction Filter



T2-2-15



Hydraulic Oil Tank



Blade/Stabilizer Cylinder



Overload (28 MPa)



SYSTEM / Hydraulic System Neutral Circuit • When the control lever is in neutral, pressure oil from the main pump passes through the control valve and returns to the hydraulic oil tank. Single Operation Circuit • Pressure oil from main pump 1 is routed to the 4-spool control valve and is further routed to each spool of the travel, bucket, boom 1, and arm 2. • Pressure oil from main pump 2 is routed to the 5-spool control valve and is further routed to each spool of the swing, arm 1, boom 2, auxiliary, and positioning. • The boom and arm are actuated by pressure oil from two main pumps. Pressure oil from each main pump is combined and supplied together.



T2-2-16



SYSTEM / Hydraulic System Positioning Cylinder Travel Motor Positioning Control Valve



Front Attachment Travel Bucket Cylinder



Auxiliary



Bucket Arm Cylinder Boom 1



Boom Cylinder



Boom 2



Swing Motor



Arm 2



Arm 1



Auxiliary Control Valve



Swing



Blade/Stabilizer Pump 2



Pump 1



 T1F3-02-02-009



 



T2-2-17



SYSTEM / Hydraulic System Combined Operation Circuit



• Swing and Boom Raise Operation



• When the boom is raised while swinging, the pilot oil pressure shifts the swing, boom 1, and boom 2 spools. • Pressure oil from pump 1 flows into the boom cylinders via the parallel circuit and the boom 1 spool, raising the boom. • Pressure oil from pump 2 flows into the swing motor via the swing spool. • At the same time, pressure oil from pump 2 flows through the parallel circuit and after being combined with pressure oil from pump 1, flows into the boom cylinders, raising the boom together with pressure oil from pump 1.



T2-2-18



SYSTEM / Hydraulic System 



Parallel Circuit



Boom 2



Boom 1



Boom Cylinder



Swing Motor



Swing Parallel Circuit



Pump 2



Pump 1



 T1F3-02-02-010



 



T2-2-19



SYSTEM / Hydraulic System Auxiliary Flow Combiner Circuit (Only available on the machines equipped with optional auxiliary flow combiner circuit.) • When an attachment such as a hydraulic breaker is operated, the pilot pressure oil from the positioning/auxiliary pilot valve shifts the auxiliary flow combiner valve and the bypass shut-out valve. • Accordingly, the neutral circuit in the 4-spool side control valve is blocked so that the pressure oil from main pump 1 is routed to the auxiliary spool via the auxiliary flow combiner valve.  NOTE: When each operation of boom (raise/lower), arm (roll-in/out), bucket (roll-in/out), and/or travel (forward/reverse) is made, each pilot control pressure is routed to the auxiliary flow combiner valve (port SN) through the signal control valve (port SN). Therefore, the auxiliary flow combiner valve is shifted by this pilot control pressure, blocking the oil flow from main pump 1. However, the combining flow rate can be adjusted by reducing the control pressure with the reducing valve.



T2-2-20



SYSTEM / Hydraulic System Pilot Pressure Routed Pilot Pressure Routed from the from the Positioning/ Signal Control Auxiliary Pilot Valve Valve *Auxiliary Flow Combiner Shift Solenoid Valve



*Reducing Valve



Blade / Stavilizer Pilot Pressure



*Shuttle Valve



Auxiliary Flow Combiner Valve SN



SM



Auxiliary



Bypass Shut-Out Valve



Pump 2



Pump 1



T1F3-02-02-011



NOTE:* Available on only machines equipped with optional auxiliary flow combiner circuit.



T2-2-21



SYSTEM / Hydraulic System Blade/Stabilizer Circuit



• When the blade/stabilizer is operated, the pilot pressure oil from the blade/stabilizer pilot valve shifts the bypass shut-out valve. • Accordingly, the neutral circuit in the 4-spool side control valve is blocked so that the pressure oil from main pump 1 is routed to the auxiliary control valve.  NOTE: One check valve, which is operated by the signal pressure from the 2-spool solenoid valve (blade/stabilizer), is installed on each cylinder port. When the check valve is closed, the cylinder is inoperable even though the blade/stabilizer pilot valve is operated. Operable cylinder is determined depending on whether the corresponding check valve is opened or closed when the blade/stabilizer pilot valve is operated. (Refer to the SYSTEM / Control System group.)



T2-2-22



SYSTEM / Hydraulic System 



From the Blade/Stabilizer Pilot Valve







Auxiliary Control Valve



From Pilot Valve



Bypass Shut-Out Valve



Check Valve Pump 1



Check Valve



 Blade/Stabilizer Cylinder







T2-2-23



T1F3-03-03-020



SYSTEM / Hydraulic System (Blank)



T2-2-24



SYSTEM / Electrical System OUTLINE The electrical circuit is broadly divided into the main circuit, the monitor circuit, control circuit, and the column box circuit.



• Main Circuit The engine and accessory operation related circuit.



• Monitor Circuit The electrical circuit group consists of the monitors, sensors, and switches, and displays the machine operation status.



• Control Circuit (Refer to the SYSTEM / Control System group.) The control circuit is categorized into the engine, pump, and valve control circuits. Each circuit consists of the actuators such as solenoid valves, MC (main controller), switch boxes, sensors and pressure switches.



• Column Box Circuit The column box circuit is used for traveling, and consisted of the headlight, turn signal, tail light and column box.  



T2-3-1



SYSTEM / Electrical System MAIN CIRCUIT The major functions and circuits in the main circuit are as follows.



• Electric Power Circuit: Supplies all electric power to all electrical systems on this machine. >Key Switch, Batteries, Fuses (Fuse Boxes, Fusible Links), and Battery Relay@



• Indicator Light Check Circuit Checks all indicator bulbs for burning.



• Accessory Circuit Becomes operative when the key switch is turned to the ACC position.



• Preheat Circuit Assists the engine to start in cold weather. >Key Switch, QOS Controller, Coolant Switch, Glow Plug Relay, and Glow Plugs@



• Starting Circuit Starts the engine. > Key Switch, Starter, and Starting Relay@



• Charging Circuit Charges the batteries. >Alternator, and Regulator@



• Parking Brake Circuit Operates the parking brake.



• Serge Voltage Prevention Circuit Prevents the occurrence of serge voltage developed when stopping the engine. > Load Damp Relay@



• Engine Stop Circuit Stops the engine using the EC motor. >MC, and EC Motor@



T2-3-2



SYSTEM / Electrical System ELECTRIC POWER SWITCH: OFF)



CIRCUIT



(KEY 



The battery ground terminal is connected to the vehicle frame. The current from the battery plus terminal flows as (shown) below when the key switch is OFF.







     



Battery p



oGlow Plug Relay



Power



oTerminal #1: Radio (Backup Power) Monitor (Backup Power)



Fusible Link oKey Switch (B) oLoad Damp Relay oFuse Box



ICX Controller (Backup Power) oTerminal #2: MC (Power)







oTerminal #3: MC (EC Motor Power)







oTerminal #10: Optional oTerminal #24: Hazard Flasher



 QOS



Battery



45amp



Load Damp Relay



Fusible Link



65amp



Monitor



Hazard Flasher



Glow Plug Relay Fuse Box



Optional MC MC



 Radio, Monitor, ICX Controller T1GL-02-03-001







T2-3-3



SYSTEM / Electrical System INDICATOR LIGHT CHECK CIRCUIT (KEY SWITCH: ON) • When the key switch is turned ON, terminal B is connected to terminals ACC and M in the key switch.



• The current from key switch terminal M excites the battery relay.



• Therefore, the battery current enters the monitor controller via the battery relay and fuse #5 and checks the indicator bulbs.   Key Switch







Battery



Battery Relay



Fuse Box



Monitor Controller







T1GL-02-03-002



 



T2-3-4



SYSTEM / Electrical System ACCESSORY CIRCUIT







• When the key switch is turned to the ACC position,







terminal B is connected to terminal ACC in the key switch.



• The current from key switch terminal ACC flows to horn, radio, lighter, cab light and auxiliary through the fuse box, making each accessory operable.    



Horn Radio Lighter Cab Light Auxiliary



 T1GL-02-03-003







T2-3-5



SYSTEM / Electrical System PREHEAT CIRCUIT (KEY SWITCH: ON / START) • When the key switch is turned ON or to the START position, terminal B is connected to terminal M in the key switch. The current from terminal M is routed to QOS controller terminal #1 through fuse #19.



• When the key switch is ON or in the START position with the coolant switch OFF (when the coolant temperature is 10 qC (50 qF) or below), QOS controller terminal #4 is connected to terminal #5 (ground).



• Accordingly, the glow plug relay is turned ON, routing the current to the glow plugs so that preheating begins.



NOTE: After preheating has been performed, heating will continue for approx. 30 seconds after the engine starts.        



• When preheating begins, QOS controller terminal #6 is connected to terminal #5 for 8 seconds, turning the preheat indicator ON. (When preheating is not performed, the preheat indicator comes ON for 2 seconds for indicator light check.)



T2-3-6



SYSTEM / Electrical System



    Monitor







Power



Coolant Temperature Switch



Preheat Indicator QOS Controller



Key Switch



Fuse Box



Glow Plug Relay



Glow Plug



 T1GL-02-03-004







T2-3-7



SYSTEM / Electrical System STARTING CIRCUIT (KEY SWITCH: START)



  Starter Relay Operation



Brake Switch at work or parking position



• When the key switch is turned to the START



• When the key switch is turned to the START



position, terminal B on the key switch is connected to terminals M and ST in the switch. The current from terminal M magnetizes the battery relay, leading the battery current to terminals B on the starter and starter relay via the battery relay. Terminal ST of the key switch is connected to terminal S on the starter relay so that the battery current flows through the coil in the starter relay, allowing the relay to close the circuit. Then, the battery current can flow to terminal C on the starter, closing the inner starter relay. Thereby, the starter begins to rotate. The current from terminal M flows to the MC, instructing that the key switch is positioned at ON or START. When this signal arrives at the MC, the MC actuates the EC motor, which moves the governor lever.



position, key switch terminal B and terminal ST have continuity in the key switch. Then, the current flows to the base of transistor (Q2) via resistance R4 in the starter relay, switching transistor (Q2) ON. Thereby, the current flows through coil (L), closing the circuit between starter terminals B and C. Then, the starter begins to rotate.



•



•



• • •



• Once the engine is started, the alternator begins to charge the batteries so that the voltage at starter relay terminal R rises. When the voltage at terminal R reaches 21 to 22 V, zener diode (Z) becomes ON. Accordingly, transistor (Q1) is switched ON so that the base current to transistor (Q2) is cut, switching transistor (Q2) OFF. At this time, continuity between starter terminal B and C is opened. Then, the starter is switched OFF. Capacitor C1 shown in the figure is used to stabilize the operating voltage. Diode D4 protects the circuit from damage when the batteries are inversely connected.



Starter Relay B



S D3 (1) R3



From Alterrater Terminal L



R



R2



Z



L



R4



C



(1) C



D2 Q1



C1



C



(2) Q2



M



B



(2) Starter



E D4



B ST Key Switch



Engine Starter Relay



12V Batteries 12V



 T1F3-02-03-001



T2-3-8



SYSTEM / Electrical System     Key Switch



Battery Battery Relay Starter



Engine Starter Relay



C



Fuse Box



Starter Relay



Brake Switch (Work or Parking position)



EC Motor MC



 T1GL-02-03-005







T2-3-9



SYSTEM / Electrical System Brake Switch at OFF or AXLE LOCK Position



 



x Start Safety Circuit (Engine Starter Relay)







x When the key switch is turned to the ON or START







position, the current from the key switch energizes the battery relay. x By the battery relay energizes, the current from the battery flows to the engine starter relay via #28 fuse. x When the brake switch is at the off or axle lock position, the current from #28 fuse excites the engine starter relay via the brake switch. x As the engine starter relay is energized, the circuit between the key switch and the starter relay is cut. x For this reason, when the brake switch is in the off or axle lock position, the starter will not start even if the key switch is turned to the START position.







   Starter Relay S



B D3 (1)



L



R4



C R3 From Alternator Terminal L



R2



R



Z



(2)



C



D2 Q1



C1



C



(1) M



Q2



B



(2) Starter



E D4



12V



$ 56 Key Switch



Engine Starter Relay



Batteries 12V



 T1F3-02-03-002



T2-3-10



SYSTEM / Electrical System      Key Switch



Battery Battery Relay Starter



Engine Starter Relay



C



Fuse Box



Starter Relay



Brake Switch (OFF or Axle Lock Position)



EC Motor MC



 T1GL-02-03-006



 



T2-3-11



SYSTEM / Electrical System CHARGING CIRCUIT (KEY SWITCH: ON)







• After the engine starts and the key switch is







released, the key switch moves to the ON position.



 



• Then, key switch terminal B is connected to terminals ACC and M in the key switch.



• The Power From Terminal M flows to the battery relay, so that the battery relay keeps ON.



• When the alternator starts generating electricity, the current flows from alternator terminal B to the batteries via the battery relay, charging the batteries.



• The current from alternator terminal L flows to the monitor controller and the ICX controller, turning the alternator indicator OFF. ( ! 16 V) Key Switch



Battery Monitor Controller ICX Controller



Battery Relay



Alternator B



L



 T1GL-02-03-007



T2-3-12



SYSTEM / Electrical System (Blank)



T2-3-13



SYSTEM / Electrical System Alternator Operation • The alternator consists of field coil FC, stator coil SC, and diodes D. The regulator consists of transistors (T1 and T2), Zener diode ZD, and resistances (R1 and R2).



• At the beginning, no current is flowing through field coil FC. When the rotor starts turning, alternate current is generated in stator coil SC by the rotor residual magnetism.



• Alternator terminal B is connected to base B of



• When the current starts to flow through field coil



transistor T1 through the circuit >B o R o RF o (R) o (R1)@.



FC, the rotor is further magnetized so that the generating voltage increases. Thereby, the current flowing through field coil FC increases and the generating voltage is increased further, to charge the batteries.



• When battery relay is ON, the battery voltage is applied to base B of transistor T1 so that collector C is connected to emitter E. Therefore, field coil FC is grounded via transistor T1.



   



  Alternator



B



Battery Relay



R RF



L



Regulator



(R)



R3



R5



R4 R6



D



ZD Battery



R2



B



SC



E



R1 FC D1 (F)



E



C B C



T2 E T1



(E)



 T157-04-02-008



T2-3-14



SYSTEM / Electrical System Regulator Operation • When the generating voltage increases more than the set-voltage of Zener diode ZD, the current is routed to base B of transistor T2, connecting collector C to emitter E.



• When the generating voltage decreases lower than the set-voltage of Zener diode ZD, transistor T2 is turned OFF, causing transistor T1 to turn ON again.



• Then, the current which was routed to base B of



• Then, the current flows through field coil FC,



transistor T1 disappears, turning transistor T1 OFF.



increasing the generating voltage at the stater coil. The above operation is repeated so that the alternator generating voltage is kept constant.



• Therefore, no current flows through filed coil FC, reducing the generating voltage at stator coil SC. 



  



   



Battery Relay



RF



R3



R4



R5



R6 Battery



ZD R2



B



SC A



E



C FC R1



(F)



E



D1



C



B



T2 E T1



(E)



 T157-04-02-009



  



T2-3-15







SYSTEM / Electrical System PARKING BRAKE CIRCUIT • When the key switch is turned to the START position, terminal B is connected to terminals M and ST in the key switch. • The current from terminal ST magnetizes parking brake relay 3. • When parking brake relay 3 is magnetized, the current from fuse #6 flows to the coil in parking brake relay 1 through parking brake relay 3. NOTE: The current from fuse #6 flows to the coil in parking brake relay 3 after passing through parking brake relay 3 and diverging at junction A. Accordingly, parking brake relay is magnetized continuously until the current from fuse #6 disappears.



• After the engine starts running and the alternator



•



• • •



•



starts generating, the generating current flows to monitor controller terminal A2 from alternator terminal L. When the current from the alternator arrives at the monitor controller, the monitor controller judges that the engine has started so that the travel system is operable. Then, the monitor controller grounds the circuit connected from parking brake relay 1 to monitor controller terminal C5 in the monitor controller. Thereby, the current from fuse #20 is supplied to parking brake relay 2 through parking brake relay 1. Unless the brake switch is in the parking brake position, the current from fuse #20 activates the parking brake solenoid valve after passing through parking brake relays 1 and 2. When the parking brake solenoid valve is activated, the parking brake is released. (Refer to the SYSTEM / Control System group.)



T2-3-16



SYSTEM / Electrical System Key Switch



Fuse #6



A2 Fuse #20 Fuse Box



Monitor Controller



C5



Junction A



Alternator



Parking



Parking Brake Relay 3



Parking Brake Relay 1



Parking Brake Relay 2



Axle Lock



OFF



Work



Brake Switch



 Parking Brake Solenoid Valve



T2-3-17



T1GL-02-03-009



SYSTEM / Electrical System SERGE VOLTAGE PREVENTION CIRCUIT • When the engine is stopped (key switch: OFF),



• When the alternator is generating electricity, the



the current from key switch terminal M is disconnected, turning the battery relay OFF.



• The engine continues to rotate due to inertia force



generating current from alternator terminal L flows to monitor controller terminal #A-2 (ZAXIS135UR: Terminal #A-13) so that the monitor controller connects terminal #C-3 to the ground.



just after the key switch is turned OFF so that the alternator continues to generate electricity.



• Then, the current flows through the load damp



• As the generating current cannot flow to the



relay exciting circuit, turning the load damp relay ON.



battery, the surge voltage arises in the circuit, possibly causing failures of the electronic components, such as the controller. To prevent the occurrence of the surge voltage, the surge voltage prevention circuit is provided.







• Accordingly, even if the key switch is turned OFF while the engine is rotating, the battery current continues to excite the battery relay via the load damp relay until the alternator stops generating. Therefore, the battery relay is kept ON, allowing the generating current to flow to the batteries. Key Switch



Battery Battery Relay Load Damp Relay



Alternator Monitor Controller



 T1SM-02-04-007







T2-3-18



SYSTEM / Electrical System ENGINE STOP CIRCUIT • When the key switch is turned from the ON position to the OFF position, the signal current indicating that the key switch is ON stops flowing from terminal M to MC terminal #C31



• Then, the MC drives the EC motor to the engine stop position.    Key Switch



EC Motor MC



 T1GL-02-03-008



T2-3-19



SYSTEM / Electrical System (Blank)



T2-3-20



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SECTION 3



COMPONENT OPERATION Group 1 Pump Device



CONTENTS



Group 5 Travel Device



Outline ...................................................... T3-1-1



Outline ......................................................T3-5-1



Main Pump................................................ T3-1-2



Transmission .............................................T3-5-2



Regulator .................................................. T3-1-4



Front and Rear Propeller Shaft................T3-5-17



Torque Control Solenoid Valve ................ T3-1-32



Front Axle................................................T3-5-18



Pilot Pump, Steering Pump ..................... T3-1-34



Steering Cylinder.....................................T3-5-20



N Sensor (Engine Speed Sensor) ........... T3-1-34



Differential Gear ......................................T3-5-22



Pump Delivery Pressure Sensor ............. T3-1-34



Reduction Gear .......................................T3-5-26



Pump Control Pressure Sensor .............. T3-1-35



Rear Axle ................................................T3-5-28 Travel Motor ............................................T3-5-31



Group 2 Swing Device Outline ...................................................... T3-2-1 Swing Reduction Gear .............................. T3-2-2 Swing Motor.............................................. T3-2-3 Swing Parking Brake................................. T3-2-4 Valve Unit ................................................. T3-2-6



Rotor Section ..........................................T3-5-32 Regulator ................................................T3-5-34 Brake Valve .............................................T3-5-45



Group 6 Signal Control Valve Outline ......................................................T3-6-1 Pilot Port ...................................................T3-6-2



Group 3 Control Valve Outline ...................................................... T3-3-1 Hydraulic Circuit ..................................... T3-3-16 Main Relief Valve .................................... T3-3-22 Overload Relief Valve ............................. T3-3-24 Anti-Drift Valve ........................................ T3-3-26 Regenerative Valve................................. T3-3-28 Flow Rate Control Valve ......................... T3-3-30 Bypass Shut-Out Valve ........................... T3-3-32 Auxiliary Flow Combiner Valve................ T3-3-34



Shuttle Valve .............................................T3-6-5 Shockless Valve ........................................T3-6-8 Pump 1 and Pump 2 Flow Rate Control Valves .......................................T3-6-10 Bucket Flow Rate Control Valve Control Spool, Flow Combiner Valve Control Spool, Swing Parking Brake Release Spool, Arm Flow Rate Control Valve Control Spool.........................................T3-6-12



Group 4 Pilot Valve Outline ...................................................... T3-4-1 Operation .................................................. T3-4-4



CBBT-3-1



 Group 7 Steering Valve Outline ...................................................... T3-7-1 Construction ............................................. T3-7-4 Operation .................................................. T3-7-5 Relief Valve............................................... T3-7-8 Overload Relief Valve ............................... T3-7-9 Make-Up Valve.......................................... T3-7-9



Group 8 Brake Valve Outline ...................................................... T3-8-1 Operation .................................................. T3-8-2



Group 9 Transmission Control Valve Outline ...................................................... T3-9-1 Operation .................................................. T3-9-4



Group 10 Others (Upperstructure) Pilot Shut-Off Valve................................. T3-10-1 Solenoid Valve Unit................................. T3-10-2 Travel Shockless Valve ........................... T3-10-6 Pilot Relief Valve ..................................... T3-10-8 Accumulator............................................ T3-10-9 Accumulator Charging Valve ................. T3-10-10 Hose-Rupture Safety Valve ................... T3-10-14 EC Motor .............................................. T3-10-18



Group 11 Others (Undercarriage) Swing Bearing......................................... T3-11-1 Center Joint ............................................ T3-11-2 Slip Ring ................................................. T3-11-3 Cylinder .................................................. T3-11-5



CBBT-3-2



COMPONENT OPERATION / Pump Device OUTLINE Pilot pump (2) and steering pump (4) are gear pumps. Pump delivery pressure sensors (6 and 8), pump control pressure sensors (5 and 7), and N sensor (engine speed sensor) (1) are provided to control pump and valve operations.



The pump device consists of main pump [pump 1 (9) and pump 2 (10)], pilot pump (2) and steering pump (4). The main pump is a swash plate type variable displacement 2-tandem plunger pump, supplying the high pressure hydraulic oil to the main circuits.







 4



3



2



1



 



 8







7



6



T1F3-01-02-007



5







 9







T1F3-03-01-002



10



 1 - N Sensor (Engine Speed Sensor) 2 - Pilot Pump 3 - Torque Control Solenoid Valve



45-



Steering Pump



7-



Pump 2 Control Pressure Sensor 6 - Pump 2 Delivery Pressure Sensor



Pump 1 Control Pressure Sensor㩷 8 - Pump 1 Delivery Pressure Sensor㩷 㩷



T3-1-1



9-



Pump 1㩷



10 - Pump 2㩷 㩷



COMPONENT OPERATION / Pump Device MAIN PUMP



 



The main pump is a swash plate type 2-tandem plunger pump. The two shafts (1) are connected with gear (6). The same type pump is mounted on each shaft (1). Shaft (1) is splined to cylinder block (5), and plungers (4) are inserted in cylinder block (5). Engine rotation is transmitted to shaft (1) via the coupling. As shaft (1) is rotated, plungers (4) rotate along with cylinder block (5). Plungers (4) slide along the surface of shoe plate (3) so that plungers (4) reciprocate in the cylinder block (5) bores as swash plate (2) is positioned at an angle toward plungers (4). Plunger (4) reciprocation functions to draw and discharge the hydraulic oil.







  



Main Pump 2



Main Pump 1



 



1



 2



3



4



4 5



6



5



4



3



2



㩷 㩷



T1F3-03-01-003



    



T3-1-2



COMPONENT OPERATION / Pump Device Flow Rate Increasing / Decreasing Operation The flow rate of the pump is varied by changing the angle of the swash plate, which changes the stroke of the plunger. The servo piston is moved by the pressure oil routed from the regulator. As the swash plate is connected to the servo piston, the swash plate angle is changed in accordance with the movement of the servo piston, so that the pump flow rate is changed.   



Servo Piston



Shaft



Valve Plate Cylinder Block Plunger







Swash Plate



  



T3-1-3



 T117-02-01-003



COMPONENT OPERATION / Pump Device REGULATOR The regulator controls the main pump flow rate in response to the various command signal pressures so that the pump driving power doesn’t exceed the engine power. Pump 1 and pump 2 are provided with one regulator each. The major parts of the regulator are lever 2 (5), pilot piston (3), pin (7), feedback lever (9), lever 1 (15), compensating piston (22), sleeve (12), spool (13) and stopper (1).



The torque control solenoid valve is located on the pump 2 regulator.



Torque Control Solenoid Valve㩷



 Pump 1 Regulator㩷



 Component Layout



T1F3-01-02-007



Pump 2 Regulator㩷



Pump 1



Pump 2



19



9 5



1



3



7 Pump 1 Regulator



Pump 2 Regulator㩷



 22



15



13



12



 1 - Stopper 3- Pilot Piston 5- Lever 2



7 - Pin 9- Feedback Lever 12- Sleeve



13 - Spool 15- Lever 1



T3-1-4



T1F3-03-01-012



Torque Control Solenoid Valve㩷 19- Servo Piston 22- Compensating Piston



COMPONENT OPERATION / Pump Device Pump 1 Regulator 



3



1



5



7







9



 T1F3-03-01-004







12



15



13







19



22



 T1F3-03-01-005



Pump 2 Regulator 



7



5



3



9



 T1F3-03-01-007







T3-1-5



COMPONENT OPERATION / Pump Device Cross Section (Pump 1 Regulator)



B



A



A



B



 T1F3-03-01-034



Cross Section A-A 



1



2



3



4



5



6



8



7







9



 T1F3-03-01-004



10



 1 - Stopper 2 - Piston 3 - Pilot Piston



4 - Pin 5 - Lever 2 6 - Pin



7 - Pin 8 - Pilot Piston



  



T3-1-6



9 - Feedback Lever 10 - Pin



COMPONENT OPERATION / Pump Device Cross Section B-B



11



13



12



14



15



16



18



17



 T1F3-03-01-005



  



23



11121314-



Return Spring Sleeve Spool Pin



22



15 - Lever 1 16 - Pin 17 - Outer Spring



20



21



18 - Inner Spring 19 - Servo Piston 20 - Pin



T3-1-7



19



21 - Compensating Rod 22 - Compensating Piston 23 - Piston



COMPONENT OPERATION / Pump Device Cross Section (Pump 2 Regulator) 



B







A



A



B



 T1F3-03-01-009



 㩷



Cross Section A-A   3







4



5



6



8



7







9 10 34-



Pilot Piston Pin



56-



Lever 2 Pin



7 - Pin 8 - Pilot Spring



T3-1-8







9 - Feedback Lever 10 - Pin



T1F3-03-01-007



COMPONENT OPERATION / Pump Device Cross Section B-B 



11



12



13



14



15



16



17



18







23



22



21



19



20



 T1F3-03-01-008



 11121314-



Return Spring㩷 Sleeve㩷 Spool㩷 Pin



15- Lever 1 16- Pin㩷 17- Outer Spring㩷 㩷



18- Inner Spring㩷 19- Servo Piston㩷 20- Pin㩷 㩷







T3-1-9



21- Compensating Rod㩷 22- Compensating Piston㩷 23- Piston㩷 㩷



COMPONENT OPERATION / Pump Device Link Mechanism Movement of pilot piston (3) is transmitted to lever 2(5) via pin (4), rotating lever 2 (5) around pin (7) held in the supporting plug. Movement of compensating rod (21) is transmitted to lever 1 (15) via pin (20), rotating lever 1 (15) around pin (14) held in the casing. Pin (6) is installed into feedback lever (9) and both ends of pin (6) are inserted into the holes on lever 1 (15) and lever 2 (5). 14㩷



 



Casing



20㩷



Accordingly, when lever 1 (15) or lever 2 (5) rotates, pin (6) comes in contact with the hole inside on the rotated lever, causing feedback lever (9) to rotate around pin (10) on servo piston (19). On the other hand, when servo piston (19) is moved, feed back lever (9) is moved via pin (10). Since lever 1 (15) and lever 2 (5) do not move at this time, feedback lever (9) rotates around pin (6), moving spool (13).  NOTE:



15



:Decreasing displacement angle :Increasing displacement angle



Hole㩷



9



21㩷



16 6㩷 5㩷 Hole㩷



7㩷



4㩷 Supporting Plug㩷



13㩷



10㩷 3







19



T117-02-01-009



 3456-



Pilot Piston Pin Lever 2 Pin



7 - Pin 9 - Feedback Lever 10 - Pin



14 - Pin 15 - Lever 1 16 - Pin







 



T3-1-10



19 - Servo Piston 20 - Pin 21 - Compensating Rod



COMPONENT OPERATION / Pump Device Regulator Functions The regulator has the following five control functions.



x Control by Pump Control Pressure When a control lever is operated, the pump flow rate control valve in the signal control valve regulates pump control pressure Pi in response to the lever stroke. Then, when the regulator receives pump control pressure Pi, the regulator controls the pump flow rate in proportion to pump control pressure Pi. When a control lever is operated, pump control pressure Pi increases Thereby, the regulator increases the pump flow rate. When the control lever is returned to neutral, pump control pressure Pi decreases, causing the regulator to reduce the pump flow rate.



Flow Rate (Q)



0



x Control by Own or Partner Pump Delivery Pressure



Pump Control Pressure (Pi)



Flow Rate (Q)



The regulator receives own pump delivery pressure P1 and partner pump delivery pressure P2 as control signal pressures. If the two average pressures increase over the set P-Q line, the regulator reduces both pump flow rates by the excess pressure from the P-Q line so that the total pump output is returned to the set P-Q line. Thereby, the engine is protected from being overloaded. The P-Q line has been designated to jointly regulate both pump operations Therefore, both pump flow rates are regulated almost equally to each other. Accordingly, although the higher-pressure side pump is loaded more than the lower-pressure side pump, the total pump output matches with the engine output. (Total Horsepower Control)



Pressure Increase Flow Rate Decrease



0



Pressure (P) P1



Pump 1



P2 Pump 2



 Pi2



Pi1



PG



Pic







Pf







Torque Control Solenoid Valve



P1 - Pump 1 Delivery Pressure Pi1 - Pump 1 Control Pressure (from maximum pump 1 flow rate limit solenoid valve) Pic - Maximum Pump 1 Flow Rate Shift Pressure (from maximum pump 1 flow rate shift solenoid valve) PG - Primary Pilot Pressure (from pilot pump)



T3-1-11



T1F3-03-01-012



P1 - Pump 2 Delivery Pressure Pi2 - Pump 2 Control Pressure (from maximum pump 2 flow rate limit solenoid valve) Pf - Torque Control Pressure (from torque control solenoid valve)



COMPONENT OPERATION / Pump Device x Control by Pilot Pressure from Torque Control Solenoid Valve The main controller (MC) operates based on both the engine target speed input data and actual speed information signals and outputs signals to the torque control solenoid valve. In response to the signals from the MC, the torque control solenoid valve delivers torque control pilot pressure Pps to the regulator. Upon receiving pilot pressure Pps, the regulator reduces the pump flow rate. (Speed Sensing Control: Increasing torque at a slow speed) (Refer to the CONTROL SYSTEM section.)



Flow Rate (Q)



0



Pressure (P)



x Control by the pilot pressure from the flow rate limit solenoid valve When signals from the work mode switch, and/or the pressure sensor (auxiliary) or the attachment mode switch (optional) arrive at the MC (main controller), the MC sends a signal to the pump maximum flow rate limit solenoid valve. In response to this signal, the pump maximum flow rate limit solenoid valve reduces pump control pressure Pi, limiting the pump maximum flow rate. (Pump flow rate limit control) (Refer to the Control System group.)



Flow Rate (Q)



0



Pump Control Pressure (Pi)



Flow Rate (Q)



0



T3-1-12



Pressure (P)



COMPONENT OPERATION / Pump Device x Control by the maximum flow rate shift solenoid valve (only pump 1 side) When signals from the engine control mode switch, the travel mode switch, the brake switch, the travel pilot pressure, and/or the N sensor (travel) arrive at the MC, the MC judges that the machine must be traveling. Then, the MC sends the signal to the pump 1 maximum flow rate shift solenoid valve. In response to this signal, the pump 1 maximum flow rate shift solenoid valve reduces the p1 maximum flow rate shift pressure Pic so that the pump 1 maximum flow rate is increased. (Travel pump 1 maximum flow rate shift control) (Refer to the Control System group.) NOTE: Minimum Flow Rate Signal Priority Control When more than two control signals are delivered to the regulator at the same time, the regulator is controlled by the minimum flow rate signal. Smaller Swash Angle Smaller (Flow Rate) Signal Priority Control







Increased Maximum Flow Rate



 Flow Rate (Q) 



Normal Pump P-Q Curve



     



0



Pressure (P)



 P1



 Pump 1



P2 Pump 2



Pi2



Pi1



PG



Pic







Pf







Torque Control Solenoid Valve



P1 - Pump 1 Delivery Pressure Pi1 - Pump 1 Control Pressure (from maximum pump 1 flow rate limit solenoid valve) Pic - Maximum Pump 1 Flow Rate Shift Pressure (from maximum pump 1 flow rate shift solenoid valve) PG - Primary Pilot Pressure (from pilot pump)



T3-1-13



T1F3-03-01-012



P1 - Pump 2 Delivery Pressure Pi2 - Pump 2 Control Pressure (from maximum pump 2 flow rate limit solenoid valve) Pf - Torque Control Pressure (from torque control solenoid valve)



COMPONENT OPERATION / Pump Device (Blank) 



T3-1-14



COMPONENT OPERATION / Pump Device Regulator Operation Although the pump 1 regulator is slightly different from the pump 2 regulator, the operational principles are the same except for the maximum flow rate sift control section. Therefore, both regulator operation is described using only pump1 regulator.  Swash Plate Inclination



 3







1



5



8 Increase







19



Decrease



Pi1



10 Pic



9



7 P1 P2







Pf T1F3-03-01-013



22







15



18



12



13



11



  1 - Stopper 3 - Pilot Piston 5 - Lever 2 7 - Pin



P1 - Pump 1 Delivery Pressure



8910 11 -



Pilot Spring Feedback Lever Pin Return Spring



12 - Sleeve 13 - Spool 15 - Lever 1



Pi1 - Pump 1 Control Pressure (from maximum pump 1 flow rate limit solenoid valve)



Pic - Maximum Pump 1 Flow Rate Shift Pressure (from maximum pomp 1 flow rate shift solenoid valve)



P2 - Pump 2 Delivery Pressure



    



T3-1-15



18 - Inner Spring 19 - Servo Piston 22 - Compensating Piston



Pf - Torque Control Pressure (from torque control solenoid valve)



COMPONENT OPERATION / Pump Device Control by Pump Control Pressure The pump control pressure control has two functions, the flow rate increase and decrease functions. The secondary pilot oil pressure proportional to the control lever stroke is routed to the pump regulator after being converted to pressure Pi at the selector valve. Thereby, the pump regulator is informed of the control lever conditions so that the regulator controls the pump swash angle.



• Flow Rate Increase Operation 1. When a control lever is operated, flow rate control pressure Pi acts on piston (2). As pressure Pi increases, piston (2) and pilot piston (3) is moved to the right until Pi pressure force comes in balance with pilot spring (8) force. 2. Pilot piston (3) moves lever 2 (5) via pin (4). Lever 2 (5) rotates around pin (7) (secured in the supporting plug) counterclockwise. 3. As pin (6) installed in feedback lever (9) is inserted into the hole on lever 2 (5). Feedback lever (9) is rotated around pin (10) by lever 2 (5) counterclockwise, moving spool (13) to the left. 4. When spool (13) is moved, the large chamber of servo piston (19) is connected to the hydraulic oil tank through spool (13). Since the pump delivery oil pressure (P) is routed into the small chamber, servo piston (19) moves to the left. 5. According to servo piston (19) moving, the pump swash angle increases so that the pump flow rate increases. 



6. As servo piston (19) moves, feedback lever (9) is moved via pin (10). Since pilot piston (3) and lever 2 (5) do not move, feedback lever (9) is rotated around pin (6) clockwise, moving spool (13) to the right. Then, when the notches on spool (13) and sleeve (12) close thoroughly, the large chamber of servo piston (19) isn’t connected to the hydraulic oil tank, then servo piston (19) stops moving. 7. Consequently, the pump flow rate increases in proportion to the control lever stroke (Pi pressure increase).  



Flow Rate (Q)



      



0







Pump Control Pressure㩷(Pi)



 Swash Plate Inclination㩷



 



3



5



Decrease



Increase



 Pi



19 10 9



7



P



 T1F3-03-01-031



  



T3-1-16



8



13



12



COMPONENT OPERATION / Pump Device 



2







3



4



5



6



7



8







9



Pi INCREASE







12



10



DECREASE To Hydraulic Oil Tank㩷



 T1F3-03-01-016



13



P







19



T1F3-03-01-023



 234-



Piston Pilot Piston Pin



5 - Lever 2 6 - Pin 7 - Pin



8 - Pilot Spring 9 - Feedback Lever 10 - Pin







T3-1-17



12 - Sleeve 13 - Spool 19 - Servo Piston



COMPONENT OPERATION / Pump Device • Flow Rate Decrease Operation 1. When a control lever is returned to neutral and flow rate control pressure Pi is reduced, pilot piston (3) is moved to the left until pilot piston (3) balances with spring (8). 2. Pilot piston (3) moves lever 2 (5) via pin (4). Lever 2 (5) rotates around pin (7) (secured in the supporting plug) clockwise. 3. As pin (6) installed in feedback lever (9) is inserted into the hole on lever 2 (5). Feedback lever (9) is rotated around pin (10) by lever 2 (5) clockwise, moving spool (13) to the right. 4. When spool (13) is moved, pump delivery oil pressure (P) is routed into the large chamber of servo piston (19) through spool (13). Although the same oil pressure (P) is routed into the small chamber, servo piston (19) moves to the right due to the difference in pressure receiving area between the servo piston ends. 5. According to servo piston (19) moving, the pump swash angle is reduced so that the pump flow rate is reduced. 6. As servo piston (19) moves, feedback lever (9) is moved via pin (10). Since pilot piston (3) and lever 2 (5) do not move, feedback lever (9) is rotated around pin (6) counterclockwise, moving spool (13) to the left. Then, when the notches on spool (13) and sleeve (12) close thoroughly, the pump delivery oil pressure (P) isn’t routed into the large chamber of the servo piston (19), then servo piston (19) stops moving. 7. Consequently, the pump flow rate decreases in proportion to the control lever stroke (Pi pressure decrease). 



 



Flow Rate (Q)



      



0







Pump Control Pressure (Pi)



  Swash Plate Inclination㩷



 



3



5



8



Decrease



Increase







19



Pi



10 9



7 13 P



 T1F3-03-01-030



   







T3-1-18



12



COMPONENT OPERATION / Pump Device   



3



4



5



6



7



8



9



Pi



10



 T1F3-03-01-019







13



12



P







19



T1F3-03-01-025



 345-



Pilot Piston Pin Lever 2



678-



Pin Pin Pilot Spring



9-



Feedback Lever ¾ Pin 12 - Sleeve







T3-1-19



13 - Spool 19 - Servo Piston



COMPONENT OPERATION / Pump Device Control by Own or Partner Pump Delivery Pressure 



6. As servo piston (19) moves, feedback lever (9) is moved via pin (10). Since compensating rod (21) and lever 1 (15) do not move, feedback lever (9) is rotated around pin (6) counterclockwise, moving spool (13) to the left. Then, when the notches on spool (13) and sleeve (12) close. Thoroughly the oil pressure isn’t routed into the large chamber of servo piston (19), then servo piston (19) stops moving. 7. Consequently, the pump flow rate decreases from Q1 to Q2, reducing the pump loads.



NOTE: The pump control, which is performed using its own delivery pressure and partner pump delivery pressure, has the following two functions. Overload Prevention Operation As load (pressure) increases, the pump delivery flow rate is reduced so that the engine is not overloaded. Flow Rate Recover Operation As load (pressure) decreases, the pump delivery flow rate is increased so that the engine output can be effectively utilized. 



 



Flow Rate (Q)



• Flow Rate Reduction (Overload Prevention)







Function 1. When pump delivery pressure (P1: its own delivery pressure, and P2: partner pump delivery pressure) increases, compensation piston (22) moves compensation rod (21) to the right until the pump delivery pressure force comes in balance with outer spring (17) force and inner spring (18) force. 2. Compensating rod (21) moves lever 1 (15) via pin (20). Lever 1 (15) is rotated around pin (14) (secured in the casing) counterclockwise. 3. As pin (6) installed in feedback lever (9) is inserted into the hole on lever 1 (15). Feedback lever (9) is rotated around pin (10) by lever 1 (15) clockwise, moving spool (13) to the right. 4. When spool (13) is moved, pump delivery oil pressure (P) is routed into the large chamber of servo piston (19) through spool (13). Although the same oil pressure (P) is routed into the small chamber, servo piston (19) moves to the right due to the difference in pressure receiving area between the servo piston (19) ends. 5. According to servo piston (19) moving, the pump swash angle is reduced so that the pump flow rate is reduced.



     



0



Pressure (P)







Swash Plate Inclination㩷



  



Increase



Decrease



19 10 9



22 P1 P2



 T1F3-03-01-028



 



 



T3-1-20



15 18



12



COMPONENT OPERATION / Pump Device 



12



13



17



15



14



18



P1



P2



22







21



20



19



12



10 13



21



15



19







9



6



T1F3-03-01-035



6



10



9



 T1F3-03-01-038



6 - Pin 9 - Feedback Lever 10 - Pin



12 - Sleeve㩷 13 - Spool㩷 14 - Pin㩷



15 - Lever 1 17 - Outer Spring㩷 18 - Inner Spring㩷







T3-1-21



19 - Servo Piston㩷 21 - Compensating Rod㩷 22 - Compensating Piston㩷



COMPONENT OPERATION / Pump Device • Flow Rate Increase (Flow Rate Recovery) 1.



2. 3.



4.



5. 6.



7.







Function When pump delivery pressure (P1: its own delivery pressure, and P2: partner pump delivery pressure) decreases, compensation piston (22) and compensation rod (21) is moved to the left until the pump delivery pressure force comes in balance with outer spring (17) force and inner spring (18) force. Compensating rod (21) moves lever 1 (15) via pin (20). Lever 1 (15) is rotated around pin (14) (secured in the casing) clockwise. As pin (6) installed in feedback lever (9) is inserted into the hole on lever 1 (15). Feedback lever (9) is rotated around pin (10) by lever 1 (15) counterclockwise, moving spool (13) to the left. When spool (13) is moved, the large chamber of servo piston (19) is connected to the hydraulic oil tank through spool (13). As pump delivery oil pressure (P) is routed into the small chamber, servo piston (19) moves to the left. According to servo piston (19) moving, the pump swash angle increases so that the pump flow rate increases. As servo piston (19) moves, feedback lever (9) is moved via pin (10). Since compensating rod (21) and lever 1 (15) do not move, feedback lever (9) is rotated around pin (6) clockwise, moving spool (13) to the right. Then, when the notches on spool (13) and sleeve (12) close thoroughly, the large chamber of servo piston (19) isn’t connected to the hydraulic oil tank, then servo piston (19) stops moving. Accordingly, the pump flow rate increases.



   



Flow Rate (Q)



      



0



Pressure (P)







   



Swash Plate Inclination㩷 Decrease



Increase



19 10 9



22 P1 P2



 T1F3-03-01-033







  



T3-1-22



15 18



13



12



COMPONENT OPERATION / Pump Device 



To Hydraulic Oil Tank㩷



12



13



14



17



15



18



P1 P2



22



21



6



9



10



20



19



 T1F3-03-01-036







12



13



21



19



6



15



10



9



 T1F3-03-01-039



6 - Pin 10 - Feedback Lever 11 - Pin



12 - Sleeve㩷 13 - Spool㩷 14 - Pin㩷



15 - Lever 1 17 - Outer Spring㩷 18 - Inner Spring㩷







T3-1-23



19 - Servo Piston㩷 20 - Compensating Rod㩷 21 - Compensating Piston㩷



COMPONENT OPERATION / Pump Device Control by Pilot Pressure from Torque Control Solenoid Valve 6. As servo piston (19) moves, feedback lever (9) is moved via pin (10). Since compensating rod (21) and lever 1 (15) do not move, feedback lever (9) is rotated around pin (6) counterclockwise, moving spool (13) to the left. Then, when the notches on spool (13) and sleeve (12) close thoroughly, the pump delivery oil pressure (P) isn’t routed into the servo piston (19), then servo piston (19) stops moving. 7. Therefore, torque constant control (overload prevention operation and flow rate recover operation) is performed conforming with the varied P-Q curve.



The pump flow rate is reduced when torque control pressure Pf is supplied from the torque control solenoid valve. 1. Torque control pressure Pf acts on the end face of pin (23). Then, compensating piston (22), and compensating rod (21) move to the right until they balance with outer spring (17) and inner spring (18). 2. Compensating rod (21) moves lever 1 (15) via pin (20). Lever 1 (15) is rotated around pin (14) (secured in the casing) counterclockwise. 3. As pin (6) installed in feedback lever (9) is inserted into the hole on lever 1 (15). Feedback lever (9) is rotated around pin (10) by lever 1 (15) clockwise, moving spool (13) to the right. 4. When spool (13) is moved, pump delivery oil pressure (P) is routed into the large chamber of servo piston (19) through spool (13). Although the same oil pressure (P) is routed into the small chamber, servo piston (19) moves to the right due to the difference in pressure receiving area between the servo piston (19) ends. 5. According to servo piston (19) moving, the pump swash angle is reduced so that the pump flow rate is reduced.



 



Flow Rate (Q)



      



0







Pressure (P) Swash Plate Inclination㩷



 



19







Increase



Decrease



10 9 22



13



P



Pf







T1F3-03-01-029



  



T3-1-24



15



18



12



COMPONENT OPERATION / Pump Device 



Pf



13



14



15



17 18



12



P



23



22



21



19



20



9



10











6



T1F3-03-01-037



13



15



6



12



21 6910 12 -



Pin Feedback Lever Pin Sleeve



13 - Spool 14 - Pin 15 - Lever 1



19



10 17 - Outer Spring 18 - Inner Spring 19 - Servo Piston



 T3-1-25



9



 T1F3-03-01-040



21 - Compensating Rod 22 - Compensating Piston 23 - Pin



COMPONENT OPERATION / Pump Device Control by Pilot Pressure from Pump 2 Flow Rate Limit Solenoid Valve 



8. As servo piston (19) moves, feedback lever (9) is moved via pin (10). Since pilot piston (3) and lever 2 (5) do not move, feedback lever (9) is rotated around pin (6) clockwise, moving spool (13) to the right. Then, when the notches on spool (13) and sleeve (12) close thoroughly, the large chamber of servo piston (19) isn’t connected to the hydraulic oil tank, then servo piston (19) stops moving. 9. Consequently, the pump flow rate increases in proportion to the control lever stroke (Pi pressure increase). However, as the maximum pump control pressure is limited so that the movement of pilot piston (3) is reduced. Therefore, the maximum flow rate is reduced to less than normal.



NOTE: Control operation performed by the pilot pressure from the pump maximum flow rate limit solenoid valve is identical to the control operation (flow rate increase) performed by the pump control pressure. 



• Limiting Maximum Flow Rate 1. The maximum pump flow rate control solenoid valve in the pump control pressure Pi circuit is activated by the signals from the MC. 2. The maximum pump flow rate control solenoid valve functions as a reducing valve, limiting pump control pressure Pi. 3. When a control lever is operated, flow rate control pressure Pi acts on pilot piston (3). As pressure Pi increases, piston (2) and pilot piston (3) is moved to the right until Pi pressure force comes in balance with pilot spring (8) force. 4. Pilot piston (3) moves lever 2 (5) via pin (4). Lever 2 (5) rotates around pin (7) (secured in the supporting plug) counterclockwise. 5. As pin (6) installed in feedback lever (9) is inserted into the hole on lever 2 (5). Feedback lever (9) is rotated around pin (10) by lever 2 (5) counterclockwise, moving spool (13) to the left. 6. When spool (13) is moved, the large chamber of servo piston (19) is connected to the hydraulic oil tank through spool (13). Since the pump delivery oil pressure (P) is routed into the small chamber, servo piston (19) moves to the left. 7. According to servo piston (19) moving, the pump swash angle increases so that the pump flow rate increases.







Flow Rate (Q)



      0







Pump Control Pressure (Pi)



  Flow Rate (Q)       0



  



T3-1-26



Pressure (P)



COMPONENT OPERATION / Pump Device  2







3



4



5



7



6



8







9



Reducing Pi Pressure



10



 T1F3-03-01-019







12



To Hydraulic Oil Tank㩷



13



P



19



 T1F3-03-01-023



 234-



Piston Pilot Piston Pin



567-



Lever 2 Pin Pin



8 - Pilot Spring 9 - Feedback Lever 10 - Pin







T3-1-27



12 - Sleeve 13 - Spool 19 - Servo Piston



COMPONENT OPERATION / Pump Device Control by Maximum Flow Rate Shift Solenoid Valve (Only Pump 1) 8. As servo piston (19) moves, feedback lever (9) is moved via pin (10). Since pilot piston (3) and lever 2 (5) do not move, feedback lever (9) is rotated around pin (6) clockwise, moving spool (13) to the right. Then, when the notches on spool (13) and sleeve (12) close thoroughly, the large chamber of servo piston (19) isn’t connected to the hydraulic oil tank, then servo piston (19) stops moving. 9. As stopper (1) moves to the right, pilot piston (3) is moved to the right more than usual, causing the maximum pump 1 flow rate to increase.



NOTE: Control operation performed by the maximum flow rate shift solenoid valve is almost identical to the control operation (flow rate increase) performed by the pump control pressure.



• Flow Rate Increase (Pump 1 Maximum Flow Rate) 1. When the pump 1 maximum flow rate shift solenoid is activated, pump 1 maximum flow rate shift pressure Pic acting on stopper (1) is routed to the hydraulic oil tank. 2. Pump control pressure Pi is pushing piston (2) to the right. As pump 1 maximum flow rate shift pressure Pic is reduced to the hydraulic oil tank pressure, stopper (1) moves piston (2) to the right. 3. Then, piston (2) moves pilot piston (3) to the right until the pressure Pi force comes in balance with spring (8) force. 4. Pilot piston (3) moves lever 2 (5) via pin (4). Lever 2 (5) rotates around pin (7) (secured in the supporting plug) counterclockwise. 5. As pin (6) installed in feedback lever (9) is inserted into the hole on lever 2 (5). Feedback lever (9) is rotated around pin (10) by lever 2 (5) counterclockwise, moving spool (13) to the left. 6. When spool (13) is moved, the large chamber of servo piston (19) is connected to the hydraulic oil tank through spool (13). Since the pump delivery oil pressure (P) is routed into the small chamber, servo piston (19) moves to the left. 7. According to servo piston (19) moving, the pump swash angle increases so that the pump flow rate increases.



 



Increased Maximum Flow Rate



Flow Rate (Q) 



Normal pump P-Q Curve



     



0



Pressure (P)



 



3



1



7



5



 Increase







Swash Plate Inclination㩷



Decrease



19 Pi



10



Pic



9



 P



 T1F3-03-01-032



  



T3-1-28



8



13



12



COMPONENT OPERATION / Pump Device 



1



2



4



3



5



7



6



8







9



Pi



Pic (To Hydraulic Tank)







10



Oil



 12



T1F3-03-01-017



To Hydraulic Oil Tank㩷



13



P







19



T1F3-03-01-024



1234-



Stopper Piston Pilot Piston Pin



5 - Lever 2 6 - Pin㩷 7 - Pin㩷 㩷



8 - Pilot Spring 9 - Feedback Lever 10 - Pin







T3-1-29



12 - Sleeve㩷 13 - Spool㩷 19 - Servo Piston㩷 㩷



COMPONENT OPERATION / Pump Device Smaller Swash Angle Smaller (Flow Rate) Signal Priority Control When both pump flow rate increase and decrease signals arrive at the same time, this regulator operates so that the priority is given to the flow rate decrease signal.







1. The pump displacement angle control signals supplied from the pump control pressure and the pilot pressure from the torque control solenoid valve is transferred to feedback lever (9) and spool (13) via the holes on lever 1 (15) and lever 2 (5), and pin (6). [Refer to T3-1-12 (Control by Pump Control Pressure) and T3-1-20 (Control by Pilot Pressure from Torque Control Solenoid Valve)] 2. Pin (6) comes in contact with the flow rate decrease side hole on lever 1 (15) or lever 2 (5) so that priority is given to flow rate and power decrease control.  



T3-1-30



COMPONENT OPERATION / Pump Device  Flow Rate Increase Directive Signal:



5



6



9



Pi



 T1F3-03-01-016



Flow Rate Decrease Directive Signal: Pf



13



15



6



P



 T1F3-03-01-022



56-



Lever 2 Pin㩷



9㩷



Feedback Lever㩷



13 - Spool㩷 㩷







T3-1-31



15- Lever 1 㩷



COMPONENT OPERATION / Pump Device TORQUE CONTROL SOLENOID VALVE The torque control solenoid valve is located on the pump 2 regulator. The torque control solenoid valve supplies the torque control pressure Pps to both the pump 1 and pump 2 regulators to reduce the pump flow rate.  Operation 1. When neutral, port T is connected to the output port through the notch on the spool. Pressure oil from port P is completely blocked by the spool. 2. When the current flows to the solenoid from the MC, the solenoid is magnetized, pushing spring 1. 3. The output port is connected to port P via the notch on spool. Then, the pressure oil is routed to the output port from port P. 4. The spring chamber is opened to port T via the passage in the spool. Since the left side spool stap flange diameter (A) is larger than the right side spool stap flange diameter (B), the spool is returned to the left side.



T3-1-32



COMPONENT OPERATION / Pump Device  When Neutral:  



Solenoid



Spring



Hole



Port P



Spool



 㩷 㩷



Port T Spring Chamber



㩷



Output



㩷 㩷



T1F3-03-01-010



  When Operating:  



Solenoid㩷



Spring㩷



Port P㩷



Hole



Spool㩷



 T1F3-03-01-018



  



Spring Chamber



Output



  



T3-1-33



A



B



COMPONENT OPERATION / Pump Device PILOT PUMP, STEERING PUMP 1



Inlet Port



Drive gear (1) is driven by the engine via the transmission which in turn rotates driven gear (2) as they are meshed together. 1 - Drive Gear



2



2 - Driven Gear



Outlet Port



 



T137-02-03-005



N SENSOR (ENGINE SPEED SENSOR) The N sensor detects the engine speed, which is used to control various operations. The N sensor is located close to the transmission teeth so that the sensor converts the number of teeth passing by the sensor into pulse signals, effectively sensing the engine speed. 3 - Tooth 4 - Output



4



5



3



5 - Output



 T178-03-01-020



PUMP DELIVERY PRESSURE SENSOR This sensor detects the pump delivery pressures, which are used to control various operations. When oil pressure is applied onto diaphragm (9), the diaphragm is deformed. The deformation of the diaphragm is detected as electrical signals.



 T157-02-03-010



6 - Ground 7 - Output



8 - Power Source (5V) 9 - Pressure Receiving Area (Diaphragm)



6



T3-1-34



7



8



9







COMPONENT OPERATION / Pump Device PUMP CONTROL PRESSURE SENSOR This sensor detects the pump control pressures, which are used to control various operations. When oil pressure is applied onto diaphragm (10), the diaphragm is deformed. The deformation of the diaphragm is detected as electrical signals. 10 - Pressure Receiving Area (Diaphragm) 11 - Ground



12 - Output



 T176-03-01-023



10



13 - Power Source (5V)



T3-1-35



11 12



13



COMPONENT OPERATION / Pump Device (Blank) 



T3-1-36



COMPONENT OPERATION / Swing Device OUTLINE The swing device consists of the valve unit, swing motor, and swing reduction gear. The valve unit prevents cavitation in the swing circuit from occurring and protects the circuit from being overloaded. The swing motor is a swash plate type axial plunger motor with a built-in swing parking brake. The swing motor is driven by pressure oil delivered from the pump, and drives the swing reduction gear.



The swing reduction gear converts the swing motor output into slow large torque to rotate the shaft. Thereby, the upperstructure is rotated.



Valve Unit



Swing Motor



Swing Reduction Gear



 T178-03-02-001



T3-2-1



COMPONENT OPERATION / Swing Device SWING REDUCTION GEAR The swing reduction gear is a two stage reduction planetary gear type. The ring gear is formed on the internal surface of the housing so that they are integrated. As the housing is bolted on the upperstructure, the ring gear doesn’t rotate. The swing motor shaft rotates the first stage sun gear. Then, its torque is transmitted to the second stage sun gear via the first stage planetary gear and carrier. The second stage sun gear rotates the shaft via the second stage planetary gear and carrier.



The shaft meshes with the swing bearing internal gear secured to the undercarriage, causing the upperstructure to rotate.



Swing Motor Shaft First Stage Sun Gear First Stage Planetary Gear



First Stage Carrier



Ring Gear



Second Stage Sun Gear



Second Stage Planetary Gear



Second Stage Carrier



Shaft



 T178-03-02-006



T3-2-2



COMPONENT OPERATION / Swing Device SWING MOTOR The swing motor consists of the swash plate, rotor, plungers, valve plate, housing and swing parking brake (springs, brake piston, plates, friction plates, and swing parking brake switch valve). The rotor in which the plungers are inserted is splined onto the shaft.



When pressure oil is supplied from the pump, the pressure oil pushes the plungers. Since the swash plate is inclined, the shoes on top of the plungers slide along the swash plate, causing the rotor and shaft to rotate. The shaft tip end is splined into the first stage sun gear in the swing reduction gear so that shaft rotation is transmitted to the swing reduction gear.



Spring Valve Plate Brake Piston Plate



Rotor



Swing Parking Brake Switch Valve



Housing



Friction Plate



Shoe



Plunger Retainer



Swash Plate



Shaft



 T178-03-02-002



T3-2-3



COMPONENT OPERATION / Swing Device SWING PARKING BRAKE The swing parking brake is a wet-type multi-disc brake. The brake is released when brake release pressure enters into the brake piston chamber (negative brake type). Brake release pressure is supplied from the pilot pump only when a front attachment and/or swing operation is made. During operations other than swing and/or front attachment or while the engine is stopped, brake release pressure is returned to the hydraulic oil tank so that the brake is automatically applied by spring. Releasing Brake: 1. When the swing and/or front attachment control levers are operated, the swing parking brake release spool in the signal pilot pressure control valve is shifted. Thereby, the pilot pressure oil from the pilot pump is routed to port SH. 2. Pilot pressure at port SH pushes to open the check valve and flows into the brake piston chamber. 3. Then, the brake piston is raised, breaking contact between the plates and friction plates so that the brake is released.



Applying Brake: 1. When the swing and/or front attachment control levers are released, the swing parking brake release spool in the signal pilot pressure control valve is returned to neutral so that the pilot pressure routed to port SH is reduced. 2. Therefore, the check valve is closed, allowing brake release pressure to flow into the swing motor housing through the orifice. 3. Consequently, spring force is applied to plates and friction plates, which are meshed with the outer diameter of the rotor and inner diameter of the housing respectively via the brake piston. Then, the rotor outer diameter is held with friction force. While the engine is stopped, no pilot pressure is routed to port SH, allowing the brake to be automatically applied.



T3-2-4



COMPONENT OPERATION / Swing Device



Spring Brake Piston Orifice



Check Valve



Friction Plate



Port SH (Brake Release Pressure) Plate Brake Piston Chamber



 T178-03-02-003



T3-2-5



COMPONENT OPERATION / Swing Device VALVE UNIT The valve unit consists of the make-up valves and the relief valves. The make-up valves prevents cavitation in the circuit. The relief valves prevent surge pressure and overloads in the circuit.



Relief Valve



Make-Up Valve During swing stop operation, the swing motor is driven by inertia force of the upperstructure. The motor is rotated by inertia force more than by pressure oil delivered from the pump, causing cavitation to develop in the circuit. To prevent cavitation, when pressure in the swing circuit is reduced more than the return circuit (port M) pressure, the poppets are opened so that hydraulic oil is drawn into the circuit from the hydraulic oil tank to compensate for the lack of oil in the circuit.



Make-Up Valve



Port M



Control Valve



 T107-02-04-013



  



Control Valve



  Poppet







Make-Up Valve



Make-Up Valve



Port M



 Relief Valve







T3-2-6



T178-03-02-004







COMPONENT OPERATION / Swing Device Relief Valve During starting or stopping swing operation, oil pressure in the swing circuit becomes high. The relief valve prevents the circuit pressure from rising higher than the set-pressure. (30.4 MPa) Low Pressure Relief Operation (Shock Reducing Function): 1. Pressure at port HP (swing circuit) is routed into oil chamber C through the poppet orifice. 2. Pressure oil in oil chamber C is further routed into oil chambers A and B via passages A and B respectively. 3. The pressure receiving area in oil chamber B is larger than oil chamber A so that the piston moves to the left. 4. As long as the piston keeps moving, a pressure difference is developed between the front and the rear of the poppet. When this pressure difference is increased more than spring force, the poppet is unseated, allowing pressure oil to flow to port LP. 5. When the piston is moved full stroke, the pressure difference between the front and the rear of the poppet disappears, causing the poppet to be seated.



Poppet



Orifice



Spring



High Pressure Relief Operation (Overload Prevention): 1. After the piston is moved full stroke, the spring is compressed so that the circuit pressure is increased to the set-pressure. 2. If pressure in port HP increases more than the spring set-pressure, the poppet is unseated, causing pressure oil to flow to port LP from port HP. 3. When pressure in port HP is reduced to the specified level, the poppet is seated by spring force.



Passage A



Passage B



Piston



HP



LP



 Oil Chamber C Oil Chamber B Oil Chamber A



T3-2-7



T178-03-02-005



COMPONENT OPERATION / Swing Device (Blank)



T3-2-8



COMPONENT OPERATION / Control Valve OUTLINE The control valve controls pressure oil, flow rate, and oil flow direction in the hydraulic circuit. The major parts of the control valve are the main relief valve, overload relief valve, flow combiner valve, anti-drift valve, flow rate control valve, regenerative valve, auxiliary flow combiner valve, bypass shut-out valve, and spools. The spools are operated by pilot pressure oil.



The spool arrangements are as follows from the machine front side. 4-Spool Side: Travel, Bucket, Boom 1, Arm 2 5-Spool Side: Positioning, Auxiliary, Boom 2, Arm 1, Swing



Control Valve



Swing㩷 Arm 1 Boom 2 Auxiliary Positioning



Arm 2 Boom 1



5-Spool Side



Bucket Travel㩷



Front



 T176-03-03-035



4-Spool Side㩷



Auxiliary Control Valve Front



 T1F3-03-03-018



T3-3-1



COMPONENT OPERATION / Control Valve Component Layout



1



2



3



4



5



6



7



9



10



11



35 12 34 33 32 31 30



13



14 15 16



29 28



17



27



26



25



24 23 22



21



20 19 18



 T1F3-03-03-014



T3-3-2



COMPONENT OPERATION / Control Valve



16 26



4 29



18, 19 7



21 12 9, 10



Front㩷



 T176-03-03-038



㩷 㪈㩷㪄㩷 Load Check Valve (Positioning Tandem Circuit)㩷 㪉㩷㪄㩷 Load Check Valve (Positioning Parallel Circuit)㩷 㪊㩷㪄㩷 Check Valve (Main Relief Circuit)㩷 㪋㩷㪄㩷 Main Relief Valve (30.4 MPa)㩷 㪌㩷㪄㩷 Auxiliary Flow Combiner Valve㩷 㪍㩷㪄㩷 Check Valve (Auxiliary Flow Combining Circuit)㩷 㪎㩷㪄㩷 Check Valve (Main Relief Circuit)㩷 㪐㩷㪄㩷 Bucket Flow Rate Control Valve (Selector Valve)㩷 㪈㪇㩷㪄㩷 Bucket Flow Rate Control Valve (Poppet Valve)㩷



11 - Bucket Regenerative Circuit



㪉㪇㩷㪄㩷 Load Check Valve (Arm 2 Tandem Circuit)㩷



㪉㪐㩷㪄㩷 Overload Relief Valve (Arm Rod Side)㩷



㪈㪉㩷㪄㩷 Overload Relief Valve (Bucket Rod Side)㩷



㪉㪈㩷㪄㩷 Bypass Shut-Out Valve㩷



㪊㪇㩷㪄㩷 Arm Anti-Drift Valve (Check Valve)㩷



㪈㪊㩷㪄㩷 Overload Relief Valve (Bucket Bottom Side)㩷 㪈㪋㩷㪄㩷 Load Check Valve (Boom 1 Parallel Circuit)㩷 15 - Boom Regenerative Circuit



22 - Check Valve (Orifice) (Arm 2 Parallel Circuit) 㪉㪊㩷㪄㩷 Load Check Valve (Arm 1 Parallel Circuit)㩷 㪉㪋㩷㪄㩷 Load Check Valve (Arm 1 Tandem Circuit)㩷 㪉㪌㩷㪄㩷 Load Check Valve (Swing Circuit)㩷



㪊㪈㩷㪄㩷 Arm Anti-Drift Valve (Selector Valve)㩷 㪊㪉㩷㪄㩷 Load Check Valve (Boom 2 Parallel Circuit)㩷 㪊㪊㩷㪄㩷 Aux. Flow Rate Control Valve (Poppet Valve)㩷 㪊㪋㩷㪄㩷 Aux. Flow Rate Control Valve (Selector Valve)㩷



㪈㪎㩷㪄㩷 Overload Relief Valve (Boom Rod Side)㩷 㪈㪏㩷㪄㩷 Boom Anti-Drift Valve (Check Valve)㩷



㪉㪍㩷㪄㩷 Arm Regenerative Valve (Selector Valve)㩷 27 - Arm Regenerative Circuit



㪊㪌㩷㪄㩷 Load Check Valve (Bucket Parallel Circuit)㩷 㩷



㪈㪐㩷㪄㩷 Boom Anti-Drift Valve (Selector Valve)㩷



㪉㪏㩷㪄㩷 Overload Relief Valve (Arm Bottom Side)㩷



㩷



㪈㪍㩷㪄㩷 Overload Relief Valve (Boom Bottom Side)㩷



T3-3-3



COMPONENT OPERATION / Control Valve



1



2



3



4



5



6



7



9



10



11



35 12 34 33 32 31 30



13



14 15 16



29 28



17



27



26



25



24 23 22



21



20 19 18



 T1F3-03-03-014



T3-3-4



COMPONENT OPERATION / Control Valve



30, 31



33, 34



28



Front㩷



17



5 6



 T176-03-03-036



13



35



㩷 1-



2-



345-



Load Check Valve (Positioning Tandem Circuit)㩷 Load Check Valve (Positioning Parallel Circuit)㩷 Check Valve (Main Relief Circuit)㩷 Main Relief Valve㩷



Auxiliary Flow Combiner Valve㩷 6- Check Valve (Auxiliary Flow Combining Circuit)㩷 7- Check Valve (Main Relief Circuit)㩷 9 - Bucket Flow Rate Control Valve (Selector Valve)㩷 10 - Bucket Flow Rate Control Valve (Poppet Valve)㩷



11- Bucket Regenerative Circuit



20- Load Check Valve (Arm 2 Tandem Circuit)㩷



29- Overload Relief Valve (Arm Rod Side)㩷



12- Overload Relief Valve (Bucket Rod Side)㩷



21- Bypass Shut-Out Valve㩷



30- Arm Anti-Drift Valve (Check Valve)㩷



13- Overload Relief Valve (Bucket Bottom Side)㩷 14- Load Check Valve (Boom 1 Parallel Circuit)㩷 15- Boom Regenerative Circuit



22- Check Valve (Orifice) (Arm 2 Parallel Circuit) 23- Load Check Valve (Arm 1 Parallel Circuit)㩷 24- Load Check Valve (Arm 1 Tandem Circuit)㩷 25- Load Check Valve (Swing Circuit)㩷



31- Arm Anti-Drift Valve (Selector Valve)㩷 32- Load Check Valve (Boom 2 Parallel Circuit)㩷 33- Aux. Flow Rate Control Valve (Poppet Valve)㩷 34- Aux. Flow Rate Control Valve (Selector Valve)㩷



17- Overload Relief Valve (Boom Rod Side)㩷 18- Boom Anti-Drift Valve (Check Valve)㩷



26- Arm Regenerative Valve (Selector Valve)㩷 27- Arm Regenerative Circuit



35- Load Check Valve (Bucket Parallel Circuit)㩷 㩷



19- Boom Anti-Drift Valve (Selector Valve)㩷



28- Overload Relief Valve (Arm Bottom Side)㩷



㩷



16- Overload Relief Valve (Boom Bottom Side)㩷



T3-3-5



COMPONENT OPERATION / Control Valve



1



2



3



4



5



6



7



9



10



11



35 12 34 33 32 31 30



13



14 15 16



29 28



17



27



26



25



24 23 22



21



20 19 18



 T1F3-03-03-014



T3-3-6



COMPONENT OPERATION / Control Valve Cross Section A



F E



D



4



C B



7 A



3 35



6



5







a







T1F3-03-03-013



NOTE: Valve (a) is not used.



T176-03-03-035



㩷



1-



2-



345-



Load Check Valve (Positioning Tandem Circuit)㩷 Load Check Valve (Positioning Parallel Circuit)㩷 Check Valve (Main Relief Circuit)㩷 Main Relief Valve㩷



Auxiliary Flow Combiner Valve㩷 6- Check Valve (Auxiliary Flow Combining Circuit)㩷 7- Check Valve (Main Relief Circuit)㩷 9- Bucket Flow Rate Control Valve (Selector Valve)㩷 10- Bucket Flow Rate Control Valve (Poppet Valve)㩷



11- Bucket Regenerative Circuit



20- Load Check Valve (Arm 2 Tandem Circuit)㩷



29- Overload Relief Valve (Arm Rod Side)㩷



12- Overload Relief Valve (Bucket Rod Side)㩷



21- Bypass Shut-Out Valve㩷



30- Arm Anti-Drift Valve (Check Valve)㩷



13- Overload Relief Valve (Bucket Bottom Side)㩷 14- Load Check Valve (Boom 1 Parallel Circuit)㩷 15- Boom Regenerative Circuit



22- Check Valve (Orifice) (Arm 2 Parallel Circuit) 23- Load Check Valve (Arm 1 Parallel Circuit)㩷 24- Load Check Valve (Arm 1 Tandem Circuit)㩷 25- Load Check Valve (Swing Circuit)㩷



31- Arm Anti-Drift Valve (Selector Valve)㩷 32- Load Check Valve (Boom 2 Parallel Circuit)㩷 33- Aux. Flow Rate Control Valve (Poppet Valve)㩷 34- Aux. Flow Rate Control Valve (Selector Valve)㩷



17- Overload Relief Valve (Boom Rod Side)㩷 18- Boom Anti-Drift Valve (Check Valve)㩷



26- Arm Regenerative Valve (Selector Valve)㩷 27- Arm Regenerative Circuit



35- Load Check Valve (Bucket Parallel Circuit)㩷 㩷



19- Boom Anti-Drift Valve (Selector Valve)㩷



28- Overload Relief Valve (Arm Bottom Side)㩷



㩷



16- Overload Relief Valve (Boom Bottom Side)㩷



T3-3-7



COMPONENT OPERATION / Control Valve



1



2



3



4



5



6



7



9



10



11



35 12 34 33 32 31 30



13



14 15 16



29 28



17



27



26



25



24 23 22



21



20 19 18



 T1F3-03-03-014



T3-3-8



COMPONENT OPERATION / Control Valve Cross Section B



Cross Section C Travel㩷







Positioning







Bucket㩷



Auxiliary㩷



12



1



2







10



33



9 11 13



34



T1F3-03-03-012



 T176-03-03-004㩷



㩷 1-



2-



345-



Load Check Valve (Positioning Tandem Circuit)㩷 Load Check Valve (Positioning Parallel Circuit)㩷 Check Valve (Main Relief Circuit)㩷 Main Relief Valve㩷



Auxiliary Flow Combiner Valve㩷 6- Check Valve (Auxiliary Flow Combining Circuit)㩷 7- Check Valve (Main Relief Circuit)㩷 9- Bucket Flow Rate Control Valve (Selector Valve)㩷 10- Bucket Flow Rate Control Valve (Poppet Valve)㩷



11- Bucket Regenerative Circuit



20- Load Check Valve (Arm 2 Tandem Circuit)㩷



29- Overload Relief Valve (Arm Rod Side)㩷



12- Overload Relief Valve (Bucket Rod Side)㩷



21- Bypass Shut-Out Valve㩷



30- Arm Anti-Drift Valve (Check Valve)㩷



13- Overload Relief Valve (Bucket Bottom Side)㩷 14- Load Check Valve (Boom 1 Parallel Circuit)㩷 15- Boom Regenerative Circuit



22- Check Valve (Orifice) (Arm 2 Parallel Circuit) 23- Load Check Valve (Arm 1 Parallel Circuit)㩷 24- Load Check Valve (Arm 1 Tandem Circuit)㩷 25- Load Check Valve (Swing Circuit)㩷



31- Arm Anti-Drift Valve (Selector Valve)㩷 32- Load Check Valve (Boom 2 Parallel Circuit)㩷 33- Aux. Flow Rate Control Valve (Poppet Valve)㩷 34- Aux. Flow Rate Control Valve (Selector Valve)㩷



17- Overload Relief Valve (Boom Rod Side)㩷 18- Boom Anti-Drift Valve (Check Valve)㩷



26- Arm Regenerative Valve (Selector Valve)㩷 27- Arm Regenerative Circuit



35- Load Check Valve (Bucket Parallel Circuit)㩷 㩷



19- Boom Anti-Drift Valve (Selector Valve)㩷



28- Overload Relief Valve (Arm Bottom Side)㩷



㩷



16- Overload Relief Valve (Boom Bottom Side)㩷



T3-3-9



COMPONENT OPERATION / Control Valve



1



2



3



4



5



6



7



9



10



11



35 12 34 33 32 31 30



13



14 15 16



29 28



17



27



26



25



24 23 22



21



20 19 18



 T1F3-03-03-014



T3-3-10



COMPONENT OPERATION / Control Valve Cross Section D Boom 1



Cross Section E Boom 2







Arm 2



Arm 1



19



31 16



29 30



18



14



32



23



20



22



24 27



15



28







17



T176-03-03-006







 T176-03-03-005



㩷







㩷 1-



2-



345-



Load Check Valve (Positioning Tandem Circuit)㩷 Load Check Valve (Positioning Parallel Circuit)㩷 Check Valve (Main Relief Circuit)㩷 Main Relief Valve㩷



Auxiliary Flow Combiner Valve㩷 6- Check Valve (Auxiliary Flow Combining Circuit)㩷 7- Check Valve (Main Relief Circuit)㩷 9- Bucket Flow Rate Control Valve (Selector Valve)㩷 10- Bucket Flow Rate Control Valve (Poppet Valve)㩷



11- Bucket Regenerative Circuit



20- Load Check Valve (Arm 2 Tandem Circuit)㩷



29- Overload Relief Valve (Arm Rod Side)㩷



12- Overload Relief Valve (Bucket Rod Side)㩷



21- Bypass Shut-Out Valve㩷



30- Arm Anti-Drift Valve (Check Valve)㩷



13- Overload Relief Valve (Bucket Bottom Side)㩷 14- Load Check Valve (Boom 1 Parallel Circuit)㩷 15- Boom Regenerative Circuit



22- Check Valve (Orifice) (Arm 2 Parallel Circuit) 23- Load Check Valve (Arm 1 Parallel Circuit)㩷 24- Load Check Valve (Arm 1 Tandem Circuit)㩷 25- Load Check Valve (Swing Circuit)㩷



31- Arm Anti-Drift Valve (Selector Valve)㩷 32- Load Check Valve (Boom 2 Parallel Circuit)㩷 33- Aux. Flow Rate Control Valve (Poppet Valve)㩷 34- Aux. Flow Rate Control Valve (Selector Valve)㩷



17- Overload Relief Valve (Boom Rod Side)㩷 18- Boom Anti-Drift Valve (Check Valve)㩷



26- Arm Regenerative Valve (Selector Valve)㩷 27- Arm Regenerative Circuit



35- Load Check Valve (Bucket Parallel Circuit)㩷 㩷



19- Boom Anti-Drift Valve (Selector Valve)㩷



28- Overload Relief Valve (Arm Bottom Side)㩷



㩷



16- Overload Relief Valve (Boom Bottom Side)㩷



T3-3-11



COMPONENT OPERATION / Control Valve



1



2



3



4



5



6



7



9



10



11



35 12 34 33 32 31 30



13



14 15 16



29 28



17



27



26



25



24 23 22



21



20 19 18



 T1F3-03-03-014



T3-3-12



COMPONENT OPERATION / Control Valve Cross Section F 



Swing



26



25



21



 T176-03-03-007



㩷 1-



2-



345-



Load Check Valve (Positioning Tandem Circuit)㩷 Load Check Valve (Positioning Parallel Circuit)㩷 Check Valve (Main Relief Circuit)㩷 Main Relief Valve㩷



Auxiliary Flow Combiner Valve㩷 6- Check Valve (Auxiliary Flow Combining Circuit)㩷 7- Check Valve (Main Relief Circuit)㩷 9- Bucket Flow Rate Control Valve (Selector Valve)㩷 10- Bucket Flow Rate Control Valve (Poppet Valve)㩷



11- Bucket Regenerative Circuit



20- Load Check Valve (Arm 2 Tandem Circuit)㩷



29- Overload Relief Valve (Arm Rod Side)㩷



12- Overload Relief Valve (Bucket Rod Side)㩷



21- Bypass Shut-Out Valve㩷



30- Arm Anti-Drift Valve (Check Valve)㩷



13- Overload Relief Valve (Bucket Bottom Side)㩷 14- Load Check Valve (Boom 1 Parallel Circuit)㩷 15- Boom Regenerative Circuit



22- Check Valve (Orifice) (Arm 2 Parallel Circuit) 23- Load Check Valve (Arm 1 Parallel Circuit)㩷 24- Load Check Valve (Arm 1 Tandem Circuit)㩷 25- Load Check Valve (Swing Circuit)㩷



31- Arm Anti-Drift Valve (Selector Valve)㩷 32- Load Check Valve (Boom 2 Parallel Circuit)㩷 33- Aux. Flow Rate Control Valve (Poppet Valve)㩷 34- Aux. Flow Rate Control Valve (Selector Valve)㩷



17- Overload Relief Valve (Boom Rod Side)㩷 18- Boom Anti-Drift Valve (Check Valve)㩷



26- Arm Regenerative Valve (Selector Valve)㩷 27- Arm Regenerative Circuit



35- Load Check Valve (Bucket Parallel Circuit)㩷 㩷



19- Boom Anti-Drift Valve (Selector Valve)㩷



28- Overload Relief Valve (Arm Bottom Side)㩷



㩷



16- Overload Relief Valve (Boom Bottom Side)㩷



T3-3-13



COMPONENT OPERATION / Control Valve



1



Auxiliary Control Valve



2 3



 T1F3-03-03-014



T3-3-14



COMPONENT OPERATION / Control Valve Cross Section X-X X



2



1



3



 T1GL-03-03-004



X



 T1GL-03-03-003



1 - Load Check Valve (Blade/Stabilizer Tandem Circuit)



2-



Overload Relief Valve (Blade/Stabilizer Rod Side)



T3-3-15



3-



Overload Relief Valve (Blade/Stabilizer Bottom Side)



COMPONENT OPERATION / Control Valve HYDRAULIC CIRCUIT Main Circuit The pressure oil from main pump 1 flows to the 4-spool side control valve and the pressure oil from main pump 2 flows to the 5-spool side control valve. Both right and left main circuits are provided with the parallel circuits, making combined operations possible. The boom and arm circuits are provided with the flow combining circuits so that the pressure oil from main pump 1 and 2 can be supplied together to each cylinder when a single operation is made. The main relief valve is located in the main circuit (between the pumps and actuators), preventing the oil pressure in the main circuit from increasing over the set-pressure during operation (when any control lever is operated). The overload relief valves are located in the boom, arm, and bucket circuits (between the control valve and actuators). The overload relief valve prevents the surge pressure, which is developed in the actuator circuit due to external loads, from increasing more than the set-pressure.



T3-3-16



COMPONENT OPERATION / Control Valve Positioning



Travel Motor㩷 Main Relief Valve (30.4 MPa)㩷



4-Spool Side Parallel Circuit㩷 4-Spool Side㩷



5-Spool Side㩷



Attachment㩷



Bucket Cylinder



Arm Cylinder㩷 Overload Relief Valve



Overload Relief Valve



Swing Motor Boom Cylinder



Flow Combining Circuit㩷 Auxiliary Control Valve



5-Spool Side Parallel Circuit Pump2



Pump1



 T1F3-03-03-015



T3-3-17



COMPONENT OPERATION / Control Valve Blade/Stabilizer Circuit



• When the blade/stabilizer is operated, the pilot pressure oil from the blade/stabilizer pilot valve shifts the bypass shut-out valve. • Accordingly, the neutral circuit in the 4-spool side control valve is blocked so that the pressure oil from main pump 1 is routed to the auxiliary control valve. NOTE: One check valve, which is operated by the signal pressure from the 2-spool solenoid valve (blade/stabilizer), is installed on each cylinder port. When the check valve is closed, the cylinder is inoperable even though the blade/stabilizer pilot valve is operated. Operable cylinder is determined depending on whether the corresponding check valve is opened or closed when the blade/stabilizer pilot valve is operated. (Refer to the Control System group.)



T3-3-18



COMPONENT OPERATION / Control Valve From the blade/stabilizer pilot valve



Auxiliary Control Valve



Bypass Shut-Out Valve



Check Valve Pump 1



Check Valve



 Blade/Stabilizer Cylinder



T3-3-19



T1F3-03-03-020



COMPONENT OPERATION / Control Valve Pilot Operation Circuit The pilot pressure oil (shown by figure letters) from the pilot valve is routed to the spool end faces in the control valve, moving the spools. Besides moving the spools, the pilot pressure oil operates the control valve at the same time in the following operations: • When arm roll-in operation (4) is made, the pilot pressure oil moves the spools and shifts the arm anti-drift valve selector valve and the hose-rupture safety valve (arm) spool. • When boom lower operation (2) is made, the pilot pressure oil moves the spools and shifts the boom anti-drift valve selector valve and the hose-rupture safety valve (boom) spool. • When positioning lower operation (10) is made, the pilot pressure oil moves the spools and shifts the hose-rupture safety valve (positioning) spool. As the air bleed circuit is provided in the upper section of the control valve so that any air trapped in the control valve will automatically be bled.



External Pilot Pressure Oil Control Circuit • The arm regenerative valve is shifted by the pilot pressure oil delivered from solenoid valve unit (SC). • The bucket flow rate control valve is shifted by the pilot pressure oil from the bucket flow rate control valve control spool in the signal control valve. • The bypass shut-out valve is shifted by the pilot pressure oil delivered from blade/stabilizer pilot valve. • The aux. flow combiner valve and bypass shut-out valve are shifted by the pilot pressure oil from positioning/auxiliary pilot valve. (Only the machines equipped with the optional auxiliary flow combining system.) • The aux. flow rate control valve is shifted by the pilot pressure oil from the aux. flow rate control solenoid valve. (Only the machines equipped with the optional auxiliary flow combining system.) NOTE: Normally, the auxiliary flow combiner valve and the auxiliary flow control valve are routed to the circuit. The auxiliary flow control solenoid valve is provided only on the machines equipped with the optional auxiliary flow combining system.



T3-3-20



COMPONENT OPERATION / Control Valve Pilot Pressure Oil from Positioning/auxiliary Pilot Valve (only on the machines equipped with Pilot Pressure Oil from the optional auxiliary flow combining system) Bucket Flow Rate Control Valve Shift Spool in Signal Control Valve 60 Auxiliary Flow Combiner Valve㩷



Auxiliary Flow Rate Control Valve㩷



10



Pilot Pressure Oil Hose-Rupture Safety Valve (Positioning)



9



Pilot Pressure Oil from Auxiliary flow Rate Control solenoid Valve (only on the machines equipped with the optional auxiliary flow combining system)



Arm Regenerative Valve㩷



11



12



Bucket Flow Rate Control Valve㩷



14 13



8



7



2 1



1



Pilot Pressure oil to Hose-Rupture Safety Valve (Arm) Pilot Pressure Oil from Solenoid Valve Unit (SC)



61



Boom Anti-Drift Valve 4 3



3



Pilot Pressure Oil to Hose-Rupture Safety Valve (Boom)



Pilot Pressure Oil form Blade/Stabilizer (Positioning/Auxiliary) 5



6



Bypass Shut-Out Valve㩷



Arm Anti-Drift Valve



 T1F3-03-03-016



1234-



Boom Raise Boom Lower Arm Roll-Out Arm Roll-In



5678-



Left Swing Right Swing Bucket Roll-In Bucket Roll-Out



9- Positioning Raise 10- Positioning Lower 11- Travel Reverse 㩷



T3-3-21



12 - Travel Forward 60 - Blade/Stabilizer Raise㩷 61 - Blade/Stabilizer Lower㩷 㩷



COMPONENT OPERATION / Control Valve MAIN RELIEF VALVE The main relief valve prevents pressure in the main circuit from increasing more than the set-pressure during operations of actuators such as the motors and the cylinders. Thereby, oil leakage from hoses and pipe joints and damage to the actuators are prevented. Operation 1. The oil pressure in port HP (main circuit) acts on the pilot poppet through orifice A in the main poppet and orifice B in the seat. 2. When the oil pressure in port HP increases more than the spring B set-force, the pilot poppet is unseated, allowing the pressure oil to flow to port LP (hydraulic oil tank) through passage A and around the outer diameter of sleeve. 3. At this time, a pressure difference arises between port HP and the spring chamber due to orifice A. 4. When this pressure difference increases more than the spring A set-force, the main poppet is unseated, causing the pressure oil in port HP to flow to port LP. 5. Thereby, the main circuit pressure decreases. 6. When the main circuit pressure decreases more than the specified pressure, the main poppet is seated by spring A.



T3-3-22



COMPONENT OPERATION / Control Valve When Normal: Main Poppet㩷



Orifice A



Orifice B



Seat㩷



Passage A



Spring B



HP







LP Sleeve㩷



T176-03-03-010



Spring Chamber㩷



Spring A



Pilot Poppet㩷



When Relieving: Main Poppet㩷



Orifice A



Orifice B



Seat㩷 Passage A



Spring B



HP







LP Sleeve㩷



T176-03-03-011



Spring Chamber



Spring A



T3-3-23



Pilot Poppet㩷



COMPONENT OPERATION / Control Valve OVERLOAD RELIEF VALVE (with Make-Up Function) The overload relief valves are provided in the boom, arm, bucket and auxiliary control valve circuits. The overload relief valve prevents each actuator circuit pressure from rising excessively when the actuators are moved by external loads. In addition, when the actuator circuit pressure is reduced, draws the hydraulic oil from the hydraulic oil tank to prevent the occurrence of cavitation (make-up function).



Make-Up Operation 1. When pressure at port HP (actuator circuit) is reduced more than port LP (hydraulic oil tank), the sleeve is moved to the right. 2. Then, the hydraulic oil flows in port HP from port LP to prevent the cavitation. 3. When pressure in port HP increases more than the specified pressure, the sleeve is closed by spring C .



NOTE: The operations of overload relief valves in boom, arm, bucket, and auxiliary control valve are same. Accordingly, operation of the overload relief valve for the boom, the arm, and the bucket is explained on this page. Relief Operation 1. The oil pressure in port HP (main circuit) acts on the pilot poppet through orifice A in the main poppet and orifice B in the seat. 2. When the oil pressure in port HP increases more than the spring B set-force, the pilot poppet is unseated, allowing the pressure oil to flow to port LP (hydraulic oil tank) through passage A and around the outer diameter of sleeve. 3. At this time, a pressure difference arises between port HP and the spring chamber due to orifice A. 4. When this pressure difference increases more than the spring A set-force, the main poppet is unseated, causing the pressure oil in port HP to flow to port LP. 5. Thereby, the actuator circuit pressure is reduced. 6. When the actuator circuit pressure is reduced to the specified pressure, the main poppet is closed by spring A.



T3-3-24



COMPONENT OPERATION / Control Valve When Normal: Sleeve㩷



Make-Up Valve㩷



Main Poppet㩷



Orifice Orifice A B



Passage Seat㩷 A



Spring B



HP



LP Spring C



When Relieving: Sleeve㩷



 Spring Chamber㩷



Main Poppet㩷 Orifice A



T176-03-03-012



Spring A Orifice B



Pilot Poppet㩷 Seat㩷 Passage A Spring B



HP







LP



T176-03-03-013



Spring Chamber㩷



When Operating Make-Up:



Spring A



Pilot Poppet㩷



Make-Up Valve㩷



HP







LP



T1F3-03-03-021



Spring C



T3-3-25



COMPONENT OPERATION / Control Valve ANTI-DRIFT VALVE The anti-drift valves are located in the boom cylinder bottom and arm cylinder rod side circuits to reduce the cylinder drift. NOTE: The boom and arm anti-drift valves are identical in construction. Boom Cylinder



Blocking Operation 1. When the control lever (the spool) is in neutral, the anti-drift valve (selector valve) is not shifted. 2. Therefore, the pressure oil in the boom cylinder bottom (arm cylinder rod side) is applied to the anti-drift valve check valve via the control valve. 3. Consequently, the check valve is seated, blocking the return oil circuit from the cylinder so that the cylinder drift is reduced. Releasing Operation 1. When rolling the arm in or lowering the boom, the pressure oil from the pilot valve shifts the anti-drift valve (selector valve). 2. The hydraulic oil in the check valve spring chamber is returned to the hydraulic oil tank via the orifice in the Selector valve. 3. Accordingly, the check valve is unseated, allowing the return oil from the boom cylinder bottom side (arm cylinder rod side) to flow to the spool.



 T176-03-03-028



Anti-Drift Valve (Selector Valve) Pressure Oil from Pump 1㩷



Anti-Drift Valve (Check Valve) To Hydraulic Oil Tank㩷 Boom Cylinder



From Pilot Valve㩷



To Hydraulic Oil Tank



 T176-03-03-029



Anti-Drift Valve (Selector Valve)



T3-3-26



Anti-Drift Valve (Check Valve)



COMPONENT OPERATION / Control Valve When Blocking: Drain



Boom Cylinder To Pilot Valve㩷 Selector valve㩷 Sleeve㩷



Spring B Seat㩷 Spring A Check Valve㩷



To Spool



 T176-03-03-017



When Releasing: Drain



Boom Cylinder From Pilot Valve㩷 Selector Valve㩷 Sleeve㩷



Spring B



Pressure Oil from Pump㩷



Seat㩷 Spring A Check Valve㩷



To spool



 T176-03-03-018



T3-3-27



COMPONENT OPERATION / Control Valve REGENERATIVE VALVE 3. Then, the return oil from the cylinder bottom side flows into the rod side so that the return pressure oil is regenerated, increasing the cylinder operating speed. 4. When the cylinder is fully stroked or digging loads increase, the oil pressure in the cylinder bottom circuit increases, causing the check valve to seat so that regeneration is stopped.



The regenerative valves are located in the boom lower and arm roll-in, accelerating the cylinder operating speeds, preventing the cylinders from making a pose in movement, and improving machine controllability. NOTE: Operational principles of each regenerative valve are almost identical. Therefore, the boom regenerative valve is used as an example.



NOTE: Arm Regenerative Valve (Selector Valve) Operation The arm regenerative valve (selector Valve) is shifted by the pilot pressure oil from solenoid valve unit (SC) so that the return oil circuit from the cylinder rod side to the hydraulic oil tank is blocked. (Refer to the SYSTEM / Control system group.)



Operation 1. When the boom is lowered, the return oil from the cylinder bottom side (the rod side in case of the arm cylinder) is routed the check valve via anti-drift valve and hole A on the spool. (Refer to T3-3-22 as for the operation of the anti-drift valve.) 2. At this moment, when the pressure oil in the cylinder rod side (the bottom side in case of the arm cylinder) is lower than the bottom side, the check valve is unseated.



Pressure Oil from Pump 1㩷



Regenerative Boom 1 Valve㩷 Spool



Boom Cylinder㩷



Hole A㩷



Anti-Drift Valve (Selector Valve)



Check Valve㩷



Anti-Drift Valve (Check Valve)



 㩷



From boom 2 spool (Pressure Oil from Pump 2 )



㩷



T1F3-03-03-022



T3-3-28



COMPONENT OPERATION / Control Valve When Operating:



Boom 1 Spool㩷



Boom 2 Spool㩷



Boom Cylinder㩷



Anti-Drift Valve (Check Valve)



Hole A



Check Valve㩷



 T1F1-03-03-016



T3-3-29



COMPONENT OPERATION / Control Valve FLOW RATE CONTROL VALVE The flow rate control valve is located in the bucket and auxiliary circuits. When a combined operation is made, the flow rate control valve restricts the oil flow so that the other actuators are given priority to operate.



When bucket (auxiliary) single operation is made: 1. The pressure oil from pump 1 acts on the check valve in the poppet via port P1. 2. Normally, the selector valve is kept open so that the pressure oil from pump 1 unseats the check valve and flows into the main spool through the selector valve. 3. Thereby, the poppet valve is opened, allowing the pressure oil to flow to the bucket spool.



NOTE: The bucket flow rate control valve restricts the bucket circuit oil flow when the bucket, boom raise and arm roll-in operations are made simultaneously. The auxiliary flow rate control valve restricts the auxiliary circuit oil flow when a combined operation with the auxiliary and other front attachment is made. The bucket flow rate control valve is used here as an example.



Poppet Valve



When the combined operation of the bucket (auxiliary), boom raise, and arm roll-in is made: 1. When the boom raise and arm roll-in functions are operated simultaneously, the selector valve is shifted so that the bucket flow rate control valve in the signal control valve is shifted by the boom raise pilot pressure. 2. Then, the oil pressure behind the poppet valve increases, and the force to close the poppet valve appears. 3. Consequently, the opening clearance of the poppet valve is reduced so that oil flow to the bucket spool is restricted, allowing the pressure oil to be routed to the high-pressure side of the boom raise circuit.



Pressure Oil from Pump 1



Selector Valve



To Hydraulic Oil Tank



Bucket Cylinder



 T176-03-03-030



Boom Raise Pilot Pressure



Pressure Oil from Pump 1



To Hydraulic Oil Tank



Poppet Valve



Selector Valve



Bucket Cylinder



 T176-03-03-031



T3-3-30



COMPONENT OPERATION / Control Valve When Normal Operation: Poppet



Check Valve㩷



Spring A Spring B



To Main Spool㩷 To Hydraulic Oil Tank㩷 Pressure Oil from Main Pump 1㩷



P1㩷



Selector Valve㩷



Boom Raise Pilot Pressure



To Main Spool㩷



 T176-03-03-019



Plug 2



When Oil Flow is Restricted: Poppet



Check Valve㩷



Spring A Spring B



To Main Spool㩷



To Hydraulic Oil Tank㩷 Pressure Oil from Main Pump 1㩷



Selector Valve㩷 P1㩷



Boom Raise Pilot Pressure



To Main Spool㩷



 Plug 2



T3-3-31



T176-03-03-020



COMPONENT OPERATION / Control Valve BYPASS SHUT-OUT VALVE



Bypass Shut-Out Valve



The bypass shut-out valve is located after the 4-spool side circuit. When the blade/stabilizer is operated, the bypass shut-out valve is shifted, blocking the neutral passage in the 4-spool side circuit.



When Neutral: Spring㩷



Spool㩷



4-Spool Side Neutral Circuit㩷



Operation 1. When the control levers are in neutral, the bypass shut-out valve is not shifted. The pressure oil from pump 1 returns back to the hydraulic oil tank through the neutral passage in the 4-spool side circuit. 2. When the blade/stabilizer is operated, the pilot pressure from the pilot valve is routed to port SJ so that the bypass shut-out valve is shifted. 3. Consequently, the neutral passage in the 4-spool side circuit is blocked, allowing the pressure oil from pump 1 to flow to the auxiliary control valve.



Return to Hydraulic Oil Tank



Port SJ



 T176-03-03-022



When Operating: Spring



Spool㩷



4-Spool Side Neutral Circuit



Return to Hydraulic Oil Tank



Port SJ



T3-3-32



 T176-03-03-024



COMPONENT OPERATION / Control Valve From Blade/Stabilizer Pilot Valve



 



Neutral Circuit㩷



SJ



Bypass Shut-Out Valve㩷 Auxiliary Control Valve Pump1



Blade/Stabilizer Cylinder



 T1F3-03-03-020







T3-3-33



COMPONENT OPERATION / Control Valve AUXILIARY FLOW COMBINER VALVE



Auxiliary Flow Combiner Valve



The auxiliary flow combiner valve is located before the 4-spool side circuit. The auxiliary flow combiner valve operates differently depending on whether a single or combined operation is made. NOTE: The auxiliary flow combiner valve operates only on the machines equipped with the optional auxiliary flow combining system. Normally, port SN and port SM are connected to the hydraulic oil tank.



When Neutral: Port SN



To Auxiliary Spool



Check Valve㩷 Pressure Oil from Pump 1



Signal Operation When a single aux. pilot valve operation is made, the aux. flow combining valve allows the pressure oil from pump 1 to flow to the aux. spool together with the pressure oil from pump 2, increasing the attachment operating speed. 1. When an aux. pilot valve is operated, the pilot pressure oil is routed to port SM and port SJ so that both the aux. flow combining valve and bypass shut-out valve are shifted. 2. When the bypass shut-out valve is shifted, the neutral circuit in the 4-spool side is blocked. 3. At this moment, the aux. flow combiner valve is also shifted, allowing the pressure oil from the 4-spool side (pump 1) to flow to the aux. spool via the aux. flow combiner valve. 4. Therefore, pressure oil from both pumps 1 and 2 is supplied to the attachment, increasing attachment operation speed.



Spring B



Spool㩷



Spring A Port SM



 T176-03-03-021㩷



When Operating: Port SN Spring B To Auxiliary Spool



Check Valve㩷



Pressure Oil from Pump 1



Spool㩷



Spring A Port SM



 T176-03-03-023㩷







T3-3-34



COMPONENT OPERATION / Control Valve



Reducing Valve㩷



Signal Control Valve㩷



Auxiliary Flow Combiner Valve SN



Pilot Pressure Oil from Positioning/Auxiliary Pilot Valve Auxiliary Flow Combining Solenoid Valve㩷



SM



Neutral Circuit㩷



Auxiliary Spool



4-Spool Side㩷 5-Spool Side㩷



SJ Pump2



Pump1



Bypass Shut-Out Valve㩷



 T1F3-03-03-019



NOTE: The reducing valve and the auxiliary flow combining solenoid valve are installed only on the machines equipped with the optional auxiliary flow combining system.



T3-3-35



COMPONENT OPERATION / Control Valve Combined Operation When the auxiliary pilot valve and the boom, arm, bucket, or travel functions are operated simultaneously, the auxiliary flow combiner valve is not shifted. Thereby, the specified operating speed of the boom, arm, bucket, or travel function is ensured. However, the combined oil flow is supplied to the auxiliary circuit when the pilot pressure to port SN is reduced by the reducing valve.



Auxiliary Flow Combiner Valve Port SN Spring B To Auxiliary Spool Check Valve㩷 Pressure Oil from Pump 1



1. When the auxiliary pilot valve is operated, the pilot pressure oil is routed to port SM on the auxiliary flow combiner valve. 2. When the boom, arm, bucket, or travel is operated at the same time, the pilot pressure oil from the signal control valve is routed to port SN. 3. The pressure oil from port SM acts on the auxiliary flow combiner valve spool toward opening direction. The pressure oil from port SN and spring A act toward the closing direction. 4. Since the force to close the spool is larger than that to open the spool, the spool is kept closed. 5. When the pilot pressure to port SN is reduced by the reducing valve, the pilot pressure in port SM overcomes the pilot pressure in port SN and spring (A) force. Then, the auxiliary flow combiner valve is opened. Therefore, the pressure oil from pump 1 and pump 2 are combined and supplied together to the auxiliary spool.



T3-3-36



Spool㩷



Spring A Port SM



 T176-03-03-037



COMPONENT OPERATION / Control Valve Pilot Pressure Oil from Signal Control Valve Reducing Valve㩷 Auxiliary Flow Combiner Valve㩷 SN



Pilot Pressure Oil from Positioning/Auxiliary Pilot Valve Auxiliary Flow Combining Solenoid Valve



SM



Neutral Circuit㩷



Auxiliary Spool



4-Spool Side㩷 5-Spool Side㩷



SJ Pump2



Pump1



Bypass Shut-Out Valve㩷



 T1F3-03-03-017



NOTE: The reducing valve and the auxiliary flow combining solenoid valve are installed only on the machines equipped with the optional auxiliary flow combining system.



T3-3-37



COMPONENT OPERATION / Control Valve (Blank)



T3-3-38



COMPONENT OPERATION / Pilot Valve OUTLINE







The pilot valve controls the pilot pressure to move the control valve spools. The 4-port pilot valve is used for front attachment and swing operation. The 2-port pilot valve is used for travel, positioning/auxiliary and blade/stabilizer operation.



Right



Left



1 2 3 4 1 2 3 4



    



• Front and Swing Pilot Valve Port No.











HITACHI ISO Standard Standard Boom Lower ← Bucket Roll-Out ← Boom Raise ← ← Bucket Roll-In Right Swing Arm Roll-Out Arm Roll-In Right Swing Left Swing Arm Roll-In Arm Roll-Out Left Swing



 



 Hydraulic Symbol







3 2



PT



4 1



3



1



PT



3 2



4



2



 P



T566-03-05-002



T



 4



 1 T1F3-03-04-001







T3-4-1



COMPONENT OPERATION / Pilot Valve 



• Travel, Positioning/Auxiliary and Blade/Stabilizer







Pilot Valve Port No. 1 Travel Forward Positioning Raise/Auxiliary Open Blade/Stabilizer Lower 2 Travel Reverse Positioning Lower/Auxiliary Close Blade/Stabilizer Raise



T T



P P



 Hydraulic Symbol P



1



T



2



 1



T1LA-03-04-001



2







 T554-02-07-009



 



T3-4-2



1



2



COMPONENT OPERATION / Pilot Valve (Blank)



T3-4-3



COMPONENT OPERATION / Pilot Valve OPERATION • Front Attachment and Swing Pilot Valves In Neutral (Pusher Stroke: A to B on the Diagram) 1. When the control lever is in neutral, spool (6) completely blocks pressure oil from port P. The output port is open to port T via the notch on spool (6) so that the output port pressure is equal to pressure in the hydraulic oil tank. 2. When the control lever is moved slightly, cam (1) is tilted to push pusher (2). Pusher (2) is moved downward together with spring guide (3) while compressing return spring (5). 3. Spool (6) is pushed by balance spring (4) and is moved downward until clearance (A) becomes zero. 4. While moving downward, the output port is kept connected to port T so that pressure oil is not routed to the output port.



Full Stroke Operation (Pusher Stroke: E to F on the Diagram) 1. When the control lever is moved full stroke, pusher (2) is moved downward until spring guide (3) comes in contact with the stepped section of the casing. 2. Then, spool (6) is directly pushed by the bottom of pusher (2) at this moment. Accordingly, even if pressure in the output port increases, spool (6) cannot move upward. Then, the output port is kept connected to port P via the notch on spool (6). 3. Therefore, pressure in the output port is maintained at the same pressure in port P. The total lever stroke is decided by stroke C of the pusher.



NOTE: The lever stroke moved until clearance (A) becomes zero, corresponds to the lever play in the neutral position. Operation Corresponding to Control Lever Stroke (Pusher Stroke: C to D on the Diagram) 1. As the control lever is moved further, port P is connected to the output port via spool (6), increasing pressure in the output port. 2. The increase pressure in the output port acts on surface B of spool (6), causing spool (6) to move upward. 3. As long as this upward pressure force is lower than balance spring (4) force, balance spring (4) is not compressed. Therefore, port P is kept connected to the output port so that output port pressure continues to increase. 4. Then, the output port pressure increases further, force to push spool (6) upward increases. When this pushing force increases more than set-force of balance spring (4), spool (6) is moved upward while compressing balance spring (4). 5. As spool (6) is moved upward, the output port is disconnected from port P. Thereby, pressure oil is not supplied to the output port from port P, stopping the pressure increase in the output port. 6. As described, balance spring (4) is compressed by the same stroke as spool (6) is moved downward. The output port pressure at this time is equivalent to the pressure balancing with spring force applied to spool (6).



T3-4-4



E



F



Pilot Pressure D



C



A



B



Pusher Stroke



 T505-02-07-006



COMPONENT OPERATION / Pilot Valve Pusher Stroke: A to B



1 2



3 4 5 Notch Port T (Clearance A:0)



䋨A䋩 Port P



6







 T577-03-04-002



Output Port



T577-03-04-003











Pusher Stroke: C to D



Pusher Stroke: E to F 







2



䋨C䋩



4



3 Port T



Notch



6 Port P



Port P



6 Surface B







  1 - Cam 2 - Pusher



Output Port



T577-03-04-004







Output Port



 3 - Spring Guide 4 - Balance Spring



5 - Return Spring



T3-4-5



6 - Spool



T577-03-04-005



COMPONENT OPERATION / Pilot Valve • Travel, Positioning/Auxiliary and Blade/Stabilizer



Control Pedal-Full Stroke (Pusher Stroke: E to F) 1. When the control pedal is moved to full stroke, pusher (2) is moved down until it comes into contact with the top of plate (3). 2. Thereby, spool (7) is pressed directly by the bottom of pusher (2). As a result, notch (B) of spool (7) does not close even if the pressure at output port rises. 3. As a result, the pressure at output port becomes equal to the pressure at port P.



Pilot Valves Control Pedal-In Neutral (Pusher Stroke: A to B) 1. When the control pedal is in neutral, spool (7) blocks the pressure oil in port P completely. The output port is connected to port T through the passage in spool (7), so the pressure at output port becomes equal to the hydraulic oil tank pressure. 2. When the control pedal is moved slightly, cam (1) moves and pusher (2) and spring guide (4) move downward together, compressing return spring (6). 3. At this time, balance spring (5) pushes spool (7) and spool (7) moves downward until clearance (A) becomes ZERO. 4. While spool (7) moves downward, the output port is connected to port T and the pressure oil does not flow into the output port.



E



NOTE: The pedal stroke moved until clearance (A) becomes zero, corresponds to the pedal play in the neutral position. Control Pedal-Operated (Pusher Stroke: C to D Metering) 1. When the control pedal is moved further, the hole on spool (7) is connected to notch (B). 2. The pressure oil in port P flows into the output port via the hole in spool (7) from notch (B), so the pressure at output port increases. 3. The pressure at output port acts on the bottom of spool (7), to push spool (7) upward. 4. If the acting force on spool (7) is smaller than the spring force of balance spring (5), balance spring (5) will not be pressed. As a result, as port P is connected to the output port, the pressure at output port increases continuously. 5. If the pressure at output port increases further, the force to push up spool (7) increases. When this force becomes larger than the spring force of balance spring (5), spool (7) pushes balance spring (5), and moves upward. 6. When spool (7) moves upward, notch (B) closes, so the pressure oil does not flow into the output port from port P. Thereby, the pressure at port P stops raising. 7. Accordingly, the amount balance spring (5) is compressed is equal to the amount spool (7) is pressed down, so the balanced pressure between the spring force and the force acting on spool (7) becomes the pressure at output port.



F



Pilot Pressure D



C



A



B



Pusher Stroke



 T505-02-07-006







T3-4-6



COMPONENT OPERATION / Pilot Valve Pusher Stroke: A to B























1 2 3 4 5 Port T



6 (A)



Clearance (A): 0 Port P



Hole



7 Passage







 T1LA-03-04-002



Output Port







T1LA-03-04-003















Pusher Stroke: C to D



Pusher Stroke: E to F



















1



2



3 5 Port T



Port T



Notch (B)



Notch (B)



Port P



Port P



Hole



7



7



 Output Port



 T1LA-03-04-004



Output Port



















 1 - Cam 2 - Pusher



3 - Plate 4 - Spring Guide



5 - Balance Spring 6 - Return Spring



T3-4-7



7 - Spool



T1LA-03-04-005



COMPONENT OPERATION / Pilot Valve (Blank)



T3-4-8



COMPONENT OPERATION / Travel Device OUTLINE The travel device consists of the travel motor, the transmission, the front propeller shaft, the rear propeller shaft, the front axle and the rear axle. The travel motor is a variable displacement bent axis type axial plunger motor. The motor is driven by the pressure oil from the pump and rotates the transmission. A regulator is provided on the travel motor to regulate the torque, which is transferred to the transmission. The travel modes (Hi and Low) are selected at the transmission by the pressure oil from the pilot pump. Travel motor rotation is transferred to the propeller shafts and axles.



Rear Axle Rear Propeller Shaft



Front Propeller Shaft



Travel Motor



Transmission



Front Axle



 T1F3-03-05-002



OSCILLATION ANGLE : r 6 q



T3-5-1



COMPONENT OPERATION / Travel Device TRANSMISSION The transmission setup consists of the shift interlock controller and the Hi/Low travel speed reduction gear. The shift interlock controller prevents the shift lever from moving from the D (Hi) position to the L (Low) position during travel operation. (See the shift interlock control description pages.) The major components of the shift interlock controller are gearshift piston (1), relief valve (2) and rotary pump (3).



The Hi/Low travel speed reduction gear is controlled by the pressure oil supplied from port P1 (high speed) or port P2 (low speed) so that either the disc brake or the disc clutch is released, selecting which the gears are to be driven. The major components of the Hi/Low travel speed reduction gear are final gears (4), planetary gears (6), ring gear (7), disc brake (8), disc clutch (9), sun gear (10), shaft (11), clutch piston (12), disc springs (13), brake piston (14), throttle check valves (15) and accumulator (16). In addition, the travel motor drain pressure sensor and the N sensor (travel speed sensor) are provided.



Hi/Low Travel Speed Reduction Gear



Low Hi Speed Speed



16



P2



Shift Interlock Controller



P1



1



15



N Sensor (Travel)



14



2



13 12



3



Travel Motor



11



4



E



10



Propeller Shaft Travel Motor Drain Pressure Sensor



 9 1234-



Gearshift Piston Relief Valve Rotary Pump Final Gear



5678-



Carrier Planetary Gear Ring Gear Disc Brake



8



6



7 910 11 12 -



T3-5-2



T1F3-03-05-003



5



Disc Clutch Sun Gear Shaft Clutch Piston



13 14 15 16 -



Disc Spring Brake Piston Throttle Check Valve Accumulator



COMPONENT OPERATION / Travel Device    



Shift Interlock Controller



Hi/Low Travel Speed Reduction Gear



 



6



12



14



16







5



2



1



15 3



4



11 13



9



8



10



7



 T1F3-03-05-001







T3-5-3



COMPONENT OPERATION / Travel Device Low Speed Selection



x Releasing Disc Clutch



1. When the shift lever is moved to the L (Low) position, the transmission control valve allows the pressure oil to flow from the pilot pump to port P2. (Refer to the COMPONENT OPERATION / Transmission Control valve group.) 2. The pressure oil is routed into clutch piston (12) chamber from port P2 via gearshift piston (1) and throttle check valve (15). 3. Then, the pressure oil pushes clutch piston (12) to the left, releasing disc clutch (9). 4. When the Low mode is selected, no pressure oil is routed into brake piston (14) chamber so that brake piston (14) is kept pushed to the right by disc spring (13). Therefore, disc brake (8) remains applied.



5. Since disc brake (8) is kept applied, ring gear (7) cannot rotate. 6. Thereby, the rotation of the travel motor is transmitted to the propeller shaft via shaft (11), sun gear (10), planetary gears (6), carrier (5) and final gears (4). 7. At this time, the travel motor rotation speed is reduced at the stages of planetary gears (6) and final gears (4). Then, the output shaft speed (propeller shaft side) is slower than the input shaft speed (travel motor side). 8. Consequently, the output shaft rotates at a slow speed. 



 Low Speed







P2



1



15 14 13



12 Travel Motor



11



4



10 Propeller Shaft



 



9



8



T1F3-03-05-004



7







T3-5-4



6



5



COMPONENT OPERATION / Travel Device 



12



14



6



5



1



From Travel Motor



15



4



11 13 LOCATION OF DRAIN PRESS. SENSOR (1.47 MPa)



To Propeller Shaft



8



9



10



7



 11



7



T1F3-03-05-001







6 10 5 From Travel Motor



4



9 8 To Propeller Shaft



To Propeller Shaft



 T1F3-03-05-037



 1456-



Gearshift Piston Final Gear Carrier Planetary Gear



789-



Ring Gear Disc Brake Disc Clutch



10 - Sun Gear 11 - Shaft 12 - Clutch Piston







T3-5-5



13 - Disc Spring 14 - Brake Piston 15 - Throttle Check Valve



COMPONENT OPERATION / Travel Device Hi Speed Selection



• Releasing Disc Brake 5. Sun gear (10) is coupled to shaft (11) through the spline joint. 6. Thereby, the travel motor, ring gear (7), sun gear (10), planetary gears (6) and carrier (5) rotate as one unit. 7. Consequently, the input shaft (travel motor side) rotation is reduced only at final gears (4) so that the output shaft (propeller shaft side) rotates at a high speed.



1. When the shift lever is moved to the D (Hi) position, the transmission control valve allows the pressure oil to flow from the pilot pump to port P1. (Refer to the COMPONENT OPERATION / Transmission Control Valve group.) 2. The pressure oil is routed into brake piston (14) chamber from port P1 via gear shift piston (1) and throttle check valve (15). 3. Then, the pressure oil pushes brake piston (14) to the left, releasing disc brake (8). 4. When the Hi mode is selected, no pressure oil is routed into clutch piston (12) chamber so that clutch piston (12) is kept pushed to the right by disc spring (13). Therefore, disc clutch (9) remains engaged.



Hi Speed P1



1



15 14 13



12 Travel Motor



4



11 10



Warninng : less than 15 kgf/cm



Propeller Shaft



2



9



8



7



T3-5-6



6



5



T1F3-03-05-005



COMPONENT OPERATION / Travel Device 



12



14



6



5



1



From Travel Motor



15



4



11 13 To Propeller Shaft



9



8



10



7



 11



7



T1F3-03-05-001



 6 10 5 From Travel Motor



4 9 8



To Propeller Shaft



To Propeller Shaft



 T1F3-03-05-038



 1456-



Gearshift Piston Final Gear Carrier Planetary Gear



789-



Ring Gear Disc Brake Disc Clutch



10 - Sun Gear 11 - Shaft 12 - Clutch Piston







T3-5-7



13 - Disc Spring 14 - Brake Piston 15 - Throttle Check Valve



COMPONENT OPERATION / Travel Device Parking Brake 1. When the brake switch is turned to the parking brake position, the transmission control valve blocks the pressure oil from the pilot pump. (Refer to the COMPONENT OPERATION / Transmission Control valve group.) 2. The pressure oil in the clutch piston (12) and brake piston (14) is allowed to flow back to the hydraulic oil tank. 3. Therefore, clutch piston (12) and brake piston (14) are moved by disc springs (13) force to the right so that disc clutch (9) is engaged and disc brake (8) is applied. 4. Consequently, all gears are locked, holding shaft (11) stationary.  



14 13



12



11



 



9



T1F3-03-05-005



8







T3-5-8



COMPONENT OPERATION / Travel Device  14



12



11 13



8



9



 T1F3-03-05-001







9 8



 T1F3-03-05-039



 89-



Disc Brake Disc Clutch



11 - Shaft 12 - Clutch Piston



13 - Disc Spring







T3-5-9



14 - Brake Piston



COMPONENT OPERATION / Travel Device Shift Interlock Control The shift interlock controller prevents the shift lever from moving from the D (Hi) position to the L (Low) position during travel operation, protecting the travel motor from being damaged. Even if the shift lever is moved from the D (Hi) position to the L (Low) position while traveling in the high travel mode, the machine continues to travel in the high travel mode. Then, after the travel speed is reduced to the gear-shift speed range (about 75 % of the maximum speed), the transmission is automatically shifted to the low travel mode.  NOTE: The shift interlock controller doesn’t prevent the machine from running away while traveling on a down slope. The travel motor brake valve makes travel speed control on a down slope.  1. As the travel speed is accelerated with the shift lever in the D position, the travel motor rotation speed increases so that the delivery pressure of rotary pump (3) increases. 2. When the delivery pressure of the rotary pump overcomes the spring force, gearshift piston (1) is shifted. 3. Thereby, even if the shift lever is moved to the L position at this time, as the travel motor continues to rotate at a high speed, the delivery pressure from rotary pump (3) is kept at a high pressure. 4. Then, gearshift piston (1) remains in the shifted position so that the machine travel speed remains unchanged in the D mode even if the shift lever is in the L position. 5. After the machine travel speed decreases to the gearshift speed range, gearshift piston (1) is returned to the original position by the spring force so that the machine travel speed mode is automatically shifted. 6. Consequently, the travel motor is prevented from running at an excessive speed. 



T3-5-10



COMPONENT OPERATION / Travel Device



   



Low Hi Speed Speed







P2



Spring



P1



1



3



 T1F3-03-05-006



   



T3-5-11



COMPONENT OPERATION / Travel Device Shockless Function Accumulator (16) is provided in the transmission high speed control circuit. Accumulator (16) maintains the oil pressure in the high speed control circuit so that activation time-lag is created between disc clutch (9) and disc brake (8), reducing shock developed when shifting the travel mode. 



x Shifting Low Mode to Hi Mode



1. The pressure oil from port P1 opens throttle check valve (15) and is routed into brake piston (14) chamber and accumulator (16). 2. As pressure oil is routed into the both brake piston (14) chamber and accumulator (16), brake piston (14) slowly compresses disc springs (13). 3. Accordingly, disc brake (8) is slowly released. 4. The pressure oil in clutch piston (12) chamber flows back to the hydraulic oil tank through the orifice. 5. Then, clutch piston (12) is slowly moved by disc springs (13), preventing disc clutch (9) from engaging too quickly. 6. Therefore, when the high travel mode is selected, the travel motor is prevented from quickly increasing the rotation speed, reducing the shock due to travel mode change operation.



T3-5-12



COMPONENT OPERATION / Travel Device



  



Low Speed



16



 Orifice



P2



Hi Speed P1



15



14 13 12



 9



T1F3-03-05-007



8



 



T3-5-13



COMPONENT OPERATION / Travel Device x Shifting Hi Mode to Low Mode



1. The pressure oil from port P2 opens throttle check valve (15) and is routed into clutch piston (12) chamber. 2. The pressure oil moves clutch piston (12) to the left causing disc clutch (9) to disengage. 3. On the other hand, port P1 is connected to the hydraulic oil tank. 4. Then, brake piston (14) is moved to the right by disc spring (13) so that pressure oil in brake piston (14) chamber and accumulator (16) flows together back to the hydraulic oil tank. 5. As the return oil flows through the orifice at this time, brake piston (14) is not quickly moved so that disc brake (8) is slowly applied. 6. Therefore, when the low travel mode is selected, the travel motor is prevented from quickly increasing the rotation speed, reducing the shock due to travel mode change operation.



T3-5-14



COMPONENT OPERATION / Travel Device



  



Low Speed



16



 Orifice



P2



Hi Speed P1



15



14 13 12



 9



T1F3-03-05-008



8



  



T3-5-15



COMPONENT OPERATION / Travel Device Disconnect Device The disconnect device is activated when towing the machine. When the manual-operated lock lever is moved to the OFF position, the parking brake is released.



Underside of Base Machine







The lock lever is secured with a bolt in position.



Lock Lever







1. When the lock lever is in the ON position, carrier (5) is coupled to final gear (4) via the disconnect device. 2. Accordingly, when the parking brake is applied, all gears are locked so that final gears (4) cannot rotate. 3. When the lock lever is placed in the OFF position, the disconnect device is activated, freeing final gears (4) to rotate. 4. Therefore, the transmission is shifted to neutral, which allows the machine to be towed at a desired speed.  T1F3-03-05-047



OFF



ON



5



Disconnect Device



4



 T1F3-03-05-003



T3-5-16



COMPONENT OPERATION / Travel Device FRONT AND REAR PROPELLER SHAFT Joint The most common type universal joint is used for the joint. The universal joint consists of a pair of forks (1) and spider (2). Fork (1) is connected to spider (2) with bearings (3). Propeller Shaft



T1GL-03-05-003



1



2



3



T1GL-03-05-005



T3-5-17



COMPONENT OPERATION / Travel Device FRONT AXLE Front axle consists of bodies (1), steering cylinders (2), differential gear (3), and reduction gears (4). The front axle functions to change the machine travel direction, to support the machine weight, and to transfer the front propeller shaft power to the wheels. The front axle is connected to the base machine via the axle lock cylinders. When the axle lock cylinders are released, the front axle is allowed to oscillate so that the machine vibration is reduced during traveling (axle lock release control). (Refer to the SYSTEM / Control System group.)



Front Axle



A



Axle Lock Cylinder



 T1F3-01-02-002



1



View A



2



4 3 IN-BORD TYPE SERVICE BRAKE



T3-5-18



NO DIFFERENTIAL LOCK PROVIDED



 T1F3-03-05-015



COMPONENT OPERATION / Travel Device Construction  3







1



1



2



2



 T1F3-03-05-013







4 2 1



 T1F3-03-05-017



1-



Body



2-



Axle Shaft



3-



T3-5-19



Steering Cylinder



4-



Double Joint Shaft



COMPONENT OPERATION / Travel Device STEERING CYLINDER The steering valve operates the steering cylinder. When the steering wheel is turned to either the right or left, the pressure oil from the steering valve is routed into the steering cylinder. Then, the piston rod in the steering cylinder is moved so that the front wheels are steered to either the right or left. Construction



4



6



5



7



8



11 12 9 10



13



3 2



1



23



24



25



26 27



7



6



22



 14







15



16



17 18



16 15 19 17



14



20 20 21



 T1F3-03-05-014



 1234567-



Castle Nut Cotter Pin Tie Rod Clamp Bolt O-Ring Stopper



8910 11 12 13 14 -



O-Ring Ring Scraper Ring Guide O-Ring Cylinder Snap Ring



15 16 17 18 19 20 21 -



T3-5-20



Snap Ring Split Ring Disc O-Ring Piston Backup Ring Seal Ring



22 23 24 25 26 27 -



Piston Rod Shim Guide Bolt Ring Scraper Ring



COMPONENT OPERATION / Travel Device (Blank)



T3-5-21



COMPONENT OPERATION / Travel Device DIFFERENTIAL GEAR The differential gear allows the right and left drive wheels to rotate at different speeds each other when the machine changes the travel direction, or when the machine travels on uneven road surfaces.  Construction



1 2







3 4 5 6 7 8 9 10 11



12



 T1F3-03-05-018







18 18



19



19



17 16 23







22



17



21



19



18



20



19



16



12



15



18



 T1F3-03-05-019



 123456-



Lock Plate Nut Washer Flange Guard Seal



78910 11 12 -



Bearing Ring Shim Bearing Pinion Shaft Ring Gear



13



14



13 14 15 16 17 18 -



T3-5-22



Spring Pin Spring Pin Half Case Gasket Side Gear Shim



19 20 21 22 23 -



Idle Gear Spider Half Gear Plane Washer Socket Bolt



COMPONENT OPERATION / Travel Device Function



• Purpose of Differential



1. When the machine is steered, the rear wheels move along the circular having its center point on the extension line of the rear wheel drive shaft. Therefore, the outer wheel must rotate faster than the inner wheel. 2. Let study the case when the rear wheels are driven by a propeller shaft via an axle having no differential gear. 3. In this case, both outer and inner wheels rotate at the same speed. If the machine is steered, the outer wheel must move faster than the inner wheel, resulting in sliding and/or premature wearing of the tire. In addition, the axle will be twisted, not allowing the constant transmission of driving force. 4. When a differential gear is installed, the outer wheel can rotate at different speed from that of the inner wheel so that the problem as mentioned above doesn’t occur.



Extension Line of Rear Wheel Drive Shaft



When the Machine is Steered:



When the Machine Travels on an Uneven Road Surface:







T3-5-23



 T202-03-05-005



COMPONENT OPERATION / Travel Device • Basic Operational Principle of Differential Gear The operational principle of differential gear is explained using a pair of racks and a pinion gear.



  



1. When handle (C) is moved upward by distance (H) while applying equal loads (W) onto both rack (A) and rack (B) respectively, both racks (A and B) move by distance (H) together with the pinion gear. 2. When handle (C) is moved upward without applying load (W) onto rack (B), the pinion gear is moved upward while rotating along rack (A) to which load (W) is kept applied. 3. Rack (B) to which no load is applied is moved upward as the pinion gear rotates. 4. At this time, the moving distance of rack (B) is longer than the moving distance of the pinion gear that rotates along rack (A). 5. The moving distance of rack (B) can be obtained as H + H = 2H. This is equal to the operational principle of the differential gear.







W



W



W C



C H



H



H



2H



Rack (B) Rack (A) Pinion



Pinion



 T202-03-05-006







T3-5-24



COMPONENT OPERATION / Travel Device • Operational Principle of Differential Gear 1. The axle shafts are coupled to side gears (17) through the spline joints. When equal loads are applied to axle shafts on both side, or when the machine is traveling straight on a flat surface, idle gears (19) don’t rotate. 2. Half cases (15 and 21) are connected to ring gear (12). Since idle gears (19) mesh with side gears (17) and mutual movement is kept stationary, half cases (15 and 21) rotate together with ring gear (12). 3. As mentioned above, as long as all parts are rotating as one unit, differential gear function doesn’t work. Therefore, side gears (17), idle gears (19) and spider (20) work as a joint connecting the axles. 4. When the machine is steered, uneven resistance forces are applied to the driving wheels. Depending on the difference in resistance force applied to the inner and outer wheels, idle gears (19) start revolving along side gears (17) while rotating around spider (20). 5. In case the resistance force applied to axle shaft (A) is larger than that applied to axle shaft (B), idle gears (19) revolve along side gears (17) in the same direction as ring gear (17) rotates while rotating around spider (20). Then, the rotation speed on axle shaft (A) is reduced. To the contrary, the rotation speed on axle shaft (B) is increased so that the differential gear function operates. 6. Supposing that ring gear (12) is driven by pinion shaft (11) at the speed of 100, the both side driving wheels rotate at the same speed as long as the machine travel straight. 7. When the machine is steered and the travel speed on the right side driving wheel is reduced to 90, the left side travel speed is increased by 10 (100-90) so that the machine is steered with the left side driving wheel rotating at the speed of 110. 8. Consequently, when ring gear (12) rotates at the speed of 100, the total rotation speed of both side wheels is kept constantly at 200 irrespective of difference in speed between both side wheels.



 



12



11



19



Axle Shaft



17



17



15



20



Axle Shaft



21



 T202-03-05-007



 



12



11



19 Axle Shaft (B)



17 15



17 20



Axle Shaft (A)



21



 T202-03-05-008



 







T3-5-25



COMPONENT OPERATION / Travel Device REDUCTION GEAR







The reduction gear is a planetary gear type one-stage reduction gear that transfers the driving force from the differential gear to the wheels. The brake equipped is a wet type multi disc brake. The major components are knuckle (1), hub (2), internal gear (3), piston (4), gear (5), friction plate (6), plate (7), plate carrier (8), sun gear shaft (9), planetary gear (10), and planetary carrier (11).  Construction 



2



1



5 4 3



11 9 8



6







10



7



 T1F3-03-05-012



 1 - Knuckle 2 - Hub 3 - Internal Gear



4 - Piston 5 - Gear 6 - Friction Plate



7 - Plate 8 - Plate Carrier 9 - Sun Gear Shaft



 



T3-5-26



10 - Planetary Gear 11 - Planetary Carrier



COMPONENT OPERATION / Travel Device Brake Operation 1. When the brake pedal is stepped on, the pressure oil from the brake valve is routed onto piston (4) in the reduction gear. 2. Then, piston (4) is moved by the pressure oil so that friction plates (6) come in contact with plates (7). 3. Accordingly, the rotation speeds of sun gear shaft (9) and planetary carrier (11) is reduced, thereby reducing the machine travel speed.



NOTE: When the machine is traveling, the pressure is routed into the hydraulic oil tank. Therefore, the disc brake is kept released.  



  Brake Valve







Brake Pedal



11



9



4



7



6



 Front Brake



Pilot Pump



Rear Brake



 Hydraulic Oil Tank



T1F3-03-05-048



  



T3-5-27



COMPONENT OPERATION / Travel Device REAR AXLE The rear axle consists of bodies, a differential gear, and a pair of reduction gears. The rear axle transfers the driving force from the rear propeller shaft to the wheels while supporting the machine weight. 



NOTE: The rear axle construction is identical to that of the front axle. Therefore, only the construction of the bodies, differential gear, and reduction gears are illustrated. 



 Rear Axle 



Body Differential Gear



 T1F3-03-05-016







Reduction Gear



  Body  1



2



 T1F3-03-05-011



 1 - Body



2-



Axle Shaft







T3-5-28



COMPONENT OPERATION / Travel Device  Defferential Gear  



14







23



1



2



21



22



19



18



19



20



18 17



13



16 15



12 3



16 17



4 5



6



7



8



9



19



18



19



18



10 11



 T1F3-03-05-026



 123456-



Lock Plate Nut Washer Flange Guard Seal



78910 11 12 -



Bearing Ring Shim Bearing Piston Shaft Ring Gear



13 14 15 16 17 18 -



 



T3-5-29



Spring Pin Spring Pin Half Case Gasket Side Gear Shim



19 20 21 22 23 -



Idle Gear Spider Half Gear Plain Washer Socket Bolt



COMPONENT OPERATION / Travel Device  Reduction Gear 1







3 2



5



6



7



4



9 8 11



10



 T1F3-03-05-010



  1 - Knuckle 2 - Hub 3 - Internal Gear



4 - Piston 5 - Gear 6 - Friction Plate



7 - Plate 8 - Plate Carrier 9 - Sun Gear Shaft







T3-5-30



10 - Planetary Gear 11 - Planetary Carrier



COMPONENT OPERATION / Travel Device TRAVEL MOTOR The travel motor consists of the motor section, and brake valve. The motor section is rotated by the pressure oil from the pump and transfers the motor rotation to the transmission. The regulator controls the motor displacement angle so that the motor is rotated at the displacement angle in proportion to the pilot pressure oil. Overload relief valves provided on the regulator prevent surge pressure due to overloads from occurring in the motor circuit. Brake Valve



The travel brake valve consists of the counterbalance valve, load check valves, check valves, and shuttle valve and prevents the machine from running away. NOTE: The make-up valve in the control valve prevents occurrence of cavitation in the motor circuit.



Motor



Counterbalance Valve



Load Check Valve/ Check Valve



Overload Relief Valve T1F3-03-05-020



Regulator



Component Layout



Check Valve



Pilot Piston T



B Counterbalance Valve Connected Transmission 3 (140 / 57.8 cm /rev)



Shuttle Valve



Load Check Valve A X Overload Relief Valve



Servo Piston (40 MPa)



T3-5-31



T1F3-03-05-023



COMPONENT OPERATION / Travel Device ROTOR SECTION FV



The rotor section consists of valve plate (1), rotor (2), drive shaft (3) and plungers (4). When the pressure oil is routed to port AM on valve plate (1), the pressure oil flows into the half side of rotor (2) so that plungers (4) are pushed. The component force (FV) of plunger pushing force (F) rotates drive shaft (3). As drive shaft (3) rotates, rotor (2) is also rotated. Then, when plunger (4) is rotated up to port BM in sequence, the pressure oil in the rotor is returned to the hydraulic oil tank. Supplying the pressure oil to either port AM or BM can achieve forward and reverse travel direction change.



F FR



4



AM 1



3



2



BM



 T216-03-05-015



1



2



3



 T1F3-03-05-021



4



1-



Valve Plate



2-



Rotor



3-



T3-5-32



Drive Shaft



4-



Plunger



COMPONENT OPERATION / Travel Device (Blank) 



T3-5-33



COMPONENT OPERATION / Travel Device REGULATOR The major components of the regulator are pilot piston (1), sleeve (2), piston (3), spring (4), bushing (5), collar (6), spring (7), return spring (8), pin (9) and servo piston (10). Corresponding to various signal pressures delivered to the regulator, the regulator opens or closes the circuit to the servo piston so that the tilt angle of the rotor is adjusted, controlling the travel motor rotation.



NOTE: The motor system pressure is constantly routed into the small chamber of servo piston (10).



2



1



Port T



Port B



Port A



Port X



10



Port A: Travel Forward Side



Port B: Travel Reverse Side



Port T: Hydraulic Oil Tank Return Side



T3-5-34



 T1F3-03-05-023



PortX: Pilot Pressure [From 4-Spool Solenoid Valve Unit (SI)]



COMPONENT OPERATION / Travel Device 1 2 3 Rotor



4 5 6 7 8 9 10



 T1F3-03-05-025



1 - Pilot Piston 2 - Sleeve 3 - Piston



4 - Spring 5 - Bushing 6 - Collar



7 - Spring 8 - Return Spring



T3-5-35



9 - Pin 10 - Servo Piston



COMPONENT OPERATION / Travel Device (Blank)



T3-5-36



COMPONENT OPERATION / Travel Device Control Function of Regulator







The pressure oil routed to pilot piston (1) controls the displacement angle of the travel motor. Pilot piston (1) controls the pressure oil routed into the large diameter chamber of servo piston (10) to control the motor displacement angle. The regulator is controlled by the following two methods.



x Control by motor driving oil pressure



  Motor Displacement Angle  



When the motor driving oil pressure increases to more than the set-pressure, the regulator increases the motor displacement angle to reduce the motor rotation speed so that the machine travels at a slow speed. When the motor driving oil pressure decreases to lower than the set-pressure, the regulator decreases the motor displacement angle to increase the motor rotation speed so that the machine travels at a fast speed. x Control by pilot pressure oil When solenoid valve (SI) is shifted by the signal from MC (main controller), the pilot oil pressure is routed to the regulator so that the motor displacement angle is increased. Then, the machine travel speed is reduced (Superfine travel speed control) (Travel motor excessive speed rotation preventive control) (Refer to the SYSTEM / Control System group.)



   



Driving Oil Pressure



   To Hydraulic Oil Tank







1



T



Motor Driving Oil Pressure A



B



X



10



  



T3-5-37



Pilot Pressure Oil [From Solenoid Valve Unit (SI)]



 T1F3-03-05-027



COMPONENT OPERATION / Travel Device Control by Motor Driving Oil Pressure



x Small Displacement Angle (Fast Speed)



1. When the control valve travel spools are in neutral, no pressure oil is routed into the small diameter chamber of servo piston (10) so that servo piston (10) moves downward by return spring (8) force, decreasing the motor displacement angle (fast speed). 2. As pilot piston (1) is being pushed upward by springs (4 and 7), the pressure oil in the large diameter chamber of servo piston (10) flows to the hydraulic oil tank through the notch on pilot piston (1). 3. When travel operation is made, the motor driving pressure oil from the control valve is routed into the small diameter chamber of servo piston (10) and on the pilot piston (1). 4. Since the oil pressure in the large diameter chamber of servo piston (10) is equal to that in the hydraulic oil tank, servo piston (10) doesn’t move. 5. Consequently, the travel motor displacement angle is reduced, causing the travel motor speed to increase.



1 Motor Driving Oil Pressure



T3-5-38



 10



T1F3-03-05-028



COMPONENT OPERATION / Travel Device In Neutral:



During Traveling:



























1



1



4



4



7



7



To Hydraulic Oil Tank



To Hydraulic Oil Tank



8



8 Motor Driving Oil Pressure



Motor Driving Oil Pressure



10 10



Small Diameter Chamber



Large Diameter Chamber











T1F3-03-05-041



T3-5-39



T1F3-03-05-042



COMPONENT OPERATION / Travel Device x Large Displacement Angle (Slow Speed)



1. The motor driving oil pressure is routed into the small diameter chamber of servo piston (10) and Motor onto pilot piston (1). Driving Oil 2. The pressure receiving area at section (B) on pilot Pressure piston (1) is larger than that at section (A). 3. When the motor driving oil pressure increases to more than springs (4 and 7) force with servo piston (10) in the minimum displacement angle position, the pressure oil pushes pilot piston (1) downward. 4. Then, the motor driving pressure oil flows into the large diameter chamber of servo piston (10) after passing through the notch on pilot piston (1) and the inner passage. 5. Although the motor driving pressure oil is routed into the small diameter of servo piston (10), servo piston (10) is moved upward because the pressure force in the large diameter chamber is large than that in the small diameter chamber due to difference in pressure acting area. 6. Therefore the motor displacement increases, causing the machine to drive at a slow speed.



T3-5-40



1



 T1F3-03-05-024



10



COMPONENT OPERATION / Travel Device During Travel:



During Parking:



























1



1 A



3



3



B



4 4 7 7 8



8



Motor Driving Oil Pressure



Motor Driving Oil Pressure



10 10



Small Diameter Chamber



Large Diameter Chamber











T1F3-03-05-043



T3-5-41



T1F3-03-05-044



COMPONENT OPERATION / Travel Device Control by Pilot Oil Pressure 1



• Large Displacement Angle (Slow Speed) 1. When the signal arrives from the MC, solenoid valve (SI) is shifted, routing the pressure oil from the pilot pump to pilot piston (1). 2. Pilot piston (1) is moved downward by the pilot pressure oil. 3. Then, the pressure oil flows into the large diameter chamber of servo piston (10) after passing through the notch on pilot piston (1) and the inner passage. 4. Although the pressure oil is routed into the small diameter of servo piston (10), servo piston (10) is moved upward because the pressure force in the large diameter chamber is large than that in the small diameter chamber due to difference in pressure acting area. 5. Therefore the motor displacement decreases, causing the machine to drive at a slow speed.



Motor Driving Oil Pressure



10



T3-5-42



Pilot Pressure Oil



T1F3-03-05-029



COMPONENT OPERATION / Travel Device During Traveling:



During Parking:



















From Solenoid Valve Unit (SI)







Motor Driving Oil Pressure



From Solenoid Valve Unit (SI)







1



1



3



3



4



4



7



7



8



8 Motor Driving Oil Pressure



10



10











T1F3-03-05-045



T3-5-43



T1F3-03-05-046



COMPONENT OPERATION / Travel Device Overload Relief Valve The regulator is equipped with the overload relief valves that prevents the surge pressure from occurring in the motor circuit. Circuit Protection 1. When the circuit oil pressure increases to higher than the set-pressure of the overload relief valve, the overload relief valve opens, allowing the surge pressure to relieve to the lower pressure side so that the travel motor is protected from being overloaded.



Overload Relief Valve



NOTE: When the motor runs faster than the oil volume supplied from the pump, the counterbalance valve is closed, increasing the return oil pressure from the motor.



Counterbalance Valve



A



B



 T1F3-03-05-036



When Relieving: 1



2



3



4



3 - Spring







B



䌁



1 - Spring 2 - Poppet



To Housing (Hydraulic Oil Tank)



5



4-



T3-5-44



Check Valve



T1F3-03-05-035



5-



Piston



COMPONENT OPERATION / Travel Device BRAKE VALVE







The travel brake valve is located on the head of the travel motor, and consists of the counterbalance valve, check valves and shuttle valve.



 



A



Counterbalance Valve: Ensures smooth start and stop travel operation, and prevents the machine from running away when traveling on a down slope. Check Valve: Blocks the return circuit from the travel motor. A



Shuttle Valve: Routes the travel motor driving high-pressure oil into the pilot piston and the small diameter chamber of the servo piston in the regulator. 



 T1F3-03-05-020



 



 



Section A-A



Counterbalance Valve



 



B



B Check Valve



Check Valve



Load Check Valve



Load Check Valve Section B-B



B



A







Shuttle Valve



  



T3-5-45



 T1F3-03-05-034



COMPONENT OPERATION / Travel Device When Traveling: 1. When the pressure oil from the control valve is supplied to port A, the pressure oil diverges into two directions. 2. The one oil flow opens check valve (6) and is routed to motor port AM and to counterbalance valve spool (1). 3. The other oil flow is routed onto the end face of spool (1) after passing through passage (7) and the inside of spool (1). 4. The return oil from the travel motor is routed to spool (1) and check valve (3) via motor port BM. However, both check valve (3) and spool (1) block the return oil flow. 5. When the oil pressure at port A increases higher than spring (2) force, spool (1) is moved to the right. 6. Then, the return oil from the travel motor flows to passage (8) through the notch on spool (1). 7. The return oil opens load check valve (4). Then, the return oil flows to port B. As the pressure oil starts flowing at this stage, the travel motor starts rotating. 8. When the travel levers are returned to neutral, spool (1) is returned to the original position by spring (2) force, closing the circuit so that the travel motor stops rotating.



When Traveling on a Down Slope: 1. While traveling on a down slope, the machine weight causes the travel to forcibly rotate so that the travel motor works as if it is a hydraulic pump. 2. Therefore, when the travel motor draws the hydraulic oil, the oil pressures at port A and motor port AM decrease. Then, spool (1) is moved to the left, restricting the return oil flow from the travel motor. 3. Therefore, the oil pressure at port BM increases, developing the brake force to the travel motor. 4. As the oil pressure at port A increases, spool (1) is moved back to the right. Repetition of this operation (hydraulic brake) prevents the machine from running away.



T3-5-46



COMPONENT OPERATION / Travel Device When Traveling: 



Notch



8



1



2







7 AM



BM



 T1F3-03-05-022







6



5



 When Traveling on a Down Slope:



A



4



B



3



1



 



AM



BM



 T1F3-03-05-022







A



 1 - Spool (Counterbalance Valve) 2 - Spring



3 - Check Valve



5 - Check Valve



7 - Passage



4 - Load Check Valve



6 - Load Check Valve



8 - Passage







T3-5-47



COMPONENT OPERATION / Travel Device (Blank)



T3-5-48



COMPONENT OPERATION / Signal Control Valve OUTLINE The signal control valve is provided in the pilot circuit between the pilot valve and the control valve and controls various kinds of the pilot signal pressure used to regulate the pumps and valves.



NOTE: The flow combiner control spool and the auxiliary spool in the signal control valve are not used.



The major components of the signal control valve are shuttle valves, shockless valve, pump 1 flow rate control valve, pump 2 flow rate control valve, flow combiner valve control spool, bucket flow rate control valve control spool, and swing parking brake release spool.



A



A



Pilot Valve Side



 T178-03-06-016



Cross Section A-A



Shockless Valve



Bucket Flow Rate Control Valve



Auxiliary Spool



Pump 2 Flow Rate Control Valve



Pump 1 Flow Rate Control Valve



Swing Parking Brake Release Spool



Flow Combiner Valve Control Spool



 T178-03-06-002



T3-6-1



COMPONENT OPERATION / Signal Control Valve PILOT PORT Pilot Valve Side



PH



C



A



E M D H B



F



SB G



PI



Pilot Valve Side



N



K



I SH



J DF SA



L



 T178-03-06-016



Pilot Valve Side Port Name Port A Port B Port C Port D Port E Port F Port G Port H Port I Port J Port K Port L Port M Port N Port SA Port SB Port PI Port PH Port SH Port DF



Connecting to Right Pilot Valve Right Pilot Valve Left Pilot Valve Left Pilot Valve Left Pilot Valve Left Pilot Valve Right Pilot Valve Right Pilot Valve         Travel Shocless Valve (Travel Pilot Valve) Travel Shocless Valve (Travel Pilot Valve) Positioning/Auxiliary Pilot Valve Positioning/Auxiliary Pilot Valve Pump 1 Regulator Pump 2 Regulator 4-Unit Solenoid Valve Unit Pilot Shut-Off Valve Shuttle Valve (Swing Parking Brake) Hydraulic Oil Tank







T3-6-2



Note Boom Raise Pilot Pressure Boom Lower Pilot Pressure Arm Roll-Out Pilot Pressure Arm Roll-In Pilot Pressure Left Swing Pilot Pressure Right Swing Pilot Pressure Bucket Roll-In Pilot Pressure Bucket Roll-Out Pilot Pressure Plug Plug Travel Reverse Pilot Pressure Travel Forward Pilot Pressure Positioning Raise/Auxiliary Open Pilot Pressure Positioning Lower/Auxiliary Close Pilot Pressure Pump 1 Control Pressure Pump 2 Control Pressure Primary Pilot Pressure Primary Pilot Pressure (Heating Circuit) Brake Release Pressure Returning to Hydraulic Oil Tank



COMPONENT OPERATION / Signal Control Valve  Control Valve Side







3



1



5



Pressure Sensor (Auxiliary)



13 4



2



SE



SK



8



Pressure Sensor (Swing)



14 Control Valve Side



7 9 6



10



SN



SL



11



 12



Control Valve Side Port Name Port 1 Port 2 Port 3 Port 4 Port 5 Port 6 Port 7 Port 8 Port 9 Port 10 Port 11 Port 12 Port 13 Port 14 Port SE Port SN Port SP Port SL Port SK



Connecting to Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Hydraulic Oil Tank     Control Valve Control Valve Pilot Pressure Shift Valve Pilot Pressure Shift Valve         Shuttle Valve     Control Valve



SP



T1F3-03-06-003



Note Boom Raise Pilot Pressure Boom Lower Pilot Pressure Arm Roll-Out Pilot Pressure Arm Roll-In Pilot Pressure Left Swing Pilot Pressure Right Swing Pilot Pressure Bucket Roll-In Pilot Pressure Bucket Roll-Out Pilot Pressure Returning to Hydraulic Oil Tank Plug Travel Reverse Pilot Pressure Travel Forward Pilot Pressure Positioning Raise/Auxiliary Open Pilot Pressure Positioning Lower/Auxiliary Close Pilot Pressure Plug Plug Pump 1 Flow Rate Control Valve Control Pressure Plug Bucket Flow Rate Control Valve Control Pressure



T3-6-3



COMPONENT OPERATION / Signal Control Valve  NOTE: Machines Equipped with Optional Auxiliary Flow Combining System  Control Valve Side







SM



Control Valve Side



SN



 T1F3-03-06-004



 Control Valve Side Port Name Port SM Port SN



Connecting to



Note



Auxiliary Flow Combiner Solenoid Valve Auxiliary Flow Combiner Reducing Valve



 NOTE: The reducing valve and the auxiliary flow combiner solenoid valve are installed only on the machines equipped with the optional auxiliary flow combining system. 



T3-6-4



Auxiliary Flow Combiner Valve Shift Pressure Auxiliary Flow Combiner Valve Shift Pressure



COMPONENT OPERATION / Signal Control Valve SHUTTLE VALVE The shuttle valve selects the pilot pressure used to perform each operation and routes it to the corresponding flow rate control valves and/or control spools. The flow rate control valves and/or control spools corresponding to each operation are as follows: Pump 1 Flow Rate Control Valve Boom Raise Boom Lower Arm Roll-In Arm Roll-Out Bucket Roll-In Bucket Roll-Out Right Swing Left Swing Travel Positioning/Auxiliary Blade/Stabilizer



{ { { { { { { { {



Pump 2 Flow Rate Control Valve { { { { { { -



T3-6-5



Bucket Flow Rate Control Valve Control Spool { -



Swing Parking Brake Release Spool { { { { { { { { { -



COMPONENT OPERATION / Signal Control Valve 



4



5



6



7



9 10



8



 Travel







Arm



Swing



Boom



Bucket



11 Positioning/ Auxiliary



12 13 14 15 Blade/ Stabilizer



3 2 1



  



Pump 1 Flow Rate Control Valve



Pump 2 Flow Rate Control Valve



Bucket Flow Rate Control Valve Control Spool



Swing Parking Brake Release Spool



   



T3-6-6



T1F3-03-06-002



COMPONENT OPERATION / Signal Control Valve



B



B



Pilot Valve Side



 T178-03-06-016



Cross Section B-B 7 3



6



5 14 15 13



11



9



12 8



4



10



1 2



 T178-03-06-009



1 - Travel 2 - Boom/Arm/Bucket/Travel



56-



Boom/Arm Boom



3 - Arm



7-



Arm/Boom Raise



4 - Boom/Arm/Bucket/Travel/ Positioning/Auxiliary/ Blade/Stabilizer



8-



Boom Raise/Arm/Swing/ Positioning/Auxiliary



9 - Boom/Arm/Bucket 10 - Boom/Arm/Bucket/Swing/ Positioning/Auxiliary 11 - Arm/Boom Raise/Swing/ Positioning/Auxiliary 12 - Bucket



T3-6-7



13 - Swing 14 - Swing/Positioning/Auxiliary 15 - Positioning/Auxiliary



COMPONENT OPERATION / Signal Control Valve SHOCKLESS VALVE The shockless valve is provided in the boom raise circuit and functions during boom lowering operation. During Boom Raising Operation: 1. The boom raise pilot pressure is routed from port A and acts on the spool. 2. Immediately after the operation is started, the low pilot pressure oil flows to port 1 via clearance C between the spool and the housing, and inner passage 2. 3. The set-force of spring A is weaker than that of spring B. Therefore, when the pilot pressure increases, the spool is moved to the left. 4. As the spool is moved to the left, port A is connected to port 1, increasing the pressure in port 1 so that the spool in the control valve is moved.



During Boom Lowering Operation (Shock Reducing Operation) 1. When the boom is lowered, the return oil from the boom raise spool in the control valve is routed to port 1. 2. Since the spool blocks the oil passage between port 1 and port A, the return oil cannot flow directly to port A. 3. Port 1 is connected to spring A side via inner passage 1 and to the oil chamber via inner passage 2. 4. The pressure oil in the oil chamber flows out of clearance C between the spool and the housing, reducing the pressure in the oil chamber. Then, the spool is moved to the right by the pressure in the spring A side. Thereby, clearance C between the spool and the housing is closed, blocking the pressure oil flow. 5. When clearance C is closed, the pressure in the oil chamber increases, moving the spool to the left. Therefore, clearance C is opened again, allowing the pressure oil to flow to port A. 6. As operations in steps (4 and 5) are repeated, the pressure oil is gradually returned to port A so that the control spool returns slowly.



T3-6-8



COMPONENT OPERATION / Signal Control Valve



Pilot Valve Side Port A Inner Passage 1



Clearance C



Spring A



Inner Passage 2 Port 1



Spool



Spring B



Oil Chamber



 T178-03-06-013



Control Valve Side



T3-6-9



COMPONENT OPERATION / Signal Control Valve PUMP 1 AND PUMP 2 FLOW RATE CONTROL VALVES The pump flow rate control valve delivers the pump control pressure Pi to the pump regulator in response to the pilot oil pressure from the pilot valve. 1. The pilot pressure from the pilot valve is routed into the spring chamber side in either the pump 1 or pump 2 flow rate control valve after being selected by the shuttle valves in the signal control valve. 2. Then, the spool is moved to the right, causing the primary pilot pressure to flow in either port SA or SB. 3. Therefore, the pressure in port SA or SB increases. 4. The oil pressure in port SA or SB acts on the right end of the spool. Thus, the spool is moved back to the left until the pressure force in port SA or SB balances with the pilot pressure force in the spring chamber so that the pressure in port SA or SB stops increasing.



T3-6-10



NOTE: The pump 1 flow rate control valve operates when the boom (raise or lower), arm (roll-in or out), bucket (roll-in or out), travel (forward or reverse), positioning/auxiliary, and blade/stabilizer functions are operated. The pump 2 flow rate control valve operates when the boom (raise), arm (roll-in or out), swing (right or left), and positioning/auxiliary functions are operated.



COMPONENT OPERATION / Signal Control Valve



Spring



Port SA, SB Spool



Primary Pilot Pressure Pilot Pressure



Shuttle Valve



 T1F3-03-06-005







T3-6-11



COMPONENT OPERATION / Signal Control Valve BUCKET FLOW RATE CONTROL VALVE CONTROL SPOOL, SWING PARKING BRAKE RELEASE SPOOL NOTE: The three captioned spools are identical in operational principle.



Bucket Flow Rate Control Valve Control Spool: To Hydraulic Oil Tank



The bucket flow rate control valve control spool is shifted by the arm roll-in control pilot pressure, allowing the boom raise pilot pressure to flow to the bucket flow rate control valve in the control valve. The swing parking brake release spool is shifted by the boom, arm, bucket, swing or positioning/auxiliary pilot pressure, allowing the primary pilot pressure to flow to the swing motor.



Boom Raise Control Pilot Pressure



Spool



Spring



 T178-03-06-014



Arm Roll-In Pi- To Bucket Flow Rate lot Pressure Control Valve



Swing Parking Brake Release Spool: To Hydraulic Oil Tank



Primary Pilot Pressure



Spool



Spring



 T178-03-06-014



Pilot Pressure



T3-6-12



To Swing Parking Brake



COMPONENT OPERATION / Steering Valve OUTLINE The steering valve is located between the steering pump and the steering cylinders. The steering valve delivers the pressure oil from the steering pump to the steering cylinders corresponding to the rotation of the steering wheel. (Refer to the SYSTEM/Hydraulic System group.) Relief valve and overload relief valves are provided in the steering valve. The relief valve prevents the circuit pressure between the steering pump and the steering valve from being increased. When the steering valve is in neutral (when no steering operation is performed), the overload relief valve prevents the circuit pressure between the steering cylinders and the steering valve from being increased by external force to more than the set pressure.



   



 



Port L (Left Steering)







Port LS



Port R (Right Steering)







Steering Wheel



 T487-03-02-001



 



Port T (To the Hydraulic Oil Tank)



T3-7-1



Port P (From the Steering Pump))



COMPONENT OPERATION / Steering Valve System Layout  



1







2 3 4



5



 9







T1F3-03-07-005



6



8 7



 1 - Gerotor



4 - Make-Up Valve



6-



2 - Check Valve



5 - Port L (To the Steering Cylinder)



Port P (From the Steering Pump) 7 - Overload Relief Valve



8-



Port T (To the Hydraulic Oil Tank) 9 - Port R (To the Steering Cylinder)



3 - Relief Valve



  5







9



A



B



8



6







T3-7-2



 T487-03-02-001



COMPONENT OPERATION / Steering Valve 



View A



F







C



View B



F



D E



D



E



D



E E



D C



T487-03-02-005 T487-03-02-004



 



Section C-C



2







  



1



Section D-D



7



 T487-03-02-007



 



Section E-E



 4



 T1F3-03-07-002







 



T487-03-02-006



Section F-F











 T1F3-03-07-003



  







T3-7-3



3



COMPONENT OPERATION / Steering Valve CONSTRUCTION







The steering valve consists of gerotor (8), drive (7), sleeve (3), spool (4), pin (5), housing (1), and centering springs (2). When the steering wheel is rotated, spool (4) is rotated, opening the oil passage between spool (4) and sleeve (3). Then the pressure oil from the steering pump is routed into the steering cylinders via spool (4) and sleeve (3). Centering springs (2) are provided in both spool (4) and sleeve (3) so that sleeve (3) is returned to neutral when the steering wheel is released.



8







3



4 3







 T1F3-03-07-005



    



2



 T1F3-03-07-002



 1







5



4



3



7



6



8



  1 - Housing 2 - Centering Spring



34-



Sleeve Spool



56-







T3-7-4



Pin Plate



78-



Drive Gerotor



COMPONENT OPERATION / Steering Valve 8



7



OPERATION Sleeve (3), spool (4) are connected to drive (7) with pin (5). The pin hole in spool (4) is an oval hole so that there is play between spool (4) and sleeve (3). When the steering wheel spool (4) is rotated, the steering wheel exact rotation is transferred only to spool (4), creating a displacement angle between spool (4) and sleeve (3). Then, port P (from the steering pump) is connected to port R or L (to the steering cylinders) via sleeve (3) and spool (4).



 2



5



4



T1F3-03-07-002



3 4



2 3



1 Port L Port R



Oval Hole



5 Port P



10 9



8



7



6



 T1F3-03-07-004



1 - Housing 2 - Centering Spring 3 - Sleeve



4 - Spool 5 - Pin 6 - Plate



7 - Drive 8 - Gerotor



T3-7-5



9 - Spacer 10 - Cap



COMPONENT OPERATION / Steering Valve Left Steering: 1. When the steering wheel is turned counterclockwise, spool (4) is rotated. Then, the pressure oil from the steering pump is routed as follow: Port P o Sleeve (3) o Spool (4) o Sleeve (3) o Housing (1) o Gerotor (8) 2. The pressure oil from gerotor (8) is routed further as follow: Housing (1) o Sleeve (3) o Spool (4) o Sleeve (3) o Port L o Steering Cylinders. Then, the steering cylinders are operated so that the machine is turned to the left. 3. The return oil from the steering cylinders flows back to the hydraulic oil tank as follow: Housing (1) o Sleeve (3)o Spool (4) o Sleeve (3) o Port T



4. When the pressure oil from the steering pump is routed through gerotor (8), gerotor (8) is rotated counterclockwise. The rotation of gerotor is transferred to sleeve (3) via drive (7), causing sleeve (3) to rotate to counterclockwise. When sleeve (3) is rotated by the same angle as spool (4) is rotated, the oil passage between sleeve (3) and spool (4) is closed so that the steering cylinder operation is stopped. Accordingly, gerotor (8) is rotated corresponding to the rotation of the steering wheel. Therefore the steering cylinders are operated corresponding to the rotation of the steering wheel.



 



Port R



Port L Overload Relief Valve



Relief Valve Make-Up Valve



Port T



1



8



Port P



Hydraulic Oil Tank



Steering Pump



7



4



2







3



T1F3-03-07-006



T3-7-6



COMPONENT OPERATION / Steering Valve Right Steering When the steering wheel is turned clockwise, the pressure oil from the steering pump as follows: Port P → Port R → Steering Cylinder The steering cylinders are operated so that the front wheel is turned to the right. The return oil from the steering cylinder flows back to the hydraulic oil tank via port L and port T.



T



L



R



P



 T487-03-02-010



T



In Neutral When the steering wheel is in neutral, the pressure oil from the steering pump is routed to port T on the steering valve. However, port P is blocked by spool (4) so that the pressure oil cannot flow to the steering cylinders. Then, the steering cylinders are inoperative.



P



4



 When Steering Pump Stops (When Engine Stops): When the steering wheel is turned to a certain angle, spool (4) touches pin (5), so that drive (7) rotates. Drive (7) rotates gerotor (8), and functions as the hand pump to send the oil to the steering cylinder. The oil is inhaled up from the tank port via the check valve. As results, the steering operation is performed even if the steering pump is completely stopped.







T



T487-03-02-011



Check Valve



4



  



T3-7-7



5



7



8



T1F3-03-07-002



COMPONENT OPERATION / Steering Valve RELIEF VALVE The relief valve is located in the steering valve, preventing the circuit oil pressure between the steering pump and the steering valve from increasing more than the set pressure. Thereby, oil leakage from hoses and pipe joints and damage to the actuators are prevented. Operation 1. The pressure oil from the steering pump acts on the poppet through the hole in the seat. 2. When the pressure oil from the steering pump increases more than the spring set-force, the poppet is unseated, allowing the pressure oil to flow to the hydraulic oil tank through around the outer diameter of the poppet.



3. Thereby, the main circuit pressure is reduced. 4. When the main circuit pressure is reduced to the specified pressure, the poppet is closed by the spring.  



 











         Relief Valve



 17.2 MPa Spring



Poppet Seat







Hydraulic Oil Tank



T1F3-03-07-010



Steering Pump







 T1F3-03-07-008



T3-7-8



COMPONENT OPERATION / Steering Valve OVERLOAD RELIEF VALVE



MAKE-UP VALVE



The overload relief valves are located in the steering valve, preventing the circuit oil pressure between the steering cylinders and the steering valve from increasing more than the set pressure.



The make-up valves are located in the steering valve. If the circuit oil pressure between the steering cylinders and the steering valve decreases below the pressure in the hydraulic oil tank, the make-up valve draws the hydraulic oil through port T to prevent cavitation.



Operation: 1. In case an external force is applied in the left steering direction as illustrated below, surge oil pressure is developed in the circuit. 2. If the circuit pressure increases more than the set pressure in the overload relief valve, the ball and holder in the overload relief valve are moved upward so that the pressure oil is routed to the hydraulic oil tank via the oil passage around the holder. 3. When the circuit oil pressure decreases, the ball and holder are moved downward by the spring force, closing the overload relief valve.



Operation: 1. If the circuit oil pressure between the steering cylinders and the steering valve decreases below the pressure in the hydraulic oil tank, the pressure oil from port T moves the ball in the make-up valve upward, allowing the pressure oil to flow into the circuit between the steering cylinders and the steering valve. 2. When the circuit oil pressure increases, the ball is moved downward by the pressure oil, closing the make-up valve.      



Steering Cylinder



Overload Valve



Relief Spring Holder



Steering Valve



Ball



22.6 MPa



Orifice



 T1F3-03-07-009



Make-Up Valve



  Ball







Port T



 



Hydraulic Oil Tank Steering Pump



 T1F3-03-07-007



T3-7-9



COMPONENT OPERATION / Steering Valve (Blank)  



T3-7-10



COMPONENT OPERATION / Brake Valve OUTLINE The brake valve is operated with the brake pedal and the brake switch (work brake). (Refer to the descriptions for the valve and work brake control in the Control System Group in the Brake Switch: System Section.) The brake valve delivers pilot oil pressure in proportion to the brake pedal stroke which in turn activates both the front and rear wheel brakes. In addition, when the brake switch is turned to the work brake position, the pilot pressure from solenoid valve unit (SG) shifts the brake valve so that the brake is constantly activated.



Brake Pedal



Brake Valve



 T1F3-03-09-001



T3-8-1



COMPONENT OPERATION / Brake Valve OPERATION x When the pedal is operated: Output Diagram: Range A to B (Neutral) 1. When brake pedal (1) is not stepped on, spool (10) is pushed toward the left by spring (12) via retainer (11). 2. Therefore, piston (13) is moved toward the left by spool (10). 3. Spool (7) is pushed toward the left by spring (9) via retainer (8) together with the reaction force of spring (14). 4. Thereby, the balance spring is pushed toward the left. 5. Push rod (2) and pilot piston (3) are held toward the left by balance spring (6) via retainers (4 and 15). 6. Accordingly, when neutral, spools (7 and 10) completely block the pressure oil flow from ports PA and PB. Since ports BA and BB are connected to port T through the outer diameter around spools (7 and 10), the oil pressure at ports BA and BB becomes equal to the tank port T pressure. 7. When brake pedal (1) is slightly stepped on, push rod (2) and pilot piston (3) are moved in so that push rod (2), pilot piston (3), retainers (4 and 15) are moved as one assembly, pushing return spring (5) and balance spring (6) toward the right. 8. As the pressure at ports BA and BB is equal to the port T pressure and the resultant spring force [springs (9, 12, and 14)] pushing spools (7 and 10) toward the left is less than balance spring (6) force, spools (7 and 10) are moved toward the right. 9. This condition is kept maintained until notches on spool (7 and 10) become connected to ports BA and BB.



T3-8-2



D Pilot Pressure



C A B Pedal Stroke



 T1F3-03-09-004



COMPONENT OPERATION / Brake Valve



 1







Port PP



3



2



5



4



7



6 Port BA



8



9



10 11 12



Port BB







 T1F3-03-09-002



15







Port T



14



Port PA



13



Port PB



 



2



1







5



4



3



6 Notch



7



9 Notch



14



15



10



12



 T1F3-03-09-002



 



Port BA (to the rear wheel brakes)



Port PP







1



Port BB (to the front wheel brakes)



12



 2







6



7



Port PA



14



10 Port PB



Port T



 1234-



Brake pedal Push Rod Pilot Piston Retainer



5678-



Return Spring Balance Spring Spool Retainer



910 11 12 -







T3-8-3



Spring Spool Retainer Spring



13 - Plunger 14 - Spring 15 - Retainer



T1F3-03-09-003



COMPONENT OPERATION / Brake Valve Output Diagram: Range C to D 1. When brake pedal (1) is further pressed, moving rod (2) and pilot piston (3), notches on spools (7 and 10) are connected to ports BA and BB, allowing pressure oil to flow in port BA and BB from ports PA and PB. 2. Oil pressure in ports BA and BB is routed into the inside of spools (7 and 10) through each spool hole, pushing each spool toward the left. 3. Until the force pushing spools (7 and 10) toward the left increases more than balance spring (6) force, balance spring will not be compressed. Therefore, spools (7 and 10) cannot move so that oil pressure in port BA and BB continues to increase. 4. As oil pressure in ports BA and BB increases further, the force pushing spools (7 and 10) toward the left increases. When this force overcomes balance spring (6) force, spools (7 and 10) compresses balance spring (6), causing balance spring (6) to move toward the left. 5. When spools (7 and 10) are moved toward the left, the notches are closed, blocking pressure oil flow to ports BA and BB from ports PA and PB. Thereby, oil pressure in ports BA and BB stops increasing. 6. As described above, balance spring (6) is compressed by the stroke of spools (7 and 10). During this operation, spring force increases in proportion to force to push spools (7 and 10). Oil pressure creating this force is equal to the oil pressure in ports BA and BB.



T3-8-4



D Pilot Pressure



C A B



Pedal Stroke



 T1F3-03-09-004



COMPONENT OPERATION / Brake Valve



 Port BA



 1







Port PP



3



2



6



Port BB



7



10







 T1F3-03-09-002



Port T







Port PB



Port PA



 



 



10



Port BB



Notch



From Port PB







10



Port BB



Notch



Hole







 T1F3-03-09-005



T1F3-03-09-006



  1 - Brake Pedal 2 - Push Rod



36-



Pilot Piston Balance Spring



7 - Spool



    



T3-8-5



10 - Spool



COMPONENT OPERATION / Brake Valve x When the work brake is operated: NOTE: The brake operates using the same mechanism as brake pedal (1) is stepped on except that the pilot oil pressure is routed from port PP. 1. The pilot oil pressure from port PP is routed into the pilot chamber in push rod (2) through the hole in push rod (2). 2. Then, the pilot oil pressure acts on the head of pilot piston (3). 3. When the pilot oil pressure force overcomes balance spring (6) force, pilot piston (3) is moved to the right. 4. While compressing balance spring (6) via retainer (15), pilot piston (3) moves pistons (7 and 10) to the right. 5. When spools (7 and 10) are moved until the notch on each spool is connected to port PA and port PB, the pressure oil is allowed to flow into port BA and BB from ports PA and PB. 6. Consequently, the brake is operated.



T3-8-6



COMPONENT OPERATION / Brake Valve



   1







6



Port PP



3



2



Port BA



7



Port BB



10







 T1F3-03-09-002



15







Port T



Port PB



Port PA



 



2







7



Pilot Chamber Port PP



Notch



10



Notch



 Hole







3



15



6



Port PA



Port PB



  1 - Brake Pedal 2 - Push Rod



36-



Pilot Piston Balance Spring



7 - Spool 10 - Spool



  



T3-8-7



15 - Retainer



T1F3-03-09-002



COMPONENT OPERATION / Brake Valve (Blank)



T3-8-8



COMPONENT OPERATION / Transmission Control Valve OUTLINE The transmission control valve consists of the parking brake solenoid valve, transmission changeover solenoid valve, reducing valve, and relief valve.



     



x Parking Brake Solenoid Valve



x Reducing Valve and Relief Valve



Operates when the brake switch is turned to the parking brake position so that the spool is moved to completely block the pressure oil flow from the pilot pump. x Transmission Changeover Solenoid Valve Operates when the travel mode switch is operated so that the spool is moved to change the travel mode control pilot oil port. (Refer to the SYSTEM / Control System group for Control of Parking Brake Solenoid Valve and Transmission Changeover Solenoid Valve.)  



 







A Parking Brake Solenoid Valve



Maintains the circuit oil pressure constant by reducing or relieving the pressure when the oil pressure from the pilot pump increases to more than the set-pressure.







(1.3MPa) Relief Valve



View A



Transmission Changeover Solenoid Valve



(3.4MPa) Reducing Valve



Reducing Valve



Relief Valve



 T1F3-03-03-002



Parking Brake Solenoid Valve



  



T3-9-1



 T1F3-03-03-001



COMPONENT OPERATION / Transmission Control Valve Component Layout 



9



11



10



 8 7



1 3.4 MPa



2



1.3 MPa



3



 5



6







T1F3-03-03-008



4



 12-



Port A (To Transmission Hi Side) Port B (To Transmission Low Side)



3-



Transmission Changeover Solenoid Valve) (S1) 4 - Parking Brake Solenoid Valve (S2)







56-



Port T (To Hydraulic Oil Tank) Relief Valve (R2)



7-



Port P (From Pilot Pump)



8-



Reducing Valve (R1)



A











E







9 - Check Valve 10 - Port DS (To Parking Brake Pressure Switch) 11 - Port S (To Accumulator)



View A







䋱



3



2



5



D



8 6



F B



F



C



 D



E



T1F3-03-03-002



4







T3-9-2



 T1F3-03-03-001



COMPONENT OPERATION / Transmission Control Valve 



View B







View C



4



3



3



4 6



8



7







 T1F3-03-03-004



10



 



Section D-D







T1F3-03-03-003



11



Section E-E



9



 T1F3-03-03-005



  T1F3-03-03-007







Section F-F







 T1F3-03-03-006



T3-9-3



COMPONENT OPERATION / Transmission Control Valve OPERATION







Reducing Valve (R1) 1. Spool (3) is pushed downward with spring (1) via spring seat (2) so that spool (3) comes in contact with plug (5). 2. The pilot pressure is routed to check valve (4) after passing through notch A and the internal passage. At the same time, the pilot pressure flows through orifice (6) and is routed to the bottom side of spool (3). 3. The pressure oil opens check valve (4) and flows further to parking brake solenoid valve (S2). 4. On the other hand, when the oil pressure acting on the bottom face of spool (3) increases more than the set-pressure of spring (1), spool (3) moves upward. 5. Then, notch B is connected to the internal passage. 6. Therefore, the pressure oil is routed into spool (3) through hole C provided at notch B. Then, the pressure oil flows to the hydraulic oil tank through spool (3) and hole D. 7. Consequently, the pressure oil acting on the bottom face of spool (3) is gradually reduced, causing spool (3) to be moved downward again by spring (1) force. 8. The oil pressure from the pilot pump is reduced as previously mentioned.



 1



Hole D



 



2



Notch A



3 To Parking Brake Solenoid Valve (S2)



From Pilot Pump



6



 Hole C







5



Notch B



4



T1F3-03-03-005



1







Hole D To Hydraulic Oil Tank



3 Notch B



 Hole C T1F3-03-03-010



 1 - Spring 2 - Spring Seat 3 - Spool



 



T3-9-4



4 - Check Valve 5 - Plug 6 - Orifice



COMPONENT OPERATION / Transmission Control Valve Parking Brake Solenoid Valve (S2) 1. When the brake switch is in the parking brake position. parking brake solenoid valve (S2) is not activated so that spool (2) is not shifted, blocking the reduced oil pressure from reducing valve (R1). The oil circuits in spools (1 and 2) are opened to hydraulic oil tank via holes on each spool and the valve internal passage. 2. When the brake switch is turned to another position from the parking brake position, spool (2) is shifted downward, allowing the notch to connect to the valve internal passage. 3. Then, the pressure oil is routed to spool (1) in transmission changeover solenoid valve (S1) through the valve internal passage. At the same time, the pressure oil flows to port S (to accumulator) and port DS (to parking brake pressure switch).







Parking Brake Solenoid Valve (S2)







Transmission Changeover Solenoid Valve (S1)



Hole Hole



2 Valve Internal Passage Port T From Reducing Valve (R1)



Port A Port B



1







T1F3-03-03-007



Port S Port DS (To Parking Brake (To Accumulator) Pressure Switch)



   



Parking Brake Solenoid Valve (S2)







Transmission Changeover Solenoid Valve (S1)



Notch Valve Internal Passage



2



1



Port T



From Pilot Pump



Port A Port B



 T1F3-03-03-007



   



T3-9-5



Port S Port DS (To parking Brake (To Accumulator) Pressure Switch)



COMPONENT OPERATION / Transmission Control Valve Transmission Changeover Solenoid Valve (S1) 1. Shift Lever: D (Hi) When the shift lever is in the D position, no signal is sent to transmission changeover solenoid valve (S1) so that spool remains unshifted. The pressure oil from reducing valve (R1) flows to port A (transmission Hi side) through around spool (1), shifting the transmission to the FAST mode. 2. Shift Lever: L (Low) When the shift lever is in the L position, spool (1) in transmission changeover solenoid valve (S1) is moved downward so that spool (1) blocks the oil circuit between port A and the valve inner passage completely. At the same time, the valve inner passage is connected to port B. 3. Then, the pressure oil flows to port B (transmission Low side) through around spool (1), shifting the transmission to the SLOW mode.



 



Parking Brake Solenoid Valve (S2)







Transmission Changeover Solenoid Valve (S1) Notch Valve Internal Passage



2



1



Port T



From Pilot Pump



Port A Port B



 T1F3-03-03-007



Port S Port DS (To Parking Brake (To Accumulator) Pressure Switch)



  



Parking Brake Solenoid Valve (S2)







Transmission Changeover Solenoid Valve (S1)



Valve Internal Passage



1



2



Port T From Pilot Pump



Port A Port B



 T1F3-03-03-007



  



T3-9-6



Port S Port DS (To Parking Brake (To Accumulator) Pressure Switch)



COMPONENT OPERATION / Transmission Control Valve Relief Valve (R2)







When the brake switch is turned from the parking brake position to other position, the pressure oil from the pilot pump is constantly routed to transmission changeover solenoid valve (S1), port S (to accumulator), and port DS (to parking brake pressure switch). 1. When the brake switch is turned to the parking brake position, spool (3) in parking brake solenoid valve (S2) is shifted, blocking the pressure oil from the pilot pump completely. 2. Then, the pressure oil stored in the accumulators flows to spool (2) in relief valve (R2) through port S and valve inner passage A. 3. When the oil pressure increases to more than set pressure [spring (1) force] in relief valve (R2), spool (2) moves upward while compressing spring (1). 4. Thereby, the hole on spool (2) is connected to valve inner passage B so that the pressure oil flows to port T (hydraulic oil tank) through valve inner passage B and spool (2). 5. Then, spool (2) is move downward again by spring (1) force. 6. Accordingly, the circuit pressure is maintained to the pressure set by relief valve (R2).



Accumulator







Parking Brake Solenoid Valve (S2) (Parking Position) S



Pilot Pump



To Parking Brake Pressure Switch Transmission DS Changeover Solenoid Valve (S1) (D (Hi) Position) To Transmission Hi Side



P



To Transmission Low Side



Valve Inner Passage A Relief Valve (R2) T Hydraulic Oil Tank







 T1F3-03-03-009



Parking Brake Solenoid Valve (S2)







Relief Valve (R2)



 



1



 3



Port T (To Hydraulic Oil Tank) Valve Inner Passage B



From Pilot Pump Port S (From Accumulator)



2



  



T3-9-7



Valve Inner Passage A



T1F3-03-03-006



COMPONENT OPERATION / Transmission Control Valve (Blank)



T3-9-8



COMPONENT OPERATION / Others (Upperstructure) PILOT SHUT-OFF VALVE The pilot shut-off valve is a manual-operated switch valve. The spool in the pilot shut-off valve is rotated by moving the pilot control shut-off lever to turn on or off the pilot oil flow to the pilot valves.



x When Pilot Control Shut-Off Lever is in UNLOCK



Position The pilot shut-off valve is set in the ON position. The pressure oil from the pilot pump to flow into the pilot valves as the drain circuit is blocked. If the control lever is operated, the pilot valve works.



NOTE: The pressure oil is constantly supplied to the travel pilot valve irrespective of whether the pilot shut-off valve is ON or OFF.



x When Pilot Control Shut-Off Lever is in LOCK



Position. The pilot shut-off valve is set in the OFF position. The pressure oil from the pilot pump does not flow into the pilot valves, but it is routed to the signal control valve. The pilot oil on the pilot valve side is routed to the hydraulic tank. The pilot valve does not work even if control lever is operated.



Section Z-Z



From Pilot Valve



A2



A1



To Signal Control Valve



 T178-03-07-002



Z



Z



T1



T2



T3



A3



A4



T4



P







A5



T178-03-07-003



A1 - Left Pilot Valve



A4 - Plug



A2 - Right/Blade/Stabilizer Pilot Valve A3 - Positioning/Auxiliary Pilot Valve



A5 - Signal Control Valve (Port PI) P - Primary Pilot Pressure



T1 - Positioning/Auxiliary Pilot Valve T2 - Left Pilot Valve T3 - Right/Blade/Stabilizer Pilot Valve







T3-10-1



T4- Hydraulic Oil Tank



COMPONENT OPERATION / Others (Upperstructure) SOLENOID VALVE UNIT This machine is equipped with the 4-unit solenoid valve for valve control and the 3-unit solenoid valve for pump control, the 2-unit solenoid valve (optional) for auxiliary flow rate control, and the 2-unit solenoid valve (optional) for blade/stabilizer control. (Refer to the SYSTEM / Control System group for regulation of each solenoid valve.)



SC



SE



SI



SG



Solenoid Valve Unit The solenoid valve unit consists of four (SC, SE, SI, and SG) proportional solenoid valves and controls the control valve, the check valve (axle lock cylinder), the travel motor valve and brake valve in response to the signals from the MC (main controller). SC : Controls the arm regenerative valve in the control valve. SE : Controls the check valve (axle lock cylinder). SI : Controls the travel motor displacement angle control valve. SG : Controls the brake valve.



 T1F3-03-10-017



Max. Pump 1 Flow Rate Shift Solenoid Valve



Max. Pump 2 Flow Rate Limit Solenoid Valve



Max. Pump 1 Flow Rate Limit Solenoid Valve



3-Unit Solenoid Valve (Pump Control) The 3-unit solenoid valve for pump control consists of the maximum pump 1 flow rate shift solenoid valve, the maximum pump 1 flow rate limit solenoid valve and the maximum pump 2 flow rate limit solenoid valve. Each solenoid valve is a proportional type solenoid valve and controls the pump flow rate in response to the signals from the MC. NOTE: Although the maximum pump 1 flow rate shift solenoid valve is the proportional type solenoid valve, it is used as the ON/OFF solenoid valve.  T1F3-03-10-016



T3-10-2



COMPONENT OPERATION / Others (Upperstructure) 2-Unit Solenoid Valve (Auxiliary Flow Rate Control) (Optional) The 2-unit auxiliary flow rate control solenoid valve consists of the auxiliary flow combiner solenoid valve and the auxiliary flow rate control solenoid valve. The auxiliary flow combiner solenoid valve is an ON/OFF type solenoid valve and shifts the control valve auxiliary flow combiner valve in response to the optional switch operation. The auxiliary flow rate control solenoid valve is a proportional type solenoid valve and shifts the auxiliary flow rate control valve in response to the signals from the MC.



Auxiliary Flow Combiner Valve



Auxiliary Flow Rate Control Solenoid Valve



 T1GL-03-10-002



Blade/Stabilizer Solenoid Valve



2-Unit Solenoid Valve (Blade/Stabilizer Control) (Optional) The 2-unit solenoid for blade/stabilizer control is an ON/OFF type solenoid valve and opens the check valve (blade/stabilizer) when the signal arrives from the control switch.



 T1F3-03-08-001







T3-10-3



COMPONENT OPERATION / Others (Upperstructure) Proportional Solenoid Valve Upon receiving an electric current signal from the MC, the proportional solenoid valve outputs hydraulic pressure proportional to the degree of the electric current. • When not energized (In neutral): 1. Spring (2) pushes spool (1) to the right, connecting the output port S to the tank port T.



T



S



P



1



• When energized: 1. Solenoid (3) pushes spool (1) to the left for a distance proportional to the electric current flowing through solenoid (3). 2. Pilot oil from port P flows into output port S, increasing the pressure at output port S. 3. The pressure at port S acts on the two banks of walls on spool (1). (See detail “a.”) Because of the pressure receiving area difference between the two walls, the pressure at port S acts as a force to push spool (1) to the right. 4. As the pressure at port S increases, the force to push spool (1) to the right also increases. When this force overcomes the force to push spool (1) to the left by solenoid (3), spool (1) moves back to the right side, closing the passage between output port S and port P. As a result, pressure increase at port S stops.



2



3



a



a



 T107-02-07-005



T3-10-4



COMPONENT OPERATION / Others (Upperstructure) ON/OFF Solenoid Valve The ON/OFF solenoid valve is used to switch the pilot pressure by switching the brake switch and each control switch.



• When not energized (In Neutral): Spool (1) is pushed to the right by spring (2). Output port S is connected to tank port T. • When energized: As solenoid (3) energized, spool (1) is pushed to the left. Pilot port P is connected to output port S, and the tank port T is blocked.



3 P



S



T



 1



1 - Spool



2 - Spring



2



T105-02-11-010



3 - Solenoid



T3-10-5



COMPONENT OPERATION / Others (Upperstructure) TRAVEL SHOCKLESS VALVE The travel shockless valve is located between the travel pilot valve and the signal control valve, preventing the travel spool from quickly returning so that the occurrence of cavitation in the travel motor is reduced. In addition, the travel shockless valve is provided with two solenoid valves, one each in the forward and the reverse circuits to restrict travel operation. (See the SYSTEM / Control System group.)



• Shockless Operation: 1. The return oil from the control valve is routed to port B1 or B2 on the travel shockless valve via the signal control valve. 2. As the return oil closes check valve (3), the return oil is routed to orifice (4). When the return oil passes the orifice, the differential pressure is developed. 3. Then, the return oil flows back to the hydraulic oil tank after passing through spool (2) in the solenoid valve and the travel pilot valve. 4. Therefore, the travel spool in the control valve is slowly returned.



Travel Pilot Valve



1



1



2



A2



A1



T



Hydraulic Oil Tank



3



3



4



4 B2



B1



Travel Shockless Valve From Signal Control Valve



• Travel Operation Restriction:



2



1. When the solenoid valve is magnetized, spool (2) compresses spring (1) while moving downward. 2. Spool (2) completely blocks the pressure oil flow from port A1 or port A2. 3. Consequently, even if the travel pilot valve is operated, the travel system cannot be operated. The return oil from the signal control valve flows to port T (hydraulic oil tank) through around spool (2) at this time.



T1GL-03-10-006



Travel Pilot Valve



1



1



2



A2



A1



2



T



Hydraulic Oil Tank



3



3



4



4 B2



B1



Travel Shockless Valve From Signal Control Valve



T3-10-6



T1GL-03-10-007



COMPONENT OPERATION / Others (Upperstructure) a







a1



Port T (To Hydraulic Oil Tank) Check Valve



Check Valve



b



b







Port B2



a



 Shockless Operation 



Port B1



a1



T1F3-03-08-004







Crosse Section b-b



Cross Section a-a, a1-a1



2 2 3



2 4



4



B2







From Signal Control Valve



To Travel A Pilot Valve







B1



T1F3-03-08-006



From Signal Control Valve







 Travel Operation Restriction







Cross Section a-a, a1-a1







T1F3-03-08-005



3



Cross Section b-b



 2



2 2 Port T (To Hydraulic Oil Tank)



4



4



From A Travel Pilot Valve



 1



B2 T1F3-03-08-005



T3-10-7



From Signal Control Valve



B1 From Signal Control Valve



 T1F3-03-08-006



COMPONENT OPERATION / Others (Upperstructure) PILOT RELIEF VALVE







The pilot relief valve consists of the relief valve and the check valve. The relief valve maintains the pilot circuit pressure constant. The check valve blocks the return oil from the accumulator.







A



 T1F3-03-08-008



 Section A







Check Valve



• Relief Operation: 1. The pressure oil from the pilot pump acts constantly on the pilot relief valve spool. At the same time, the pressure oil acts on the bottom of the spool through the hole in the spool. 2. When the oil pressure force overcomes the spring force, the spool is moved upward while compressing the spring. 3. Accordingly, the pressure oil is returned to the hydraulic oil tank.



From Pilot Pump



 T1F3-03-08-003



 



Relief Valve







Spring



To Hydraulic Oil Tank



From Pilot Pump



 Hole



 



T3-10-8



Spool



T1F3-03-08-002



COMPONENT OPERATION / Others (Upperstructure) ACCUMULATOR The accumulators are provided in the pilot circuits for the brake valve, the pilot relief valve, and the transmission control valve. The accumulator is charged with high pressure nitrogen gas. The oil pressure from the pilot pump compresses the nitrogen gas via the film. The compressed gaseous nitrogen maintains each circuit oil pressure constant.



Nitrogen Gas



Film



 T1F3-03-08-007



From Pilot Pump



T3-10-9



COMPONENT OPERATION / Others (Upperstructure) ACCUMULATOR CHARGING VALVE







The accumulator charging valve is located between the pilot pump and the brake valve circuit. The accumulator charging valve functions to give the pressure oil priority to flow to the brake circuit and simultaneously charges the accumulator in the brake circuit with the pressure oil. In addition, after charging the accumulator, the valve allows the pressure oil to flow to the pilot circuit. (Refer to the SYSTEM / Hydraulic System group.)



      



9







• Charging Pressure:



To Pilot Relief Valve



8



To Pressure Sensor



N



S1 S2



NOTE: Usually, the pressure oil from port P opens compensation plunger (8) so that the pressure oil flows to port N. 1. When the oil pressure in the brake circuit (accumulator) is reduced, the pressure oil from port P is routed into the sleeve through orifice (5). Then, the pressure oil flows to spool (1) through around check valve (6), holes on sleeve (10), and passage (3). 2. The pressure oil is routed onto the end face of compensator plunger (8) through around spool (1) and passage (9). 3. Then, compensator plunger (8) is moved downward, blocking the oil flow to port N. Thereby, the oil pressure in port P gradually increases. 4. When the oil pressure in port P overcomes spring (7) force, the pressure oil opens check valve (6) so that the pressure oil flows to port S2. 5. As mentioned above, the pressure oil flows to the brake circuit and simultaneously starts charging the accumulator.



Pilot Pump



To Brake Circuit (Accumulator)



P



10 1



7



T



6



5







4



Hydraulic Oil Pump



3



2  T1GL-03-10-003



  S2 P



  T1GL-03-10-003



 12345-







T3-10-10



Spool Spring Passage Passage Orifice



678910 -



Check Valve Spring Compensator Plunger Passage Sleeve



COMPONENT OPERATION / Others (Upperstructure) 







2



4



T



1



N



9



3



8



7



7



S2



S2



5







P







Hole



1 - Spool 2 - Spring 3 - Passage



10 6 4 - Passage 5 - Orifice







P



T1GL-03-10-008







67-



T1GL-03-10-004



6 Check Valve Spring



T3-10-11



8 - Compensator Plunger 9 - Passage 10 - Sleeve



COMPONENT OPERATION / Others (Upperstructure) • Stopping to Charge (Holding) Pressure: 1. When the charged pressure in the accumulator reaches the saturation pressure (cutout pressure), the pressure in port P increases again. 2. The pressure oil acts on the poppet in the piston. When this pressure overcomes spring (2) force, the poppet and spool (1) are moved to the direction of arrow. 3. When the notch on spool (1) is connected to passage (9), the oil pressure in passage (9) [pushing compensator plunger (8) downward] flows to port T through the notch on spool (1). 4. Therefore, the pressure oil in passage (9) becomes equal to that in port T, allowing the oil pressure in port P to open compensator plunger (8) so that the pressure oil flows from port P to port N. 5. Accordingly, the oil pressure in port P is reduced to lower than port S2. Then, spool (1) is again moved to the direction of arrow by spring (2) force, blocking the oil flow from passage (9) to port T. 6. At the same time, check valve (6) is closed so that port P is disconnected from port S2. 7. Consequently, the oil pressure in the brake circuit (accumulator) is maintained.







9







To Pilot Relief Valve



8



To Pressure Sensor



N



S1 S2 To Brake Circuit (Accumulator)



P



Pilot Pump



1



7



T



6







5



4



Hydraulic Oil Tank



3



2







T1GL-03-10-003



  N S2



T



 T1GL-03-10-005



12345-



T3-10-12



Spool Spring Passage Passage Orifice



6789-



Check Valve Spring Compensator Plunger Passage



COMPONENT OPERATION / Others (Upperstructure) 







2



4



2 1



T



T N



9



N



1 Notch



9



Poppet



8



Piston



8



3 7 S2



S2



5







P







Hole



123-



Spool Spring Passage







P



T1GL-03-10-009



6



T1GL-03-10-010







6 45-



Passage Orifice



67-



Check Valve Spring



T3-10-13



89-



Compensator Plunger Passage



COMPONENT OPERATION / Others (Upperstructure) HOSE-RUPTURE SAFETY VALVE The hose-rupture safety valves function to hold the front attachment in position if any hose for the front attachment is punctured accidentally. The hose-rupture safety valves are attached to the bottom side of the boom cylinder, the rod side of the arm cylinder, and the rod side of the positioning cylinder. NOTE: The following explanation will be made about the hose-rupture safety valve for the boom cylinder as an instance.



Chamber a Passage c



Passage b



• Hose-rupture safety valve operation when the control lever is in neutral. 1. Because the pilot pressure Pi does not act on the spool, the spool remains in neutral. 2. The cylinder-holding pressure at the cylinder port B is applied to the poppet and to the spool through passage c. 3. The cylinder-holding pressure, after passing through passage c, is blocked by the spool. The pressure in the chamber a is applied to the spool through passage c, but not transmitted to passage a by blocking with the spool. 4. As a result, the cylinder pressure at cylinder port B is maintained unchanged. Therefore, even if any hose at the front attachment is punctured, the front attachment is held in position to avoid unintended lowering.



T3-10-14



Pilot Pressure Pi Port B Port A



To the Spool in the Control Valve



Poppet



Spool Setting : Passage a 8 kgf/cm 2



T178-03-07-006



COMPONENT OPERATION / Others (Upperstructure)       



X



Section X-X



Passage a



Passage b



Spool Passage c Chamber a



Poppet



Port A



Port B







X



T178-03-07-008



  



T3-10-15



COMPONENT OPERATION / Others (Upperstructure) x Hose-rupture safety valve operation when the boom



lower control lever is operated 1. When moving the boom lower control lever at half stroke or less, the pilot pressure Pi acts on the spool, and makes the spool move to the orifice B position. 2. At this time, the spool blocks passage B, so that the poppet is pushed against the seat. 3. As a result, the pressurized oil from the port B flows through passages c and a in order to lower the boom. 4. When moving the boom lower control lever at half stroke or more, the pilot pressure Pi acts on the spool, and makes the spool shift to the orifice C position. 5. Then, passages b and a are connected through orifice C. At this time, an oil passage, from port B to orifice A to chamber a to passage b to orifice C to passage a to port A, is opened. 6. The oil from passage c is blocked by the spool, so that the oil does not flow into passage a. 7. The pressure in the chamber a lowers, and the poppet rises accordingly, so that the return oil from the cylinder port B flows into port A through the poppet to lower the boom.



 The Boom Lower Control Lever: Half Stroke or less 



Relief Valve



Chamber a Passage c Passage b







Orifice A Poppet



Pressure Pi Port B



Spool



Port A To the Spool in the Control Seat Valve







 Passage a



Orifice B T178-03-07-009



   The Boom Lower Control Lever: Half Stroke or More Chamber a Passage c Passage b







Relief Valve



Passage A



Orifice C Pressure Pi



Port B



Spool Port A



  



T3-10-16



To the Spool Poppet in the Control Valve



Passage a



 T178-03-07-007



COMPONENT OPERATION / Others (Upperstructure)       



Section X-X







X



Relief Valve Passage a



Orifice B



Spool



Pressure Pi



Orifice C Passage c



Passage b Chamber a Spring Orifice A



From Port B Poppet Port A



Port B







X



T178-03-07-008



   



T3-10-17



COMPONENT OPERATION / Others (Upperstructure) EC MOTOR Output Gear



The EC motor is used to control engine speed. A worm gear is incorporated into the EC motor to prevent a loss of synchronism from occurring. The EC sensor is provided to detect the degrees of the EC motor rotation to calculate the governor lever position. (Refer to the Control System Group in SYSTEM Section.)



Output Shaft



Worm Gear



Motor



  



Sensor Gear



EC Sensor



Worm Wheel T157-02-05-018







T3-10-18



COMPONENT OPERATION / Others (Undercarriage) SWING BEARING This bearing is a single-row shear ball-type bearing, comprising outer race (1), inner race (3), balls (6), supports (5), and seals (2), (4). Outer race (1) is bolted to the upperstructure and inner race (3) is bolted to the undercarriage.



The internal gear of inner race (3) engages with the output shaft of the swing reduction gear.



1



2



5



3



4 6



    T135-03-02-001



1 - Outer Race 2 - Seal



3 - Inner Race 4 - Seal



5 - Support



T3-11-1



6 - Ball



COMPONENT OPERATION / Others (Undercarriage) CENTER JOINT



 



The pressure oil flows through the spindle to each port on the body. Then, the pressure oil is routed to the travel motors, the transmission, the front and rear wheel brakes, the check valve (blade/stabilizer), the steering cylinders, the 2-unit solenoid valve (blade/stabilizer), the stabilizer cylinders, and the blade cylinders. 9



 15







Spindle



10 11



1



3







4 8 5



14 13



2



7



12



5



Body



6



9



3 Seal



14



8 4 1



6



2



10



7 Seal



12



11



13



 T1F3-03-10-001



   1 - Port 7: Travel Motor Displacement Angle Control Pilot Pressure 2 - Port 9: To Left Steering Cylinder 3 - Port 3: To Blade/Stabilizer Cylinder Rod (Raise) Side 4 - Port 6: To Axle Lock Cylinder 5 - Port 1: To Blade/Stabilizer Cylinder Bottom (Lower) Side



6-



Port 8: To Right Steering Cylinder



7-



Port 11: Transmission Hi Mode Shift Pilot Pressure 8 - Port 5: To Travel Forward 9-



Port 2: To Travel Reverse



10 - Port 10: Check Valve for Axle Lock Cylinder Control Pilot Pressure



 



T3-11-2



11 - Port 14: Transmission Low Mode Shift Pilot Pressure 12 - Port 12: To Rear Wheel Brake 13 - Port 13 To Front Wheel Brake 14 - Port 4: Check Valve for Blade/Stabilizer Cylinder Control Pilot Pressure 15 - Port D: To Hydraulic Oil Tank



COMPONENT OPERATION / Others (Undercarriage) SLIP RING







The slip ring is installed on the upper part of the center joint. The slip ring is a joint which rotates 360°. When the upperstructure rotates, it transmits the current to the undercarriage while preventing the wiring from twisting. Also, it transmits the detected figures from sensors installed on the undercarriage to the upperstructure.























Center Joint



















Slip Ling



  Spindle



 T1F3-03-10-015



 T1F3-03-10-014







  



T3-11-3



COMPONENT OPERATION / Others (Undercarriage) (Blank) 



T3-11-4



COMPONENT OPERATION / Others (Undercarriage) CYLINDER







The axle lock cylinders, the stabilizer cylinders and the blade cylinders are mounted on the track frame. Each cylinder consists of the cylinder section and the check valve section.



      







Axle Lock Cylinder



Check Valve



A







Blade/Stabilizer Cylinder



 



B



B



 B



B







A



Check Valve T1F3-03-10-004 T1F3-03-10-005







Section A-A



 



Section B-B



 Check Valve



T1F3-03-10-002



   Check Valve



 



T3-11-5



T1F3-03-10-003



COMPONENT OPERATION / Others (Undercarriage) Check Valve (Axle Lock Cylinder) • When releasing the axle lock: 3. Consequently, the pressure oil in both right and left axle lock cylinders can move freely between them and to the hydraulic oil tank, allowing the axle lock cylinders to oscillate.



NOTE: When the brake switch is turned OFF, the solenoid valve unit (SE) is activated. (Refer to the SYSTEM / Control System group.) 1. When the solenoid valve unit (SE) is activated, the pressure oil from the pilot pump is routed into port P of the check valve so that the pressure oil acts on the piston, causing the piston to move to the right. 2. The piston pushes the poppet and the check valve to the right, connecting port A (axle lock cylinder) to port T (hydraulic oil tank).



NOTE: The reaction loads from the travel road surface are absorbed by oscillation of both right and left axle lock cylinders. (Refer to the SYSTEM / Control System group.) 







Check Valve



 T P



Axle Lock Cylinder



A



Solenoid Valve Unit



Pilot Pump



Solenoid Valve Unit (SE)







Hydraulic Oil Tank



T1F3-03-10-008



 Piston







Check Valve



Poppet



Check Valve



P



T Pilot Pump Hydraulic Oil Tank



A



Axle Lock Cylinder



 T1F3-03-10-006



T3-11-6



COMPONENT OPERATION / Others (Undercarriage) • When operating the axle lock: 2. As long as the check valve is kept opened, the oil pressure in port A is equal to that in port T. Thereby, the poppet and the check valve in the check valve is moved to the left by spring force. 3. Therefore, port A (axle lock cylinder) on check valve is disconnected from port T (hydraulic oil tank). 4. Consequently, The pressure oil is enclosed in the axle lock cylinder so that the axle is locked.



NOTE: When the brake switch is in the work brake, parking brake, or axle lock position, the solenoid valve unit (SE) is deactivated. (Refer to the SYSTEM / Control System group.) 1. The pressure oil from the pilot pump is blocked by the axle lock solenoid valve spool.  



Check Valve







T P



Axle Lock Cylinder



A



Solenoid Valve Unit



Pilot Pump Solenoid Valve Unit (SE) Hydraulic Oil Tank



 T1F3-03-10-009



Piston



Check Valve



Poppet



P



Spring



Check Valve



T



A Axle Lock Cylinder



Hydraulic Oil Tank



 T1F3-03-10-011



T3-11-7



COMPONENT OPERATION / Others (Undercarriage) Check Valve (Blade/Stabilizer Cylinder) • When operating the blade/stabilizer: NOTE: When the blade/stabilizer control switch is operated, the 2-unit solenoid valve (blade/stabilizer) is activated. (Refer to the SYSTEM / Control System group.)



2. The piston pushes the poppet and the check valve to the right, connecting port V to port C. 3. Then, the pressure oil from main pump 1 flows to either the rod or bottom side of blade/stabilizer cylinder via port V and port C on the check valve, causing the cylinder to extend or retract.



1. When the blade/stabilizer 2-unit solenoid valve is shifted, the pressure oil from the pilot pump is routed to port P on the check valve so that the piston is moved to the right.







Blade/Stabilizer Cylinder



2-Unit Solenoid Valve



C



P



Pilot Pump Hydraulic Oil Tank



Check Valve



V







Main Pump 1



T1F3-03-10-010



 T



Blade/Stabilizer Cylinder



Hydraulic Oil Tank



C



Check Valve P



V Check Valve



Piston Pilot Pump



Main Pump 1



T3-11-8



Poppet



 T1F3-03-10-007



MEMO ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... .......................................................................................................................................................................



MEMO ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... .......................................................................................................................................................................



Hitachi Construction Machinery Co. Ltd Attn: Publications, Marketing & Product Support Fax: 81-298-31-1162



Hitachi Ref. No.



SERVICE MANUAL REVISION REQUEST FORM NAME OF COMPANY:



MODEL: PUBLICATION NO.:



YOUR NAME: DATE: FAX:



(Located at the right top corner in the cover page)



PAGE NO.: (Located at the bottom center in the page. If two or more revisions are requested, use the comment column)



YOUR COMMENTS / SUGGESTIONS: Attach photo or sketch if required. If your need more space, please use another sheet.



REPLY:



(Copy this form for usage)



G E A R B O X D IA G R A M 2 H L -1 0 0 M A N U A L G E A R B O X W IT H S H IF T IN T E R L O C K - O F F -R O A D S P E E D



T A B L E - 8 L E G E N D :



M E A S U R IN G =



M A S H S Y C O L U R E B L L E S U = = = = = = = =



N U A L T R A IF T IN T E R L S T E M P R E S N T R O L P R E B R IC A T IN G T U R N F L O W E E D IN G A K A G E O IL C T IO N L IN E



N S M O C K S U R S S U O IL IN



IS S IO N E



=



=



= S



K =



=



P R P R S U A N



E S E S C T D



S U S U IO G E



M =



=



R O A O F F P U M A N D



D S P -R O A P P R G E R



E E D E S A



D S P E E D S U R E F O R S H IF T IN T E R L O C K B O X L U B R IC A T IO N



T O T H E T A N K



C O N T R O L C IR C U IT



C O N N E C T IO N S : M E A S U R IN G P O IN T IN T E R F A C E O N T H E T R A N S M IS S IO N B L E E D E R



L IN E S : B



= L



R E S H IF T IN T E R L O C K



S Y M B O L S : =



J



P O IN T S :



R E L I R E L I N L IN A R B O



N E N E E F X



F R O M F R O M O R R O L U B R I



S H S H T O C A



IF T I IF T I R P U T IO N



N T E R L O C K T O M U L T I-D IS K B R A K E N T E R L O C K T O M U L T I-D IS K C L U T C H M P (C O N T R O L P R E S S U R E - S H IF T IN T E R L O C K )



N



E



P 1 = P 2 = =



=



P R E P R E L E A C O N



S S U S S U K A N E



R E P R E P G E O C T IO



O R T O R T IL C N IN



R O A D O F F -R O N T R O D U C T I



S P O A L C V E



E E D D S P E E D IR C U IT T R A N S M IT T E R (O P T IO N A L )



S H IF T IN T E R L O C K



M A N U A L T R A N S M IS S IO N M K



B



J



N P 2 P 1 L



C H E C K V A L V E



T H R O T T L E C H E C K V A L V E S



G E A R S H IF T P IS T IO N N O N -R E T U R N C H A N G E -O V E R V A L V E



B L E E D E R M U L T I-D IS K B R A K E



R E S E R V O IR



M U L T I-D IS K C L U T C H



D IS E N G A G E M E N T D E V IC E



L E A K A G E C H E C K V A L V E



P R E S S U R E L IM IT IN G V A L V E



H Y D R O -M O T O R



E O IL S U P P L Y T R A N S M IS IO N C O N T R O L



M U L T I-D IS K B R A K E



S O IL S U P P L Y M A N U A L G E A R B O X



O U T P U T



O U T P U T



L U B R O T T R A S H IF S C R E E N F IL T E R : F IL T E R A R E A : G R A D E O F F IL T R A



R IC A T I N S M T IN



A T O N IS T E



IN G IN S IO R L



O V E N O C



IL P U M P W IT H S E N S E O F R S IO N F O R O IL S U P P L Y A N D C O N T R O L P R E S S U R E K



a b o u t 1 2 5 c m T IO N : a b o u t 2 0 0 m y



2



RETURN



RETURN



RETURN



Attach to Vol. No. : TTCBBE-00



ZAXIS 160W CHASSIS HARNESS



CAUTION: Parts numbers on the drawing are provided only for reference purpose. To order parts on the drawing,be sure to consult the Parts Catalog.



F-O/R-SOL/V PLUG



R-SOL/V



F-SOL/V



CONNECT



Z03F-GY



Z03F-GY



Z03M-GY ASSEMBLE CAMPTY PLUG



2 872



3 981



1



3



2



871



874



982



F-O/R-SOL/V PLUG Z03M-GY ASSEMBLE CAMPTY PLUG



1 873



C 0(



C



YAZAKI RV03FB



490(COT)



60



809



874



873



872



871



8



7



6



5



140(COT)



320(COT)



0(



899



59



870



981



0( C



1



29



2



O T)



260(COT)



Z08M-GY 3



COLOR



60



0.5



YR



SLIP RING-2



809



0.5



W



SLIP RING-1



870



0.5



B



SLIP RING-4



DRAIN PRESSURE SENS. -3



871



0.5



R



SLIP RING-5



O/R F-SOL/V-1



872



0.5



G



SLIP RING-6



O/R F-SOL/V-2



873



0.5



Y



SLIP RING-7



O/R R-SOL/V-1



874



0.5



RW



SLIP RING-8



O/R R-SOL/V-2



899



0.5



RY



SLIP RING-3



DRAIN PRESSURE SENS. -1



980



0.5



B



N SENSOR -2



981



0.5



B



O/R F-SOL/V-3



982



0.5



B



O/R R-SOL/V-3



FROM



TO



T) O



SIZE



C



NO.



SPPED SENS



COMMENT



Z02F-GY



DRAIN PRESSURE SENS. -2



N SENSOR -1



870 CHASSIS GND 981



260(COT) 10



SLIP RING



4



CONNECT



12



870



0(



60



TRAVEL MOTOR DRAIN PRESSURE SENSOR



12



899



O T)



3



O T)



2 1



1



2 980



809



CHASSIS GND



RETURN



RETURN



RETURN



RETURN



RETURN



Attach to Vol. No. : TTCBBE-00, TTCDBE-00



ZAXIS 160W/210W ELECTRICAL CIRCUIT DIAGRAM (OVERLOAD ALARM) CAUTION: Parts numbers on the drawing are provided only for reference purpose. To order parts on the drawing,be sure to consult the Parts Catalog.



18



10A



GL



B C 0.85B A



C-5



7 6



K



5 L



BZ 1 BUZZER



RB



W



0.85G



0.3WG



0.3WB



4



1



OVERLOAD ALARM



2



OVER LOAD



2



5



2



C20



7



3 RELAY



1



3



A14



6



RB 0.3W



0.3W



A15



0.3WB



RB



GL



0.3WB



GW



0.3WG



9



DIODE



5



0.3WG



A



B



L



DIODE



A



B



8



K



B



3



GL



0.85R



4



2 1



B



0.85GL



1



3



0.85R



2



4



POWER UNIT



0.85GL



1



2



3



A28



B21



B19



BOOM BOTTOM SENS.



OVER LOAD ALARM



SENS_GND



+5V



PUMP1 PRESS.



MAIN CONTROLLER



C16



S



+



-



CANCEL SW



MONITOR



RETURN Attach to Vol. No. : TTCBBE-00, TTCDBE-00



ZAXIS 160W/210W ELECTRICAL CIRCUIT DIAGRAM



CAUTION: Parts numbers on the drawing are provided only for reference purpose. To order parts on the drawing,be sure to consult the Parts Catalog.



LY BrB



GLOW RELAY



+ -



SPERKER-R #4361302



+ -



SPERKER-L #4361302



3BY



REAR COMB. LAMP(R)



REAR COMB. LAMP(L) #*******



#*******



TAIL 10W STOP 25W TURN 25W



TAIL 10W STOP 25W TURN 25W



3B



GLOW PLUG



4 0.85RW



0.85RW



RB



RB



5



3



2



1



4



ENG HARNESS



CHASSIS HARNESS



2



R3



STOP LAMP #4436534 4



R18



SEAT COMPR



1



2



2



OPT.3(BATT)



OPT.1(ALT)



OPT.2(ALT)



AIR CON.



POWER ON



1.25WR



SOLENOID



SW BOX



E.C.MOTOR



WY



CONTROLLER



1.25BrR



1.25W



2RY



BrW



YG



B-12



RB



B-13



BrB



C-16



2G



BrW



B-15



2



3



5



1



2



R4



1



YL



LG



B-14



YB



C-1



LAMP2 #4436534 3



5



1



2



1 2



3



4 5



6



GL



A



1



R27 4 5



3



2



1



D24



R30



K



2



7



WL



8



O



2



CHANGE 8'



GL



B



D23



CHASSIS FRAME



1



A



1



MISSION CHANGE #4436534



R20



K



D19



4



2



3



5 2



K



B



0.85G



GW



AXLE LOCK #4436534



R19



5



3



2



1



1



JAPAN



12



11



3



1



9 10



4



5



6



7 8



K



D7



1



LY



LY



A



C-12 C-9



B LgW



A



E



0.85L



L



0.85B



WY



2B



0.85W



2Br



RY



BL



BR



RW 3



2



1



4



2



S



1



3



4



-



DIAL A/I,A/A MODE SW



WR



2



WG



WG



3



WR



-



WB



4



WB



A/A



LY



9



L



A/I



L



8



OrB



6



OrL



A



SUB/H ONLY 200W



BrW



Y



+ S -



C-13



RY



C-14



BL



Lg



0.3BW



0.3BW



2Br



R



1



2



BrW 14



1 OFF



BrY



GW



0.3G



0.3GW



P



0.3Br



L



0.3Y



G



G



2



L



P



A



GyL



P Or



1 2 3



ENG CTL MODE SW



11



GR



RW



DIAL GY



0.3Lg



12



R



1



B



15



1.25B



BrY



A 3



BrW



2 5 3



4



ASSIST



1 2



GLIP(R)SW-C = POWER DIG.SW



CAP



POW DIG.



COMBINATION SW #4462366



F/V



LOGIC



0.3B



J-3



0.85R B



4



2



5



1



3



PARKING ALARM #4436534



1



3



4



R23



3



1



TRAVEL(F) Pi CUT #4436534



3



1



R24



TRAVEL(R) Pi CUT #4436534



R25



1



3



2



1



4



3



RB



5



0.3W



2



RB



4



0.3WB



5



0.3B



2



0.3WG



4



GL



5



0.85B



2



0.85R



4



B



5



GB



MOTOR ALARM #4436534 2



G PL



B



3



0.85B



1



GR 0.3YG



0.3B



RG



3



RG



1



RG



3



RG



1



B



3



W



0.85B 0.85R B



RG



1



GB



B



WASHER #4436534



R6 WIPER A #4436534



R9



WIPER-B



BrW



WIPER-A



LG



WASHER



YB



R7



WIPER B-3 #4436534



WIPER B-1 #4436534



R8



2



5



4



2



5



4



4 BrB



BrG



BrY



5



2



4 BrR



7 6 C



5



4



3



POWER UNIT 1



2



1



1



2



3



4



5



6 7



5



2



REMOTE OUT



CTS



BACKUP



RS232C GND



RTS



RXD(RS232C)



INFORM SW CONNECT SW



TXD(RS232C)



R



W A1



A14



D5



BP



Br D3



Or B14



Lg



BL B6



B13



B5



WY



RW



BR A6



B4



LW A7



A17



WAKE UP GND



WAKE UP



RXD



TXD



GND BW



R L B2



B3



B10



LY



W



D11



C10



B9



D21



A9



D8



D6



D19



D17



G



W



CAB/H



A5



PUMP2 FLOW SOL/V



PUMP1 FLOW SOL/V



A4



A22



ENG/H



D14



D4



SOLENOID GND ON/OFF GND STEP/M GND



8



5



9



6



7



PB 0.3WL 12 13 14



1



2



3



4



5



8 10 11



MAIN POWER KEY-ON SIGNAL SOLENOID POWER STEP/M POWER T/M RPM SENS. T/M DRAIN SENS.



B15



MISSION H/L SW



C10



NUTRAL SW WORKING BRAKE SW



PUMP3 PRES.SENS.



POWER DIG SW



A26



TRAVEL ALARM



A27



SWING ALARM OVER LOAD ALARM



A29



Tr-Pi CUT (F)



A30



Tr-Pi CUT (R)



A31



MOTOR ALARM



A32



PARKING ALARM



ATT_MODE2 ATT_MODE1



C11



10



R



2



LgY



LgY



21



G



1



P



P



22



L



2



Or



Or



23



Or



1



OrB



OrB



24



Gr



2



W



19



W



1



SHIELD



B



B



20



B



2



Br



Br



13



Br



1



Or



Or



14



Or



3



R



R



15



R



2



16



Y 0.85RY RW 0.85BY WG



0.3WR



C7



C13



1



RW



2



6



BY



3



R



1



O



2



2



RG



0.3RG



C1



4



RY



8



1



YB



0.3YB



Y



5



3



GY



0.3GY



C4



0.3WPu



C15



Y



4



A14



A24 A9



ARM FLOW SOL/V



A10 A15



T/MOTOR q SOL/V



A16



OIL-TEMP SENS.



C24



TRAVEL(R) PILOT SENS.



C23



SWING PILOT SENS.



ARM CROUD PILOT SENS.



BOOM UP PILOT SENS.



Gr



2



B



3



R



1



L



2



B



3



R



1 2



2



Y



Y



1



WG



WG



2



LOr



W



1



LW



G



2



LgB



L



1



LgR



Lg



2



LY



A



OVER LOAD



SWING ALARM



0.3BR



0.3R



0.3RB



0.3BL



ARM DUMP PILOT SENS.



WR



WY



1



RY



R B



2



GB



GB



4



PL



PL



1



B



2



Y



1



3



POWER UNIT 2



WIPER B-2 #4436534



B



D16 RW



7



BR



1



LG



11



G



2



LB



9



W



1



LR



10



R



2



LgY



21



G



1



P



22



L



2



23



RW



1



24



B



2



W



19



W



1



B



20



B



2



Br



13



Br



1



Or



14



Or



3



R



15



R



2



Y



16



PUMP TORQUE



SB



PUMP2 FLOW



SA



PUMP1 FLOW



SOLENOID/V ST



PUMP TORQUE



SB



PUMP2 FLOW



SA



PUMP1 FLOW



#4400442



SOLENOID/V



PUMP1 MAX-Q +



REVOLUTION/S



-



#4265372



A A B



STEP/M EC MOTOR ASSY



B #4360509



+ S



ANGLE/S



+ S + S



PUMP1CTL PRES. PUMP2CTL



K



A A



A



2



Y



4



0.85RY



5



RY



1



RW



8



RW



2



0.85BY



6



BY



3



R



1



O



2



WG



1



PRESSURE/S(LOW) #4436536



YB



2



+ S



RG



PUMP1 PRESS.



-



PRESSURE/S(HIGH)



+



#4436271



S



PUMP2 PRESS.



GY



3



4



+ S



PRESSURE/S(HIGH) PUMP3 PRESS.



Y



SE



AXLE LOCK



SG



WORKING BRAKE



SOLENOID/V #*******



SC



ARM FLOW



SI



1



TEMPERATURE/S



2



B



3



R



1



WL



2



B



3



R



1



Gr



2



B



3



R



1



L



2



B



3



R



1



Y



25



#4436271



-



1



WY



2



BY



3



RY



1



WG



2



BY



3



RY



1



BR



2



BY



3



RY



1



R



2



BY



3



RY



1



RB



2



BY



3



RY



1



BL



2



BY



3



+ S



3 1



LgW



2



Y



1



WG



2



W



1



G



2



L



1



Lg



2



JOINT_CON (WATERPROOF)



TRAVEL(F) PILOT



S + S + S -



TRAVEL(R) PILOT SWING PILOT FRONT PILOT



+ S + S -



ARM CROUD PILOT BOOM UP PILOT



JOINT_CON



CAP TRAVEL



TRAVEL(F) Pi CUT TRAVEL(R) Pi CUT



DIFFERENCE IN 200W *POWER DIG.SOL/V *AXLE LOCK SOL/V



+



SHOCKLESS/V #*******



PRESSURE/S(LOW) #4436535



2



B Lg



#4250260



RY



PUMP MOUNT



SOLENOID/V



PRES.



1



ATT.



LY



SOLENOID/V ST



BY



0.3GB RW



1



B



0.85BY



C2



3



R



LgW



ATT.PILOT SENS. ATT.FLOW SOL/V



B



3



0.3WG



C5



2



1



0.3WY



C21



WL



B



0.3LY



C14



1



RW



0.85RY C17



3



Y



25



0.3BY



TRAVEL(F) PILOT SENS.



B R



Lg



BOOM BOTTOM SENS.



C9 B14



A17



LR



0.85BY



A23



FRONT PILOT SENS.



A18



LR



GERMANY SW



A28



C12



1



PARKING BRAKE SW



B11 C20



C16



W



RW



A11



WORKING BRAKE SOL/V



2



9



JOINT_CON (WATERPROOF) POWER DIG SOL/V



1



G



LB



0.85RY



C18 B22



PUMP2 PRES.SENS.



BR



LB



Y



D5



PUMP1 PRES.SENS.



11



W



D13



D3



PUMP2CTL PRES.SENS.



7



LG



#*******



A19



D2 STEP/M DRIVE



LY



LG



Y



ILL COLUMN BOX #*******



PUMP/H



#*******(PUMP MOUNT)



A21



PUMP1 MAX-Q SOL/V



LY



TO OPPOSITE OUTSIDE OF CAB C



T/A CANCEL SW Y



BrB



PL



WIPER-C



B



L8



R2 P-BOX



200W( ENABLE) OTHERS(DISABLE)



GL



D20



R22



L9



L10



L11



L12



L13



L14



L15



L16



L17



L5



REGULATOR



GL



0.3B



TURN R



NUTRAL



TURN L



T/M 2nd



BOOM LAMP



OPT



MOTOR ALM



AUX 1



T/M 1st



GND



AUX 2



LAMP GND



BUZZER IN



BUZZER OUT



GND(A)



AXLE LOCK



POWER(IGN)



WORKING



CLEARANCE



BRK.PRESS.



UPPER BEAM



PARKING



TURN R



TURN L



OFF



A/L



PRAK



WORK



HORN



3



ENG/H



B



BUZZER



L1



6



BZ



BRAKE SW



L2



AUX 1/2



6



HORN SW



L3



4 3 5



HAZARD SW



GW



3



HEAD LAMP SW



L4



2



L6



WIPER & WASHER SW



GR



GW



A A 1



QUICK HITCH



A



TURN SW



#4411058



A



1



1



WASH



L7



0.3G



G



B



L



0.3RL



BrR



0.3Y



0.3RL



0.3Y



B



P



G



L



A



BrR



MISSION SW



BUZZER



U



SERVICE BRK.



L



II



WIPER ON



I



R



ON



WIPER 5V



N



INT



8



WIPER GND



INT



1



7



WIPER OUT



2



6



SPEED V



5 P



GND(C)



4



GND(A)



3



HAZARD



2



SPEED SENS



4



1 OFF



SM



3



9 10 11 L



BRAKE SENS



2



12 13 14 15 16 17 18 OFF



BPM



1



5



WIPER INT1



1



4



WIPER INT2



2



3



WIPER COMMON



GLIP(R) 3



2



GND(A)



1



K



BR



GY



GR



200W( ENABLE) OTHERS(DISABLE)



B



D-5



D-10



D-3



D-12



D-4



D-11



D-2



D-9



D-1



C-5 D-7



D-8



H-2



H-1



C-4



C-6



B-3



B-5



B-9



B-2



B-7



A LR



D18 B-8



I-1



C-2



B-4



C-1



C-3



CABLAMP FRONT +2



1



N



D5



LY



2



GY 2



RG



B



LW



CAB LAMP REAR



L



1



0.3B



GB



GR



CAP



GERMANY



RG



B



LB



PAT LIGHT



RY RB



0.85RG LgW



D10



RG



GB



2



0.85RG



B



1



0.3WB



GL



RG



GB GL



RL



0.3Or



0.3G



0.3GB



0.3Y



0.3RL



Br



R



B



YL



RW



R



0.3GR



L



RG



R



BY



GL



Y



GR



W



WY B-6



I-5



I-2



I-8



I-9



I-3



I-6



B-1



E-2



E-5



E-3



E-6



G-1



F-1



A-2



A-6



K I-7



A



2



0.3WG



BrB



RG



0.3Y



0.3BW



0.3Br



0.3RY



YW



BR



Gy



GB



P OrB



2 K



B-10



B-4



A-1



A-4



A-3



B-5



B-1



B-6



B-7



B-8



1



B-9



3



1



BrR



A 3



GL



A



5



B-3



3 A 6



GLIP(R) SW-C



2



A 1



B



D13 E-4



1 A



GLIP(L) SW-C



B



B



D14



A-5



GLIP(R) SW-B



G-2



0.3Y



0.3R



0.3G 0.3WG



0.3WG



1



PUMP/H



5



A3



CREEPER MODE SW



D1



B9 B3



0.3BR



K3



2



PUMP HARNESS



MAIN GND



C19 C3



0.3WPu



0.3G



1



ENG HARNESS



C



ENG. PULSE



PEDAL EC SW



A2



0.3GY



0.3BR



0.3Lg 0.3L



Br



G



W



B



B GLIP(L) SW-B



A1



0.3Y



0.3WPu



D15



0.3Y



GLIP(R) SW-A



F-2



GLIP(L) SW-A HEATER UNIT (OPT)



C31



1.25BrW



0.3Y



A



K



3 4



WORK MODE SW



B24



BrW



0.3YR



A



B13



B17



BrY 1.25BrR



0.3RY



2



E MODE SW



B7



0.3YR



2



B2



D6



0.3RY



A



HP MODE SW



A25



WR



1K



B6



A13



1.25BrW



B



AUTO IDLE SW



A12



0.3Or



B



B16



GND



0.3BrW



0.3BrW



A



0.3Or



0.3LB



YR



YG



Lg



0.3BW



4



2



A20



B8



YG



NO TURNING POINT BECAUSE OF UNDER THE FLOOR



SENS_GND



B25



Or



D11



+5V



AUTO ACCEL SW



B18 C



YR



A



TXD0 EC DIAL



B12



C8



0.85B



R B



0.3GY



4



A 0.3GY



C



A 1



D9



0.3LB



1



D17



1.25BrR



W



5



PUMP1CTL PRES.SENS.



0.3W K



ML SW



B21



B4



Or



W 2



4



C



13



GR



ILL.



BrR



D12



CAB HARNESS



B20



PEDAL



Lg



A



3



EC ANGLE SENS.



2



1



A



GLIP(L)



C6



W



7



YW



E



BW



Br



AIR-CONDITIONER UNIT



3



B19



P



HP,P,E MODE SW



D22



D21



1 2



SUN/S #4405814



LIGHT SW



G



1



D10



OFF HP



BrY



0.3Y



SERVICE BRAKE PRESS.SW #4459497



2



B



+



5



3



REGULATER



POWER-ON WG



WIPER



K



D6



B10



RW



+



2



C



2



5



S



A



J-1



3 4



SW-BOX



ENG CONTROL



WIPER-MOTOR #4430922



WY



AIRCON



DIRECT ENG



ONLY PROT



A6



0.3RL



AIRCON SEN



1



M



A



BL



BRAKE REMAIN PRESS.SW #4459498



FLASH MEMORY



Dr.EX



PUMP TORQUE SOL/V



Or



RY



C



A/A LED CUT #4436534



1



0.3GW



C.B.



0.3YR



B



6



A



ENG



B



R26



SW BOX #4462381



WB



RY



BrY



R



Br



G



2



G



C



3



W



3B



B



13



C



Y



4



O/R CTL



3



RG



2



4 5 MISSION



2



FRONTWINDOW OPEN : ON



NORMAL OPEN



0.3GW



W



NEUTRAL SGN. #4436534



1



C



4 R



C-10



3



P



NORMAL CLOSE



0.3Y



LY



RW



5 CAP A



BUZZER



A 3



A A 1 3



2



1



0.85Y



2



B-5



LEARNING SW #4359384



WWES #4387837



BW Lg



0.85R



R21 4



3



A A



SLIP RING #4462363



ENG/H



3



Or P



S



1



5 2



B-3



M



4 GL



Or



C-8



Br



MISSION



BW



C-11



ML SW



7'



B-4



LB



H/L SW



1



Lg



BW



LW



BOOM BOTTOM SENS.



Y



BZ



ENG OIL PRESSURE SW #*******



0.3Br



Or



CONTROLLER MAIN POWER



6



2



2



RL



0.3L



0.3L



B-2



B



WR 1



17



0.3OrB



B-1



A 1



POWER ON



6'



FUEL/S #4257128



J-3



MBES



R



PARKING BRAKE 3 #4436534



J-3



RL



Lg



B



ML TXD0



2



A-16



WR



WR



P



GW



Tr-Pi CUT (F)



2



2



CAP



5



1



#*******



3



R-SOL/V



4



5 2



4



RL



R11 1



2



BR



B



Tr-Pi CUT (R)



F-SOL/V



RL



2



MISSION CTL/V



L



5



1



POWER



5'



3 CAP



RW



PARKING BRAKE



OrB



WR



0.3BW



BACK LAMP POWER



B



BACK LAMP



R



4



GND(A)



1



1



3



4'



GND(C)



3



MAGNET CLUCH



AIR/S



3'



2



A-15



P



B



1



H/L SW CON.



-



NUTRAL SW CON.



S



H/L SW N



+



MOTOR DRAIN PRESS.



PRESSURE SW BODY



A-14



Gr



GY



0.85R



R



0.85B



PARKING BREAK 1 3 #4436534



A-12



WB



C-5



RW PARKING BREAK 2 3 #4436534



RL



GL



Gr



2



0.85W



H/L SW L



1



H/L SW H



2' 2



B



B



18 C-6



L



SPEED/S 0.85WR



2



WATER TEMPERATURE/S #4436537



WWMO



WR



BrW



4 BY



BACK_UP.



B-11



RW



OPT.



3



5



1



R17



1



OPT.3



W



1



RY



RB BW



LAMP1(BOOM) #4436534



SLIP RING 1'



1



GR RW



4



3



2



2



SEAT HEATER



1



M4 B



R14



R13



WORKING INDI. #4436534



5 ENGINE



HEAD LAMP R #4436534



WB



GyL



WB



1 M4



Br



WB



GyL



A-7



GL



1



Br



WB



GW



3



4



Br



B-6



P



1



5 2



GB



B-7



WB



0.3B



2



4



HEAD LAMP L #4436534



C-7



Br



C28



3



G



GB



0.3WG



E F



5



OVER HEAT SW #4371318



O/R OUT



3



A-11



AIR CLEANER SW #4334759 (200W #4224238)



2



BL



C27



4



B-8



C26



L



R29



CAB HARNESS 0.85RW



BL



B



M4



RL



0.3B



0.85RW



AEX LY



OIL FILTER SW(OPT)



GL



0.3BW



W



RADIO #4333195



A



WL



B5



ENG HARNESS



R



UPPER BEAM #4436534



CAB/H



1



ENG.PROGRAMING SW



2



ENG/H



J-3



MAIN CONTROLLER



2



RB



C-4



0.3BP



5



L



D-5



0.3BL



4



M10



FRAME



GL



D-4 YW G



OPT.4 1



A-13



YR



0.3B



1



GL



R12



R28



CAB



W



B1



2



1



5B



M6



LR



D11



3



2



GND(C) CAB EARTH1



CAB EARTH2



D-2



Dr.EX RXD1



3



3



M8



FROOR



M10



Dr.EX CONNECT SW



2



1.25BrW



AUXILIARY



ROOMLAMP



LIGHTER



RADIO



WIPER



HORN RW



LAMP



POWER UNIT



O/R CTL



ASIST CTL



OTHER



COLUMN BOX



BACK LAMP



HEATER 2Br



LY



3RG



BrR



CONNECTOR



GR



1



5



M8 GND(A) FROOR



W W



D-3 B-16



W



D12



4



4



CLEARANCE L #4436534



4



9 10



6



C



Dr.EX TXD1



1



8



0.3BG



0.85RG



2



7



4



5B



RG



0.85RG



3



2



ICX CONTROLLER #9194416



0.3L



R



5



C-15



G LR



A CLEARANCE R #4436534



4



1



C10:MCX COMMUNICATE GND D11:DIGITAL GND



0.3GR



R



BrY



1



5



JOINT-1



Y



D-1 W



LIGHTER #4184395



GR



2



3



SATELLITE/PC



B9:MONITOR COMMUNICATE GND



0.3WB



B M6



5



CAB HARNESS



MONITOR HARNESS



0.3WG



M6 E



0.85WG



ACG



A



MONITOR HARNESS



1.25B ANT #4280527



GND



3



ROOM LAMP #4187082



2Br



LAMP 1



GR



5



A CONNECTED



RW



LAMP 2



GL



GR



RY



A



0.3BW



6



C



0.85B



0.85R



R



GLOW RELAY #4452159



A-6



5



GY



OPT.2(ALT)



GL



GR



RB



ALTERNATOR



BW



A



OPT.1(ALT)



GL



4



BrR



R15



LY



HORN #4198639



G



1



A TURN L #4436534



STOP LAMP



2 (LO)



0.85B



TURN L R



B



UPPER BRAM



3



YL



BOTH MALE



E



1.25GY



5



GL



0.85B



HORN SIDE



L 4



YB



TURN R #4436534



HEAD LAMP R



R16



1.25GB



0.85RG



0.85RG (HI)



CLEARANCE R



FLASHER #4413974



GW



1



AUX 2(ALT)



3



AUX 3(ALT)



5 2



QUICK HITCH



4



CAB LAMP FRONT +2



HORN #4436534



CAB LAMP REAR



R5



AV 2RL



JAPAN LAMP



CAP



CAB HARNESS



D3 K



WARNING LAMP



70WX3



HORN #4198638



A



1



0.3Br



2



R1



0.85RY



3R



A



SUB/H



3



R



3



A-5



1



3



MAIN GND



SEAT COMPR



(BOOM)



0.85 RW



1.25B



Br



3



1 2



MAIN



Pu



2



1.25BW



BODY



0.3Y



POWER



OPT.3(BATT)



E R



ANTI LOADDUMP #4436534



0.85RG



E



2



RL



1



SUB/H



R



0.3WB



A-4



LR



Pu



L



M



0.3WR



A-3



B



LB



A-2



Y



WL



B



0.85 RG POSITION LAMP



5



0.85RG



8W S



1



3 1



SEAT HEATER



-



2



WR WB



A



GR B



J-2 A



3



R



ALT B



3



GL



S



D1 5



WL



C-2



WR RL



2



SAFETY./R



A-8



R



ACC LOAD 3RW



HEAD LAMP L



S



1.25BW



ALT L



4



1.25GB



+ A



A



C



B



R10



ENG START 1 #4436534



WG



RY



CLEARANCE L



A



ENG/H



WASHER #4133585



PARKING BRAKE PRESS.SW #4459499



Y



B



G 3



3



2



B



1



25W 12W



1



SAFETY Ry



C



5RL



5RB



5RL



5RB



SAFETY Ry



+ S



BRAKE PRESS.



0.85B



INCLUDED STARTER



C STARTER



TURN 25W



G



M



STARTER



UPPER 75W



12W 25W 5W



M5 C



CLEARANCE 12W



A-1



GW



2RB



ALT B



4



-



A



M10



Y



M



UPPER 75W



HEAD 70W



LY C



J-2



BATT. + J-2



3RB



A



ALT L



K



GW



TURN 25W



CAB/H



FROM OPOSITE OUTSIDE OF CAB



#4436271



2B



60B B



BODY



M10



HEAD 70W



CLEARANCE 12W



STARTER ASS'Y B



K



C-3



B



6



BATT. +



D2



0.85RY



E M4



5



GY J-2



0.85RG



A M8



FUSIBLE LINK(65A) #4423418



STARTER ASS'Y 200W BODY



#*******



4



A-9



GL



ALT B



#*******



3



ICX Dr.EX



W



GW



B1



ALT L



5W



PRESSURE/S(HIGH)



2



A-10



A2



LY



FRONT COMB. LAMP(R)



W



A12



LY 5W 3B FRONT COMB. LAMP(L)



B-10



1.25BW



S



#4255762 FRAME



BATT./R



M4



BATTERY RELAY



M10



BATT. +



1.25B



M8 B



1



BATTERY 12V X 2 #4199874 #4431289(200W)



GLOW RELAY



3R



1.25BW



60R



2



60R



GY 2RW



B-9



GR



C3



2RB



2RW



YG



START 1



GY 3R



FUSIBLE LINK(45A) #4315323



MONITOR



CAB



ON



A5



6



C11



3



G



1



4



GR



2 A



BrB



A



A26



K



C12



5



D4 L G



60B



CAB



WG



PARKING FREE



2



MONITOR



ACC



1



WATER TEMPERATURE SW(ENG) #4404303



STARTER SW #*******



OFF



OUTSIDE OF CAB



INSIDE OF CAB



BL



A25



CAP



PC



GR



H



A13



QOS CONTROLLER #4452160



A24



INSIDE OF CAB



A11



OUTSIDE OF CAB



FUEL PUMP



G G ACC M ST



B



AXLE LOCK



#4462432



REVOLUTION/S



+ -



#4265372



A A B



STEP/M EC MOTOR ASSY



B #4360509



+ S



ANGLE/S



+ S + S



PUMP1CTL PRES.



PRESSURE/S(LOW)



PUMP2CTL



#4436536



PRES.



+ S



PUMP1 PRESS. PRESSURE/S(HIGH)



+ S



#4436271 PUMP2 PRESS.



+ S



PRESSURE/S(HIGH) PUMP3 PRESS. #4436271



SG



POWER DIG.



SE



WORKING BRAKE



SC



ARM FLOW



SOLENOID/V #4400477



SI



RETURN



Attach to Vol. No. : TTCBBE-00, TTCDBE-00



ZAXIS 160W/210W ELECTRICAL CIRCUIT DIAGRAM (BLADE/STABILIZER) 1



2



SW MAIN 1



2



3



4



3



SW F/R



5



1



2



3



4



5



6



SW R/L 1



ON



FRONT



LEFT



OFF



ALL



ALL



OFF



REAR



RIGHT



CAUTION: Parts numbers on the drawing are provided only for reference purpose. To order parts on the drawing,be sure to consult the Parts Catalog.



2



3



4



5



SELECT E



SHORT/H 5 BL



SHORT/H 1 R-O/R



4



3 A



SHORT/H 2



4



3



R-O/R



B 1



2



1



2



C 1



4



D 2



3 SHORT/H 4



SHORT/H 3



R-BL F-BL



D2 RELAY 1



2 K



D1



2 K



D4



2 K



D3



2 K



4



FRONT RIGHT 3



5



A A



A A



A A



A A



1



2



3



3



3



3



1



1



1



1



RELAY 2 FRONT LEFT 3



4



1



Y



5



2



W



1



2



3



L



4



GB



RELAY 3 4



REAR RIGHT 3



5



1



2



O/R OUT



RELAY 4 4



REAR LEFT 3



5



5



RW



1



2



4



Y



3



G



2



R



1



LY



6



B



O/R CTL C



SOL3



SOL2



M1



X



MA



P3



P2



T



P



D



A4



A3



A2



A1



P



A2



A



SOL1



S



P1



PD



T



Pic



Pi1



A5



B5



SC



5 14 11



Forw Low Hi



7



12



13



2



Back



6



9



8



10



5 SW L



3 ARM OUT



PD2



SWING



A1



a1



SB



B



DS



Pi



DY



A



4BG1-TC



12



SI



S A



L



DK



B'



PRIM.ARM



Dr2



SK



T



P



SE



T4



DD



T3



SC



T2



DE



Dr



A6



1



G



A1 PI



SEC.BOOM



T



A2



B4



A4



up



T



T



A



A



B



B



P



P



DH



T



T



A



A



B



B



P



P



1



7



6



5



4



3



2



T2



TO 3



PI3



1 BM UP



8 BKT OUT



11 Back



SJ



A4



A3



B3



A2



B2



DK



A1



B1



P1



V



V



V



Dr



A1



4 D D



3 D D



1 D D



D D



7



12



D



13



11



14 5



2



6



10



9



8



J 11 Dr



Dr



Dr P



Dr



P



P



Dr



V



V



V



P



P



Dr



P



P



Dr



P2



T



1



Dr



60



32



30



7'



6'



5'



4'



3'



2'



B3



A3



5



B2



A2



3



B1



A1



S1



T



Pi



A



10



B C



B1



9



A1



N



DG



PP



P



A2 B2



V



1



DS



S



M



P1



a3



Pi2



DC



SEC.ARM



A10



P1



T



P



X



P2



P1



Dr



PF



1



T



2



S2



V



V



V



CO



B



Dr



P



Dr



P



P



Dr



B'



TO MAIN C/V



A'



C'



B'



P1



A



PF



TO PTO VALVE



P



1



A



SOL.2



Red./V 1



B3



A3



P2



A9



T3



2



V



3



B



P



B1



Dr1



IN



4 ARM



PRIM.BOOM



BUCKET



TRAVEL



T



Dr



P



Dr



P



P



Dr



14



13



Dr



3



4



1



1



3



3



4



down



S0L.1



PD1



6 SW R



PI2



2 BM DWN



7 BKT IN



14 AUX A



Red./V 2



a2



SL



MB



A3 PE



DF B



10



SG



9 B6



SP



E



DG



PH A2



PB



I



PA



4



M



PF



A5 M



K



A



SA



Pi



D



B



SN



TO 1



3



Dr



C



PI1



2 S3



T



B



DY



SH



SY



A



13 AUX B



SE



AUX



8



A7



H



AUX 2



7 D



B7



6



10 AUX A



G P2



AUX B



F



12 Forw



P



SM



9



5 SK



13



SM



1



E P1



A1



A



4



M



T



P



2



up



BLADE, OUTRIGGER down



30



J



T1 14



A8



3



Att.



N



SN



T



T



IN



61



B1



P



BUCKET OUT



10



A2



1



UP



12



B8



3



BOOM DOWN



Y



B2



1



L



60



B



4



SWING



10



A



B1



T



R



12 31



B



B2



P



OUT



Z



A



T



2



ARM



9



SPEED PICUP



L



1



IN



11



P2



P



A1



T



F



9



P1



T



A2



P



TRAVEL



11



L



R



2



R



T



V



V



V



A



B



6



P4



4



2



S



B'



PP



61



33



31



PA



Pi



P5



P4



P3



P2



P1



P



T



T P



A



DG



A



Dr



PB



PA



T



B



PP



Pi



BB



BA



P



2 O/R + BL



4 O/R



B2



B



A1



B1



A2



A



B



P



D



T



P2



P1



RETURN



Attach to Vol. No. : TTCBBE-00



ZAXIS 160W HYDRAULIC CIRCUIT DIAGRAM (FULL OPTION) NOTE: Refer to the perrformance standard table in the Technical Manual for the set pressure of each relief valve.



Dr



P V



P V



SOL3



SOL2



T



P



D



A3



A2



P



T



Pic



Pi1



T2 5 14 11



Hi



7



12



13



2



Low



6



Forw



a1



SB



9



A1



Dr2



SK



8



10



PD2



SWING



PRIM.ARM



1



Back



4BG1-TC



5 SW L



3 ARM OUT



PI1



SEC.BOOM



AUX



T



A2



B4



A4



up



1



1



B



PD1



B3



A3



A



SOL.2



Red./V 1



P



B1



Dr1



4 ARM IN



P2



DS



S



M



A9



T



A



P1



a3



Pi2



DC



B



PRIM.BOOM



BUCKET



P



DH



T



T



A



A



SEC.ARM



B



B



P



P



1 BM UP



7



6



5



4



3



2



1



T2



TO 3



8 BKT OUT



11 Back



SJ



A4



A3



B3



A2



B2



DK



A1



B1



P1



13 V



V



S3



4 D D



3 D D



1 D D



D D



7



12



D



13



11



14 5



2



6



10



9



8



Dr



Dr



P



Dr



P



Dr P



P



Dr



P



X



V



V



P



T



TO PTO VALVE



60



7'



6'



5'



4'



3'



2'



N



T



B1



A1



1



Dr



S1



2



T



Pi



B



B1



A1



P1



A



CO



S



B'



A2 B2



V



V



Dr



P



P



Dr



FOR 1 OPTION



PTO VALVE



S2



P2



P1



Dr



PILOT CHANGE VALVE



SOLENOID "DE"



TO VALVE CONTROL



2P BOOM



1



up



BLADE, OUTRIGGER down



Dr



P



P



Dr



9



3



3



4



1



1



3



3



4



down



S0L.1



Red./V 2



a2



6 SW R



PI2



2 BM DWN



14 AUX A



7 BKT IN



A10



SHUTTLE VALVE



Dr



M1



X



MA



P3



P2



A1



SI



SE



A5



B5



SC



A6



B6



TO 1



DY



SY



13 AUX B



10 AUX A



T3



2



SM



A



SOL1



S



P1



A4



TRAVEL



T



P



B



PD



Pi



DS



A



DY



S



DK



B'



SC



P



DD



A2



DE



Dr



PE



T4 V



T



A3 PI



SG



DF



AUX 2



SL V



G



DG



9



E



PF



10



PB



I A



11



B



K



PA



J SK



P



SM Dr



MB



A1 M



12



A



4



Pi



L S3



M



B



SA



Dr



D 12 Forw



SE



A7



SN



9 AUX B



1



13



B7



SP



A8



3



B8



C



B



2



T



T3 M



B



SW/MO



SH



A8



A



RELIEF VALVE



8



TO C/V T3



T



H



B1



6



A1



7



A2



G



SM



5



SN



F



B8



4



14



TO C/V



2



E



B2



3



Att.



M



TO OIL TANK



T



IN



N



10 AUX A



P



BUCKET OUT



7 P



J



T1



A5 6



B



PH 5



CONTROL VALVE



1



UP



14



2P BOOM



4



BOOM DOWN



61



POSITIONING CYL.



2



L



10



VALVE HOLDING



1



SWING



Y



A



B1



A1



T



R



10 60



B



B2



A2



P



OUT



12



A



T



3



ARM



12



SPEED PICUP



L



1



IN



11



P2



P



T



F



9



L



T



P



TRAVEL



Z



11



P1



R



2



R



T



V



V



A



10



9



14



13



2



B'



P



P1



61



PA



Pi



P5



P4



P3



P2



Dr



PB



PA



T



BB



BA



PP



4 O/R



REAR BLADE



B2



B



A1



B1



A2



TO MAIN C/V Pi



Pi



T



P2



P1



RETURN



Attach to Vol. No. : TTCBBE-00



ZAXIS 160W HYDRAULIC CIRCUIT DIAGRAM (STANDARD) NOTE: Refer to the perrformance standard table in the Technical Manual for the set pressure of each relief valve.



Dr



P V



P V