‘SEBM021U0101 SHOW IMTANINTOA\I Ls KOMATSU PC28UU-1 MACHINE MODEL SERIAL No. PC28UU-1 1001 and up ‘specifications are subject to change without notice. 00-1 ®CONTENTS 10 STRUCTURE AND FUNCTION .......0....... 20 TESTING AND ADJUSTING .. 30 DISASSEMBLY AND ASSEMBLY ........000.0.00.... cee 40 MAINTENANCE STANDARD .......00 0... 021U01The affected pages are indicated by the use of the following marks. It is requested that necessary actions Mark Indication Action required, ‘must be taken to these pages according to the list below. © | Page to be newly added Add © | Page to be replaced Replace (1 | Page to be deteted Discard Pages having no marks are those previously revised or made additions. LIST OF REVISED PAGES van row Seon Yu row 00 Ja aw Ratan won ae noise umber ‘number number aoa) ~ © 00-1 oO ° eo02 o | o 2 m2 OD | 0-11 5 oo-t2 S oO ee090 10-1 ° 10-2 ° 10-3 10-4 10-5 10-8 10-7 10 10-9 c 10-10 0-11 10-12 10-13 10-14 10-15 10-16 10-17 ° 10-18 10-19 ~~ 10-20 10-21 10-22 10-23 10-24 10-25 10-26 o2iuot ooo oo0 ooc00 SO99e00008G000000 2 20-1 ° 20-2 20-3 20-4 20-5 20-6 20-7 50600 loo 00.2.1 @A IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this ‘manual are both effective and safe methods of operation. Some of these operations re- quire the use of tools specially designed by Komatsu for the purpose. To prevent injury to workers, the symbols Lb, and “A are used to mark safety oe- cautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider sofety. and take the necessary actions to deal withthe situation A SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1.Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing Always wear safety glasses when hitting parts with a hammer. « Always wear safety glasses when grinding parts with a grinder, etc. 3.|f welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4.When carrying out any operation with two ‘or more workers, always agree on the op- erating procedure before starting, Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5.Keep all tools in good condition and learn the correct way to use them. 6.Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. ‘Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for ‘smoking. Never smoke while working PREPARATIONS FOR WORK 7.Before adding oil or making any repairs, ark the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving, 8.Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them 9.When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine, If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing 00-3PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug ‘or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing compo- ents of the oil, water or air circuits, first remove the pressure completely from the cirouit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. ‘Wait for the oil and water to cool before car- rying out any work on the oil or water circuits, 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (—) terminal first. 14,When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- ternal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires, 18. As a general rule, do not use gasoline to wash parts. In particular, use only the mini- mum of gasoline when washing electrical parts. 00-4 19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. «When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the ma- chine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines ‘When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track.FOREWORD. This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of ‘components; these chapters are further divided into the following sections. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section, DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. NOTICE subject to change at any time and without any advance notice. Contact your KOMATSU distributor for the fest information. 00-5HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as a guide to carry- ing out repairs. They are divided as follows: Chassis volume: Issued for every machine model Issued for each engine series Each issued as ‘one volume to cover all models Engine volume: Electrical volume Attachments volume ‘These various volumes are designed to avoid duplicating the same information. Therefore to deal with all repairs for any model, it is neces- sary that chassis, engine, electrical and attach- ment volumes are ready. DISTRIBUTION AND UPDATING ‘Any additions, amendments or other changes will be sent to KOMATSU distributers. Get the most up-to-date information before you start any work FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples shows how to read the page number. Example 1 (Chassis volume) 10-3 Item number (10. Structure and Function) |___ Consecutive page number for each item. Example 2 (Engine volume): 12-410 4 Unit number (1. Engine) tem number (2. Testing and Adjusting) Group No. (4. Fuel system) \— Consecutive page No. (Page 10 of Group 4) 3. Additional pages: Additional pages are in- dicated by a hyphen (-) and number after the page number. File as in the example. Example: 10-4 12-203, 10-4-1 12-203-1 10-4-2 }~Added pages L 12-203-2 10-5 12-204 00-6 REVISED EDITION MARK (Q@@-~) When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages. REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page. ‘SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Syne] Tem = Speci safety procavtons are A eeccoey itn porting the won Safety Extra special safety precautions ‘are necessary when performing the work because itis under internal pressure, Special echnical precautions or ther precautions fr Ik | caution | preserving standards are Reoessery when porfonming the work [Weight of parts or systems, Caution necessary when Weight | selecting hoisting wire, or when working posture is important, ete. ignten. | laces that require special Sz (|, 1ighten: | attention for the tightening 19 torque} torque during assembly Places to be coated with Coat | adhesives and lubricants ete. Places where oil, water or fuel Oil, water | must be added, and the capacity Places where oll or water must be drained, and quantity tobe drained, wie | DrainHOISTING INSTRUCTIONS HOISTING INSTRUCTIONS Ay Heavy parts (25 kg or more) must be lifted with a hoist etc. In the Disassembly and Assembly section, every part weigh- ing 25 kg or more is indicated clearly with ‘the symbol Ce 1. If 2 part cannot be smoothly removed from the machine by hoisting, the following checks should be made: * Check for removal of all bolts fastening the part to the relative parts. * Check for existence of another part causing interference with the part to be removed, 2. Wire ropes 1)Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below. Wire ropes (Standard "2" or “S” twist ropes without galvanizing) Rope diameter (mm) | Allowable load (tons) 10 1.0 11.2 14 125 16 14 22 16 28 18 36 20 44 22.4 56 30 10.0 40 18.0 50 28.0 60 400 The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. 2)Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion. 100% = BB 79% 1% 96 3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load B Singing with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding Position on the load, which can result ina dangerous accident. 4)Do not sling a heavy load with ropes forming a wide hanging angle from the hook When hoisting @ load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. ‘When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°. & Load capacitySTANDARD TIGHTENING TORQUE Qo] STANDARD TIGHTENING TORQUE 1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of "Disassembly and Assembly”. Thread diameter Width of bolt across flat (mm) (mm) kgm Nm 6 10 1.354015 13.2414 8 13 32403 31.4429 10 7 6.7407 65.7+68 12 19 11.5+1.0 112498 14 22 18.0+2.0 177419 16 24 285+3 27929 18 27 3944 383439 20 30 56+6 549458 22 32 76+8 745+78 24 36 94.510 92798 27 a 135415 1320+ 140 30 46 175+20 1720+ 190 33 50 22525 2210+240 36 55 280+30 2750+290 39 60 335435 3280+340 This torque table does not apply to the bolts with which nylon packings or other non- ferrous metal washers are to be used, or which require tightening to otherwise specified torque. + Nm (newton meter): 1Nm # 0.1 kgm 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Thread diameter Width Tightening torque of bolt across flats (mm) (mm) kgm Nm 10 12 65.7468 112498 27929 00-8STANDARD TIGHTENING TORQUE ‘Seating surtace 3. TIGHTENING TORQUE FOR NUTS OF FLARED — Use these torques for nut part of fared — Thread diameter] wiath across fats Tightening torave Sata Ghatpar es | Tightening torque tn tran ion Nm 4 19 25205 raseag 18 2 522 494196 22 27 8x2 7e5+196 2 22 1483 13734294 20 36 183 1765294 33 a 205 196.1449, 36 46 25=5 245.249 42 86 2025 294.2449 COATING MATERIALS aa The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. Nomenclature | Komatsu code ‘Applications — LT-18 | Used to apply rubber pads, rubber gaskets, and cork pugs Ura | Used to appiy resin, rubber, metalic and Adhesives non-metalc parts when fast, ston seals needed Preventing bolts, nuts and plugs from loosening and leaking oil a Provides an alight, electrically insulating seal Used for aluminum surfaces, is-1 Used with gaskets and packings to increase sealing effect. 1G.3 | Heat-rsistant gasket for precombustion chambers Gasket sealant __|_andexhaust piping _ _ ice Used by itself on mounting surfaces on the fina drive and trans mission cases. (Thickness after tightening: 0.07 — 0,08 mm) ~ Used by itself to seal grease fittings, tapered screw LG-5 fittings and tapered screw fittings in hydraulic circuits of less than 50 mm in diameter. Antifriction com- pound (Lubricant Applied to bearings and taper shafts to facilitate press-fitting and to including molybde- Prevent sticking, burning or rusting. num disulfide) Grease G2u ‘Applied to bearings, sliding parts and oil seals for lubrication, rust (Lithium grease) prevention and facilitation of assembling work. Vaseline _ Used for protecting battery electrode terminals from corrosion. “LT-2 is also called LOCTITE in the shop manuals. 00-9ELECTRIC WIRE CODE ELECTRIC ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: O5WB indicates a cable having a nominal number 05 and white coating with black stripe. CLASSIFICATION BY THICKNESS Bergravard] Coston) ERG” [uM] ona cei tren | tne O82 088 za 12 | Staring tahtng anal ete 02 28 032 209 a 20 | shine. sonatete 08 3 O82 523 ae 37] hong and saa! 5 3 045 7338 70 =o] Storing (iow pl 7% 35 O80 wis [aia 738] Sienna «0 127 080 wae | 136 178) Sterna 709 27 oso | 1081 176 730 | Sterna CLASSIFICATION BY COLOR AND CODE Create Priniy stating | charging | tigntng | sionat | instrument | oer cassia cow | 8 w a 3 Y T 1 | mary cl coor | atk | Wnie | Red Geen | Yetow | She cove | aw wa aw ow YR iw 2 Color | Black & White| White & Red | Red & White |Green & White] Yellow & Red | Blue & White cou | BY we 78 A e a . | Coir [Bick 6 Vetow|wnite@ Biock] Rea lack | Green Red [reiow@ Black] Blue Res ca Code BR WL RY GY YG uy ‘ Color | Back Red | White Blue |Red& Vellow [Green 6 Volonhveiow @ Green| Blu @ Velow cow | wy a oe B 5 coir | = |Witebvetow| Reve Green | Groen & Back |Yolow 6 Bue | Blue @ Black cow |= we a ow Ww . Color | = [write @ Green] Red Biv | Greene Give Yotowewie 00-10o21uo1 WEIGHT TABLE Ai This weight table is a guide for use when transporting or handling components. Unit:k9 eo Machine model Po2auU-1 Machine model Pczauu-1 1 Serial No. 1001 and up Serial No. 1001 and up Engine and hydraulic pump assembly | 187.6 Work equipment assembly 470 (excluding water and cil) = Boom assembly Engine assembly (including P.7.0.) | 179 First boom 905 Hydraulic pump as . Second boom 44 Third boom Radiator assembly (excluding water) 8 ae 2 ‘Arm assembly 53 Fuel tank assembly (excluding fuel) 16 Bucket assembly 44 Hydraulic tank assembly (excluding oil] 36 res ne seserDly ul = Boom cylinder assembly 30 Revolving frame assembly ced ‘Arm cylinder assembly 205 Canopy 44 Bucket cylinder assembly 133 - Offset cylinder assembly 4 Operator's cab BI bl 121.3 2spool control valve 6 oon ~~ - Blade cylinder assembly 124 6-spoo! control valve 16 motor assembly 32 Center swivel joint 15 42 Track frame assembly 846 Track frame 380 Idler assembly 3x2 Recoil spring 95x2 Track roller assembly 6x8 = Sprocket 85 x2 ‘Track shoe assembly (300mm) 196 x2 Travel motor 35, 00-11TABLE OF OIL AND COOLANT QUANTITIES PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS AMBIENT TEMPI CAPACITY (2) vesenvon ]empor | awmeyrrewgsarige a, [= 6% $838 S| Specitied [en nae Engin ol pan ay 4a Tee Swing machinery case | 07 07 Final drive case(each) | 08 oa Idler (each) Engine oil ThE om 0.04 “Track roller (each) 0.02 0.02 Hydraulic tank 56 38 Fuel tank Diesel fuel 32 = Cooling system Water ‘Add antifreeze 37 37 5% ASTM D975 No. 1 ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers Specified capacity’ Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. NOTE: (1)When fuel sulphur content is less than 0.5% —_(2)When starting the engine in an atmospheric change oil in the pan every periodic mainte- temperature of lower than 0°C, be sure to nance hours described in operation and use engine oil of SAE10W, even though and maintenance manual. Change oil according atmospheric temperature goes up to 10°C to the following table if fuel sulphur content more or less in the day time. is above 0.5%. (3)Use API classification CD as engine oil and if Fel sullen Change interval of oil API classification CC, reduce the engine oil content in engine oil pan change interval to half 0.5 to 1.0% 1/2 of regular interval Above 1.0% 1/4 of regular interval o2iuo110 STRUCTURE AND FUNCTION Power train sesttitisesecssneee 106 2 Swing circle coves . 10-3 Track frame and recoil spring . 10-4 Idler ....... — soe 10-5 Track roller .. 10- 5 Track shoe 10- 6 Hydraulic piping . - 10-7 Hydraulic circuit schematic ............. 10+ 8 Hydraulic circuit diagram ........ 10- 9 Hydraulic tank ..... severe, 10-10 Hydraulic pump sees 10-11 ~ 6-spool control valve ............. 10-12 3 2-spool control valve . 10-14 8 Center swivel joint .... - 10-15 ° ‘Swing motor (with reduction gear)... 10-16 Travel motor (with reduction gear) ..... 10-17 Hydraulic cylinder . “ 10-22 Work equipment control .... 10-24 Work equipment 10-25 Electrical circuit diagram . 10-26 10-1POWER TRAIN elt ooo} 1+ (\—— _| ste 10-2 1. Idler 2. 2-spool control valve 3. Swing motor 4. Travel motor 5. Final drive 6. Sprocket 7. Engine 8. Hydraulic pump 9. Center swivel joint 10. 6-spool control valve 11, Swing circle 21UF003 o21u01SWING CIRCLE : co ie | — L ) 2. ==! coy | ——|| 7 ot ~ Section AA 20PF004 1. Swing circle outer race SPECIFICATION 2. Ball bearing . 96 _ 3. Swing circle inner race Reduction ratio: 57 = 8.0 12 10-3TRACK FRAME AND RECOIL SPRING 1. Idler 2. Track frame 3. Travel motor 4. Sprocket 5. Track shoe 6. Idler cushion 21UF 004 7. Recoil spring 8. Sliding plate 9. Lubricator 0. 1 . Track roller Guard o21u01IDLER 1. Idler 2. Support 3. Floating seal 4. Shaft 5. Bushing ‘SPECIFICATION Volume of lubricating oi: 40ce (Engine oil SAE3O) F021U01001 o21uo1 1. Roller 2. Shaft 3. Bushing 4. Floating seal 5. Support SPECIFICATION Volume of lubricating oil: 20ce (Engine oil SAE3O) 1 J Fo21U01002 10-5TRACK SHOE 1, Master bushing 2. Master pin 3. Regular bushing 4. Regular pin 5. Link 6. Shoe 10-6 ‘SPECIFICATIONS Link pitch: 101.6mm Shoe width: 300mm No. of shoe: 40 (each side) Fo21U01003, o21u01o2iuot HYDRAULIC PIPING 21UF00S 1. Bucket cylinder 2. Arm cylinder 3. Offset cylinder 4. Hydraulic tank 5. Hydraulic oil filter 6. Oil cooler 7. RH. travel motor 8. Hydraulic pump 9, LH. travel motor 10. 6-spool control valve 11. Swing motor 12. Center swivel joint 13. 2-spool control valve 14, Blade cylinder 18, Strainer 16. Boom cylinder 10-7HYDRAULIC CIRCUIT SCHEMATIC 1. Offset cylinder 2. Bucket cylinder 3. Boom cylinder 4. Arm cylinder 5. 6-spool control valve 5a, Main relief valve 5b. Offset control valve &c. Boom control valve 8d. Bucket control valve Be. RH. travel control valve (| 5f. Center block | 5g. LH. travel control valve } 5h. Arm control valve 5i, Main relief valve 6. Swing motor 7. 2-spool control valve oe) 7a. Main relief valve 7b. Swing control valve 7c. Blade control valve 8. Center swivel joint 9. RH travel motor 9a. Brake valve 9b. Motor 10. LH. travel motor 10a. Brake valve | 10b. Motor 11. Return oil filter 12. Hydraulic tank 13, Blade cylinder 18a | 14, Engine 15, Hydraulic pump ‘sb | 18a. Front pump 15b. Center pump 18c. Rear pump = 21UF028 10-8 o2tuoto21u01 2 spool control valve HYDRAULIC CIRCUIT DIAGRAM pT ais a vaeg oo ress cape (a raraue ( ey Lea! | | ' | | [iso weal | (aan j ' ae Biade cylinder : roa TH) Off set cylinder €20X35 250 pees ea Engine 3078-10 M a ett if t } Hydraulic pump iE: Bucket syne 70x35 Conter Swivel joint Arm cylinder 80xa0 450 ( Laniotio+6 a “Theorie ervey 104 10-48, Sy ve | Dieharge volume: 254234 19-68 mn (av 2500-0) 21UF 006 10-9HYDRAULIC TANK 1. Sight gauge 2. Cover 3. Strainer 4. Hydraulic tank 5. Hydraulic oil filter 6. Drain plug 7. Strainer 10-10 21UF007 SPECIFICATIONS Tank capacity: 62 Volume of oil: 38.5 2(H level) 36.52(L level) Oil filter by-pass vaive cracking pressure: 1.5 kg/cm? 021001HYDRAULIC PUMP LBR10+10+8 a Q es 3 e 8 Front pump (LBR10) Center pump (LBR10) Rear pump (LBR8) Fo21U01004 1. Drive gear SPECIFICATIONS 2. Bracket Theoretical delivery: 10.0+10.0+8.5cc/rev 3. Gear case Maximum pressure: 200kg/em* — 4. Cover 5. Coupling 6. Driven gear 10-116-SPOOL CONTROL VALVE oa ee PL: PL port (From center pump) Pr: Pr port (From front pump) 1: A1 port (To offset cylinder bottom side) ‘Az: Az port (To boom cylinder head side) ‘Aa: Aa port (To bucket cylinder bottom side) ‘Aa: Aa port (To RH. travel motor forward side) As: As port (To LH. travel motor forward side] ‘Ae: As port (To arm cylinder head side) 10-12 = 20NF2010-K : B1 port (To offset cylinder head side) : Bz port (To boom cylinder bottom side) Bs port (To bucket cylinder head side) 4 port (To RH. travel motor rever Bs port (To LH. travel motor re : T port (To tank) o2iu01o21u01 @NOMAYNS Check valve spring . Check valve Main relief valve . Spool (Arm) Spool (L.H. travel) Valve body Spool (R.H. travel) Spool (Bucket) BOO 2 Section BB 10. " 12. 13. 14, 15. 16. OTONO WOT Section FF 20NF2020 ). Spool (Boom) Spool (Offset) Main relief valve Spool return spring Safety-sction valve Safety valve Suction-safety valve Suction valve 10-132-SPOOL CONTROL VALVE 1. Spool (Blade) 2. Spool (Swing) 3. Valve body 4. Main relief valve 5. Spool return spring 10-14 6. Safety-suction valve 7. Check valve spring 8. Check valve 9. Suction-safety valve F20MO5020A-K P : P port (From rear pump) 1: Ax port (To swing motor) ‘Az: Az port (To blade cylinder head side) By: Bs port (To swing motor) B2: B 2port (To blade cylinder bottom side) T : Tport (To tank) o21u01o21uo1 CENTER SWIVEL JOINT 20NF2022 1. Slipper seal A1: A port (From RH. travel control valve) E1: E port (From blade control valve) 2. Shaft ‘A2:A port (To RH. travel motor) Ez: E port (To blade cylinder head side) 3. Rotor B1: B port (From L.H. travel control valve) F 1: F port (From blade control valve) 4, Flange Ba: B port (To LH. travel motor) Fa: F port (To blade cylinder bottom side) C1: C port (From RH. travel control valve) G1: G port (To tank) C2: C port (To RH. travel motor) G2: G port (From travel motor drain port) D1: D port (From LH. travel control valve) D2: D port (To LH. travel motor) 10-15SWING MOTOR (WITH REDUCTION GEAR) 21UF 008. 1. Swing pinion ‘A: Aport (From swing control valve) SPECIFICATIONS 2. No.2 planetary carrier 8: B port (From swing control valve) Type: PC-100-19-6-0936A 3. No.2 planetary gear Dr: Dr port (To tank) Theoretical delivery: 13.6 cc/rev 4. Ring gear C: Lubricating oil filler port Operating pressure: 120 kg/cm? 5. No.1 planetary carrier D: Lubricating oil level port Motor speed: Max. 1.556 rpm 6. No.1 planetary gear E: Lubricating oil drain port Reduction ratio: 19.4 7. Swing motor 8. Motor output shaft 9. No.1 sun gear 10. No.2 sun gear 10-16 o21u01o21u01 TRAVEL MOTOR (WITH REDUCTION GEAR) 1. Brake valve 2. Motor 3. Reduction gear 20NF 1023 SPECIFICATIONS Type: PH-200-41-448B Theoretical delivery: Operating pressure: 200 kg/cm? Motor speed: 974 rpm (at 35 2/min) Reduction ratio: agp = 0025 0.6 10-17,1. MOTOR 1. Oil seal 2. Bearing 3. Swash plate 4. Shaft 5. Piston 10-18 6. Body 7. Cover 8. Valve plate 9. Cylinder barrel 20NF1027 o21u01o21u01 2, BRAKE VALVE 1. Valve body 2. Spring 3. Spool 4, Plug 5. Check valve 20NF 1029 FUNCTION 1) The brake valve acts to stop the inertia pro- duced as the motor tries to rotate with the inertia of the machine. It applies the brake smoothly to stop the motor. 2) It also acts as a check valve to prevent cavi- tation of the hydraulic motor. 3) It opens the port to free the parking brake when the motor starts, and to close the port when it stops. 10-19OPERATION 1) Starting travel + The oil delivered from the pump flows to Port PA through the control valve. It pushes ‘open check valve C1 and flows from motor inlet port MA to motor outlet port MB. How- ever, the outlet side of the motor is kept closed by check valve C2, causing the oil pressure to go up. (Fig. 1) + The oil also flows into chamber E1 through orifice D1. If the pressure in chamber E1 reaches the spool switching pressure, the spool is pushed to the left. Port MB and port PB are connected, and the circuit on the motor outlet side opens. Then the motor starts. (Fig. 2) 2) Braking operation when traveling downhill + When the machine travels downhill out of control, the motor will race and the oil pres- sure on the motor inlet side will decrease ‘The pressure in chamber E 1 also goes down since this chamber is connected to the motor inlet through orifice D1. + When the difference in pressure between chambers E1 and E2 goes below the force of the spool change-over spring, the spool is returned to the right by spring $2 and port MB on the outlet side is made smaller. If this port is throttled, the pressure on the outlet side decreases and rotating resistance is pro- duced in the motor. Thus the machine is kept in control. Even if port MB on the outlet side is closed, the motor is kept rotating by the inertial force, but the flow rate of the re- turning oil is gradually reduced to stop the motor smoothly according to the changing speed of the spool and the shape of the notch. + As described above, the speed is controlled according to the discharge of the pump. + The drain oil from the motor flows from port F to ports DR and DRz. (Fig. 3) 10-20 20NF 1030 20NF 1031 20NF 1032 021U01o21u01 3. REDUCTION GEAR FUNCTION The reduction consists of a combination of two planetary gear mechanisms. To make the total mechanism smaller, one sun gear is employed, and the two planet gears form one unit. The first and second sets of planet gear greatly reduce the high speed rotation from the hydrulic motor and convert it into low-speed, high torque to rotate the hub (or |, which in turn rotates the sprocket. OPERATION First reduction gear set + The first reduction gear set is a planetary gear mechanism whose ring gear is fixed. That is, the power from the motor drives sun gear (S1). Consequently, planetary gear (P1) revolves around the sun gear, and the carrier rotates together with the planetary gear. Thus, the power of the ‘sun gear is transmitted to the carrier. Second reduction gear set + The second reduction gear set is a plane- tary gear mechanism whose carrier is fiexed. The rotation of carrier (C1) in the first reduction gear set becomes the rota- tion of sun gear (S2) in the second reduc- tion gear set Second reduction First reduction 9° St gear set a 20NF 1024 Motor output (First reduction gear set) 20NF 1025 (Second reduction gear set) 20NF 1026 10-21HYDRAULIC CYLINDER 1. BOOM CYLINDER § wi \\ lf \\ 2. ARM CYLINDER mae Wd \ : Sg 10-22 F021U01005 F021U01006 Fo21u01007 o21uo1o21uot 4. OFFSET CYLINDER 5, BLADE CYLINDER 1. Bushing 2. Head side tube 3. Bushing 4, Bottom side tube 5, Piston rod 6. Cylinder head 7. Bushing 8. Cylinder 9. Plunger 10. Piston 11. Piston ring 12. Wearing 13. Piston nut 14. Spacer Fo21u01008, 1 it El s 67 a a (- OF} Fo21v01009 SPECFICATIONS Unit: mm Item Cylinder) Boom | Arm | Bucket | Offset | Blade Piston 10d 0.0. wo | | | | Cylinder 1.0 | 4 | a5) 35 | 40 Stoke e80 | 460 | 400 | 250 | 136 Max stroke 1685 | 1190 | 1065 | e30 | sas Min, strok oes | 730 | 05 | se0 | 410 Width across fats of piston rot | ar | an | ar | 6 | 10-23WORK EQUIPMENT CONTROL Blade RAISE a RH. travel ~ wo] FORWARDS averse avers Blade LOWER | LH, travel a, / LH. travel FORWARD ReVence Bucket UMP | Boom RAISE { RS) A 2 21UF 009 1. RH. work equipment control lever 6. Boom offset pedal 2. Blade contro! lever 7. 2-spool control valve 3. Lock lever 8. 6-spool control valve 4. RH. travel control lever 9. Lock lever 5. LH. travel contro! lever 10. LH. work equipment contro! lever 10-24 o21vo1021U01 WORK EQUIPMENT 1. Third boom 2. Second boom 3. Arm cylinder 4, Offset cylinder 5. Boom cylinder 6. First boom Fo21u01010 7. Blade 8. Blade cylinder 9. Bucket 10. Bucket cylinder 11. Arm 10-25ELECTRICAL CIRCUIT DIAGRAM20 TESTING AND ADJUSTING o21uo1 Table of judgement standard valve . 20- 2 Testing and adjusting tool list .......... 20-10 Testing and adjusting hydraulic pressure (20-11 Measuring delivery of main pump 20-12 * The following precautions are necessary when using the Table of judgement standard value to make judgements during troubleshooting or during testing and adjusting, 1 2 The values in these tables are based on the values for new machines leaving the plant, so they should be used as target values when repairing or when estimating wear after a period of use. The standard values in these tables for judgement when troubleshooting are estimated values based ‘on the standard values for the machine when shipped from the plant, and on the results of various tests. Therefore, they should be used as reference in combination with repair and operating records when making judgements. These standard value tables must not be used for standard values when judging claims. In addition, do not use these values alone to make simple judgements. 20-1 oTABLE OF JUDGEMENT STANDARD VALVE + FOR ENGINE ON TEST BENCH Engine 3078-1 Genin cation Item Condition, ete. Unit ‘Standard value Permissible value 8 |Fiywheel horsepower HP/rpm| 23.3/2,500 _ : Maximum torque kgm/rpm 7,711,900 _ Elem Low idling speed rpm 900 60 Engine speed - = __[Fosine spew High idling speed rom 2,650 * 50 _ * Necessary oc rpm Min. 200, starting speed =20° C {Using starting aid) | rpm Min. 400_ _ lotake resistance | All speed mnnti20 Max, 203 508 % exhaust pressue | Alt speed mmHg Max, 660 4,000 = eles rel All speed - - ag Exhaust tempereture] (ina air temp.: 20°C) © 5S Quick acceleration Bosch Max. 5.5 Max. 5.5 * | Exhaust color £ oe At high idling scale Max.10 Max. 1.0 E |Valvectearance | Intake valve mm 02 = at 20°C Exhaust valve mom 02 = & compres ‘Oil temperature: kg/em? Min. 30 Min. 26 8 ‘pressure | (Engine speed) (rpm) (250) (250) 2 ‘At rated speed 7 E [low by Pressure | oii temperature: min, 60°¢| ™H20 7 JOil pressure At high idling. kg/em? 3.0-4.0 Max, 3.0 § _|(SAE30, Oil tempera] ture: 80°C min.) _ | At low idling kg/cm? Min, 1.5 Max. 1.5, § All speed © |oit temperatur 4 [Oteemperture | (Oi io pan Mex. 115 Mex. 120 5 - ; 5 ‘At continuous ated output 3 * j0x.0. 0x, {Ratio to fuel consumption) eee eo Fuel injection re | Nozzle tester kglem? 200 195 Furinneton [aro Dewee 6 6 All speed Max. 115 |Cootant temperature pe % , - pe (at engine outlet) i {open air 40°C) € Valve cracking temperature] °C 69.5-72.6 60.5-72.5 E |rnermostat function Full opening temparaure | °C 35 26 ? Full opening lit mm 8 8 ‘3 [Radiator pressure | Opening pressure 2 8 Kineton (Ditterential pressure) __|_Ko/e™ 0940.18 ee [Fan beit tension | Deflect when pushed with 78 6 Alternator) a force of 6 kg mm . Note; The values given in the Testing and Adjusting data are NOT for adjustment of the output. Do not use these values as a guide to change the setting of the fuel injection pump. 20-2 o21uoto2iuot + FOR CHASSIS Item Condition Unit | Standard value | Permissible value When one pump circuit |*Hydraulic oil temperature: 45—55°C Engine oil pressure: within operating - | Jor irete van 5 Engine water temperature: 2 Within operating range [When two pumps circuit |.one pump relief: Bucket circuit relief oil is ré ‘Two pumps relief: Bucket and arm Ce) Ses itrelief T Boom control valve & eye ep}aye ‘ ‘Arm control valve - ale Bucket control valve _| I. bo “Neutral zo0r173 [Blade Control valve z mm | 20 | 60/60 | 20 |6.0 | 60 J oftset control valve & [swing control valve LH, travel contro! valve | RLM, travel control valve | 1 ‘At center of lever Neutral + Boom control lever | At # pie 87210 Measure at end of | Neutral > ‘Arm control lever aaa In end Out 86+10 — ‘Engine stop Neutral > ~ 7 Bucket control lever ie 85210 g Neutral > B [Blade controt lever Rc 6810 2 Neutral > LH. ™m | B00m ote pede! pea Toren 1745 & Neutral > LH. § | swing contro! iever ie saz 10 Neutral > For. Travel control lever ini S| 75210 Low idling > : Fuel control le aera 110215 Engine stop Knob Stop + Running eo+10 20-3Gent i tam Condition Unit | standard vaiue | Permissible value Boom contr lever | “Ensine speed: High idling 23208 23208 Hydeaulic oll temperature: 45-65°C + Hook pushpul sale on cantar of ‘Arm control lever lover knob to measure 2.3208 29205 + Measure operating force to end of travel Bucket control lever 2.3208 23205 & | cade control ever 17203 17203 3 3 | B00m oftet pet 78210 75210 : ko | Swing contol ever 2208 | 23205 8 Teavel control lever 23408 29205 Fuel contol lever o5t15 e5t15 Engine stop knob 1525 1525 Boom se syd enon: 45-55" wot? | 200°? Reliet pressure a engine high idling (Be relieved olin only measuring ; — cea m0*2 | aot? g , +7 47 | Becket circuit 200 +7 200*? G elem ; iS + +5 Blade circuit 175*8 175*8 £ 7 7 E | offer ciruit 200+? 200°? Swing cireut 120 #8 12025 “7 “7 Travel eireut 200*? 200+? 20-4 ®@ o21uotom “eee tion tem Condition Unit Standard value o21u01 Swing Time taken to start swing Posture of work equipment [Max. reach] 20RFS106 Engine speed: High idling Hydraulic ol temperature: 45—55°C Degree| Put match marks on the swing circle outer ‘Mesture the distance between the match ‘marks after the upper structure comes to the stop. (1: Braking canes on ewing ile outer Max. 30 (167.5) Max. 30 (167.5) Porture of work equipment (Max, reach] No toed Sec, Engine speed: High ating h “Hydraulic oll temperature: 45—88°C * Maesure the time required tor the ‘upper structure to ewing from, ts farting position past the 180° points Max. 4.0 Max. 4.5 Normal swing speed Posture of work equipment (Max. reach) Engine speed: High iting . Hydraulle ol temperature: 45—55°C Measure time taken to swing for 6 turns, tr swinging one turn as an soproach swi Max. 31.6 Max. 35 Hydraulic drift of swing Posture of work equipment 20885108, Engine: Stopped . Hydraulle ol temperature: 45—55°C With the tracks facing uphill op 2 18° slope, turn the upper structure to 90° anal Put match marks on the swing crete outer rack frarve, Walt 5 minutes, the dltance between the match Max. 90 Max, 90 20-5 ®Gear ‘oe Item Condition Unit | Standard value | Permissible value ten] Machine posture with track spinning 20865108 + Engine speed: High idling Sec, | 32522 40 + Hydraulic oil temperature: 45—-55°C Raise one track off the ground, let it spin one revolution, then measure the time required for it to spin § revolu- tions. Repeat this procedure for the other track. Travel speed (1) Travel posture Travel speed (2) Engine speed: High idling See | 9542 ° Hydraulic oil temperature: 45—65°C + On a flat surface, make an approsch run of atleast 10m, then measure the time required for the machine to travel 20m, Travel Travel posture o- a De | Engine speed: High idling Travel deviation Hydraulic oil temperature: 45~B5°C = On a flat surface, make an approach un of at least 10m, then travel another 201m, Measure the travel deviation. mm | Max. 500 Max. 550 10m Measure dimension &, 208° 2402 20-6 © o21uo1o21u01 Tan fee Item Condition Unit | Standard vaiue [Permissible value Messuring posture y | Hvdraulic drift of travel i - Engine: Stopped =| mm | Mox.200 | Max. 200 Hydraulic oil temperature: 45~55° C * On astope of 20", stop the machine with the sprocket ‘sections on the Upper side of the slope. + Wait minutes, then messure the distance the machine moves. Entire work equip. | Meaturing posture ment (Hydraulic rift a the tip of Max. 400 bucket teeth) Boom cylinder {nthe posture shown above, measure (Retraction of the extension and retraction of each . cylinder) cylinder as well asthe hydraulic. drift ne aa atthe tip of the bucket teeth Bucket: Rated load (126 ks) Fiat level surface Contra! levers in neutral ‘Arm eylinder fe + Engine: Stopped em Hydraulic ot temperature Max. 15 30 ovlinden + Start measuring immedi | setting Measure the hydraulic drift every 5 minutes, and make judgement after £ | Bucket cylinder | 1 minutes, ez | 2 |(Rewaction of | - Blade: Set evlinder fully retracted. | mm 30 & | § [evtinaen Leave for 5 minutes after stopping 5/2 engine, then measure amount Bla 2\2 tip moves during next 15 minutes. 3 | |plade = | | itivdrautic drift at 20 the tip of blade) Engine: Stopped . Hydreulic oil temperature: 45—65°C Bucket: Rated load (126 ko) + Place the machine in the same posture Off set and stop it on a 18° slope with upper Max, 10 20 structure turned at right angles to the Mesture the amount of movement of the cylinder for the next 15 minutes, 20-7a 3 estos 18 Bucket teeth on = ee | cyte uty jf Hydraulic oil temperatu g oie Cylinder fully Notdad p= oi ote Engine speed: High idling 5 Hydraulic oil temperatur ° eee) 54 45-65°C i |e © |e) Cynder say 5 seas 4s & | E) retracted io a7 = ® | Z| cylinder fully a B} extended z £0, Mu + Engine speed: High idling a 30205 38 — 45-65°C | Blade on the y g 17403 22 ro wr Z a Cylinder fully. - c retracted + Engine speed: High idling a + Hydraulic oil temperature: 3 2,240.3 28 45-55°C a Offset 2 Cylinder fully s eri 8] | aso | oe i ( i Cylinder fully e 5 oxi F + Engine speed: High idling [3 34208 43 45-55°C 20-8 @ o21u01o21u01 Giant tion tem Condition Unit ‘Standard value Permissible value Work equipment | Boom Mesuring posture (Vay 20115116 Engine speed: Low idling Hydraulic oil temperature: 45-55°C. Bucket unloaded ‘Arm and bucket cylinder fully retracted ‘Measure time taken from bucket tooth ‘touching the ground to the machi raised Measuring postu Engine speed: Low idling Hydraulic oil temperature: 45-55°C Top of boom is in horizontal, arm cyl inder fully retracted Measure time taken from arm stopped when arm came into vertical to arm moved again Max. 5 Bucket Blade Measuring posture 20188118 Engine speed: Low idiing . Hydraulic oil temperature: 45-55°C. ‘Arm is in vertical Measure time taken from bucket stop: ‘ped when bucket tooth came in bot: tom to. bucket moved again ——s\ Enno: Low ing Hydraulic oil temperature: 45—-56°C Measure ime tke om ad ous iat pound he mace eed Max. 1 Max. 2 Max. 2 20-9 @TESTING AND ADJUSTING TOOL LIST + FORENGINE —~T Check item Remarks 1 | Engine spec 799-203-8000 aac H: 60-19,999 rpm 2 | Water and oil temperature] Thermistor kit 799-101.6000 | —50 -1,200°C Hydraulic tester 799-101-5000 25, 60, 400, 600 kg/em? 2 | Lutvient pressure . Digital hydraulic tester 790-261-1100 500 kg/cm? onan Comprenion gue ressozrz10 | 9-7OKan? 4 | Compression pressure ~ Adopter 2406592850 5 | Blowty pressure low-by eecker 7902011604 | 0 800mm H0 6 | Valve clearance Feeler gauge ‘Commercially available Intake : 0.2 mm Exhaust : 0.2 mm Exhaust gas color ‘Smoke checker 799-201-9000 Commercially Discoloration 0-70% With standard color (Discolora- Smoke meter Ba tion % x 1/10 # Bosch index) + FOR CHASSIS No| Check item Tool Part No, Remarks 1 Joit temperature Thermistor kit 799.101.6000 | —50-1,200°¢ Hydraulic tester 799-101-5000 | 26, 60, 400, 600, kg/em? 2 |Hveraulic ol pressure Digital hydraulic tester | 790-261-1100 | 500 kg/em? 3 Engine speed Multi-tachometer 790-203-8000 | Pista csplay 1b: 82.000 0m H: 60-19,999rpm 4 |Operating force Push-pull scale Commercially available 5 |Travel, hydraulic dritt Scale «4 [Work ecuipment, swing, [travel speed ‘Stop watch 7 Pump performance Flow meter kit 790-303-1002 20-10 o21u01o2iuor TESTING AND ADJUSTING HYDRAULIC PRESSURE Wx Lower the work equipment completely to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1. Measuring Plug(1):6-spool control valve pressure pick-up (Offset, boom, bucket, RH. travel) Plug(2):6-spool control valve pressure pick-up (Arm, LH. travell Plug(3):2-spool control valve pressure pick-up (Blade, swing) 2. Adjusting * If the results of the measurement show that the set pressure is not correct, adjust the set pressure of the main relief valve as follows + 2-spool control valve (Blade, swing) :(4) + 6-spool control valve (2-spoo! side) (LH. travel, arm):(5) + 6-spool control valve (4-spool side) (RH. travel, bucket, boom, offset):(6) Loosen locknut (7) of the main relief valve, then turn adjustment screw (8) to adjust the set pressure * Adjust the pressure as follows To INCREASE pressure, turn screw CLOCKWISE To DECREASE pressure, turn screw COUNTERCLOCKWISE * One turn of the screw adjusts the pressure by about 56 kg/cm?. + Set pressure: -spool valve. 175 * 8 kg/cm? 6-spool valve (2-spool side, 4-spool side): +7 200 * 2 kg/cm? * After adjusting, measure the pressure again and check that itis within the standard range. roses) 20-11 'MEASURING DISCHARGE OF PUMP 1. Disconnect hoses (1), (2), or (3) (pump for 2-spool control valve) between the control valve and the pump being measured. 2. Using nipple B and bushing C, install flowme- ter kit A between the control valve and the pump disconnected in Step 1, then measure To contol vave fp EJ == the discharge of the pump pues : 4 @ From pume — ef [— —HE a 20-12 i o21uot30 DISASSEMBLY AND ASSEMBLY o2iuor ENGINE Removal 30-1 Installation 30- 2 swivel JOINT Removal 30- 6 Installation 30- 6 Disassembly 30- 6 Assembly 30- 6 RECOIL SPRING Disassembly 30- 8 Assembly 30. 8 CONTROL VALVE Disassembly 30- 8 Assembly, 30- 8 WORK EQUIPMENT Removal 30-10 ____Installation 30-10 -) 0 (ef LS swine moron FINAL DRIVE Disassembly 30-12 Assembly, 30-14 * When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and piping, always bleed the air as follows 1. Start engine and run at low idling 2. Operate hydraulic cylinder 4 to 5 times, stopping 100 mm from stroke and. 3. Next, operate cylinder 3 to 4 times to stroke end 4 After doing this, run engine at normal speed * After repair or long storage, follow the same procedure. 30-1REMOVAL OF ENGINE ASSEMBLY 1. Dre ng oil Ai Loosen oil filler cap to release pressure inside hydraulic tank. 1) Remove drain plug and drain oil from hy- draulic tank. Hydraulic tank: Approx. 38 & 2. Cover, hood Remove cover and hood 3. Wiring Disconnect starting motor wires (1), alterna- tor wire (4), heater, sensor wire (6) and ground connection (5). (See P1, P2) 4. Fuel hose Disconnect fuel supply hose (7) and fuel return hose (8). (See P2) * Fit the blind plugs to the hoses to stop the fuel from flowing out. 5. Radiator assembly, oil cooler assembly 1) Loosen radiator drain valve (9) and drain cooling water. (See P3) * If the coolant contains antifreeze, dispose of it correctly. 2) Disconnect hose (10) for oil cooler. (See P3) 3) Disconnect upper hose (11) and lower hose (12) at engine end. (See P3) 4) Remove bolts (13), then remove radiator assembly (14) and cooler assembly (15) (See P3) 6. Piping 1) Disconnect pump outlet hose (16). (See Pa) 2) Disconnect pump inlet tube (17). (See P4) 30-2 ® 7. Engine assembly 1) Remove nuts (18) (4 places). (See P5) 2) Lift off engine assembly (19). (See PS) * When raising the engine, be careful of the location of the center of gravity, and check again that all wiring and piping has been removed, * tg ” Engine assembly : 190 kg. 2101INSTALLATION OF ENGINE ASSEMBLY 1. Engine assembly 1) Raise engine assembly (19), set in position ‘on frame, align with cushion bolt, then lower engine. (See P1) 2) Tighten nuts (18) (4 places). (See P1) Some Nut: 11.5 & 1 kgm 2. Piping 1) Connect pump inlet tube (17). (See P2) 2) Connect pump outlet hose (16). (See P2) 3. Radiator assembly, oil cooler assemly 1) Set radiator assembly (14) and cooler as- sembly (15) in position on bracket, and tighten bolts (13). (See P3) 2) Install upper hose (11) and lower hose (12). (See P3) 3) Connect hose (10) for oil cooler. (See P3) 4) Install radiator drain valve and add water to radiator. 4. Fuel hoses Connect fuel hoses (7) and (8). (See P4) 30-4 5. Wiring Connect starting motor wires (1), alternator wire (4), heater, sensor wire (6) and ground connection (5) (See P4, P5) 6. Cover, hood Install cover and hood. 7. Refilling with oil Tighten drain plug and add engine oil through oil filler to the specified level ‘i Hydraulic tank: Approx. 452 4 Run the engine to circulate the oil through the system. Then check the oil level again. o21u01REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY * Lift up the machine and put the blocks (height: approx. 300 mm) under the track shoe. GK Retract the arm and bucket cylinders fully, lower the work equipment complete- ly to the ground and stop the engine. Then operate the control levers several times to release the remaining pressure in the hydraulic piping Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank 1. Swivel joint upper piping Remove floor plate and swing motor assem- bly, and disconnect piping. 2. Swivel joint lower piping 1) Disconnect drain tube (1) for travel. (See Pa) 2) Disconnect tubes (2), (3), (4), and (6). (See P1) 3) Disconnect hoses (6) and (7). (See P1) 3. Swivel joint assembly Remove nuts (8) (4 places), then remove swivel joint assembly (9). (See P1) DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY Remove flange (10) and O-ring (11). (See F1) 2. Remove snap ring (9) and washer (8). (See Ft) 3. Remove swivel shaft from rotor (1). (See F1) 4. Remove O-rings (2) and (3) from rotor (1) 30-6 o INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY 1. Swivel joint assembly Set center swivel joint assembly (9) in posi- tion on frame, and tighten mounting nuts (8) {4 places). (See P1) 2. Swivel joint lower piping 1) Connect hoses (6) and (7) for blade. (See P41) ‘e /Sleeve nut: 2.5 + 0.5 kgm 2) Connect tubes (2), (3), (4), and (5). (See Pa) 6 4 | Sleeve nut: 8 2 kgm 3) Connect drain tube (8) for travel. (See P1) Dee Sleeve nut: 5 = 1 kgm 3. Swivel joint upper piping Connect piping, and install swing motor as- sembly and floor plate. % Run the engine and bleed the air from the piping. Then check the oil level in the hy- draulic tank. ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY * Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing 1. Install O-rings (2) and (3) in rotor (1). (See FA) 2. Install swivel shaft (4) in rotor (1), then install washer (8) and fix with snap ring (9). (See Ft) 3. Install O-ring (11) and flange (10). (See F1) o21u01o21uo1REMOVAL OF WORK EQUIPMENT ASSEMBLY 1. Raise boom to upper limit, and remove boom cylinder cover (10). (See P1) Extend the arm and the bucket fully, lower the work equipment assembly com- pletely to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping, Then loosen the hydrau- lic tank cover mounting bolts slowly to release the pressure inside the hydraulic tank. 2. Sling boom cylinder assembly and pull out connecting pin (1) at rod end, (See P2) 3. Lower boom cylinder assembly on block. 4, Disconnect arm hose (3), bucket hose (4), and offset hose (5) at first boom foot end. (See P3) 5. Disconnect lighting wiring (6). (See P3) 6. Sling work equipment assembly (7), and pull out boom foot pin (8), then lift off work equipment assembly to front. (See P4) ke > Work equipment assembly : 440 kg. 30-8 INSTALLATION OF WORK EQUIPMENT ASSEMBLY 1, Raise work equipment assembly (7), set in position on revolving frame, install boom foot pin (8), then lower work equipment as- sembly to ground. (See P4) Soe) Bolt: 11.5 + 1 kgm 2. Connect lighting wiring (6). (See P3) 3. Connect offset hose (5), bucket hose (4), and arm hose (3). (See P3) * Install the hoses without twisting or interference. se Sleeve nut :5 + 1 kgm te | Sleeve nut : 2.5 + 0.5 kgm 4. Sling boom cylinder assembly, and install connecting pin (1) at rod end. (See P2) se Bolt: 11.5 + 1kgm * Pun the engine to circulate the oil through the system. Then check the oil level in the hydraulic tank again 5. Pull boom up to upper limit, and install boom cylinder cover (10). (See P1) * Coat all pins with grease (G2-LI) o21u01lonizo 30-9 'DISASSEMBLY OF SWING MOTOR FINAL DRIVE ASSEMBLY 1. Draining oi Remove drain plugs (1) and (2), and drain tu- bricating oil. (See P1) ‘clay Lubricating oi: Approx 07 & 2. Final drive assembly and motor assembly 1) Remove bolts (3). (See P2) 2) Pull out hydraulic motor (4), and remove from final drive assembly (32). (See P3) * The flange has a pilot, so tap the sur- rounding with a hammer to make it easier to remove. 3. Gear Remove spacer (5), then remove gear (6) (See P4) 30-10 4. Carrier assembly I Remove carrier assembly Il (7). (See P5) 6. Thrust collar Remove thrust collar (8) from carrier assem- bly Il (7). (See P6) 6. Carrier assembly | Remove carrier assembly | (9). (See P7) * The internal gear “a” is press fitted to the body so it cannot be disassembled. 7. Snap ring Remove snap ring (10). (See P8) o21uo1o21uo1 2fgPear IUD zrvPon 30-11 18. Pinion Set body (10) on cylindrical jig@), and pull out pinion shaft (11) using press @ and spacer(2). (See F1) By Press force: 1000 kg the spacer securely. needed, so set 9. Bearing Set pinion shaft (11) on cylindrical jig ®. remove bearing (12) using press @) (See F2) Ay Press force: 1200 kg is needed, so set jig @ securely, * When bearing (12) is removed, ring (13) is deformed, so it cannot be used again. 10. Bearing Set body (10) in reverse, and pull out bearing (14) using press @) and spacer (J). (See F3) * When bearing (14) is removed, seal (15) is deformed, so it cannot be used again. Ai Press force: 400 kg is needed, so set spacer () securely. 30-12 ASSEMBLY OF SWING MOTOR FINAL DRIVE ASSEMBLY 1, Bearing Fill body (10) with grease (G2-LD), and press fit bearing (12). (See F4, P1) * Set with the bearing shield surface facing the outside. & Press-fitting force for bearing: 1000 kg. 2. Ring Assemble ring (13). %* Coat the outside circumference of the ring (in contact with body (10) with grease before assembling. (See P2) 3. Pinion Press fit pinion shaft (11). (See P3) * Press-fitting force: 1200 kg oziuo1o21uo1 Trt | A pseg “13 iT i a + | PEL ti 8 ' F3 15 30-134, Bearing 1) Assemble oil seal (15). (See P1) * Be sure to assemble the oil seal facing in the correct direction. 7. Carrier assembly Il Install thrust collar (8) to carrier assembly Il (7), and assemble in body. (See P5, P6) 2) Press fit bearing (14). (See P2) * Press-fitting force: 400 kg. 5. Snap ring 8. Gear ‘Assemble snap ring (10). (See P3) ‘Assemble gear (6) and install spacer (5) (See P7) 6. Carrier assembly | 9. Oil Assemble carrier assembly | (9). (See P4) 1) Wind plug (16) with seal tape, and install in body (10). (See P8) sr Plug : 3.5 kgm 30-14 ® o21vot30-15 12) Add oil. (See F1) i ot: Approx 0.7¢ 10. Final drive assembly Fit packing (18) to flange mating surface of final drive assembly. (See P1) 11, Assembly of final drive assembly and hy- draulic motor assembly 1) Swing motor assembly ')Set hydraulic motor assembly (4) in posi- tion on final drive assembly (32). (See P2) * Be sure that the drain plug of the final drive assembly and the oil filler of the hy- draulic motor assembly are facing the cor- rect direction. (See F2) 30-16 @ ii) Tighten bolts (3). (See P3) = Bolt: 2.6 - 3.3 kgm + Tighten 6 bolts (3) uniformly. 2) Plugs Wind plugs (1) and (2) with seal tape, and in- stall to swing motor assembly. (See P4) (om) Plug : 3-4 kgm o21u0toziuor i filter Drain plug 21UFO29 2itroor 30-1740 MAINTENANCE STANDARD o21u01 Swing circle Track frame and recoil spring Idler Track roller .... Track shoe ... Hydraulic pump 6-spool control valve 2-spool contro! valve Hydraulic cylinder Work equipment 40-1SWING CIRCLE Section BB om 4,11. + 1.0kgm 6 ~T \ Y Se 11.54 1.0kgm 20°F010 Section AA Unit: mm No, Check item Criteria Remedy Standard size Clearance limit 1 | Axial clearance of bearing [— 0.05 - 0.25 04 | Repiece 2. | Backlash between swing pinion and 012-073 14 40-2 swing circle o21u01o21uo1 TRACK FRAME AND RRCOIL SPRING 20UFOO4A Unie mm No] Check item Criteria Remedy | Standard size Repair limit eee ~ Rebuild 1 | Vertical width of | fame 96 ier guide F iar - Rebuild or _ | support . L replace Track 2 Horizontal width | frame a Rebuild of idler guide Idler ~ Rebuild or support ee _ replace _ Standard site Repair init Frastength | Tnstaled | —trvtalled | gree engen | Tstaled 3 | Recoil spring roo. engi GT [Free tonath | Hed | pepiace roo3x | 171 | soos | 2008 | 1.400 ka i 40-3IDLER 2 ri 20PFO12 Unit: mm — No. Check item Criteria Remedy 1 | Outiaeaismeter ot Standard size Repair limit protrusion aaa = ‘Outside diameter of | 2 {side diame 335 327 frase Rebuild or 3. | Width of protrusion 28 20 replace 4 | Total width 70 65 5 | Width of tread 2 25 iucterans) Standard | Clearance 1g | Clearance between shaft Shaft Hole | clearance limit | Replace and bushing 3 “0.028 | +0142 | 0.108= 1s bushing ~0.064 | +0.080 0.206 i Clearance of shaft and 0.028 | 70.038 | 0.025 > 7 support 6 -0.064 | 0 0.103 oeeeae Side clearance of idler . Replace 8 | ae Repair limit: 2.0 rai 40-4 o21u01021u01 TRACK ROLLER 5 6 3 4 om] {~] aod a} ' i) L-A, ~ - - ‘20PFO13 2 | Outside diameter tread. 90 82 or replace Standard Tolerance Standard Clearance ‘and bushing t 0 70.183 | 0.144— a) | 0.013 +0.144, 0.196 one) Standard Tolerance Standard Interference | Replace g | Interference between roller size Shaft Hole interference} Vnie. bushing as a +0.073 | —0.039 | 0.009— aa aos [a |S [e 7 | Side clearance of roller ~ | =| 40-5TRACK SHOE \e yO 20PFO14 29) Wa Unit: mm No. Check item Criteria Remedy ‘Standard size Clearance limit Replace bushing 1 | Link piteh : ~Jand pin or tink , 102 105 a 2. | Height of grouser 165 65 3. | Height of link 61 55 Outside diameter of 4 | canine 32 265 [Standard |_ Tolerance Standard | Interference Interference between size | shatt | Hole | interference | limit | Replace 5 | regular pin and link 7025 | 008 19 | tory | ‘o | o12-023 | oz Interference between +0.24 | +0.05 © | bushing and ink 2 | 4020 | 0 | 912-023 018 Standard | _ Tolerance Standard | Clearance 7, | Clearance between master | size “Shaft | Hole | Clearance Beni pin and fink =002 [+005 19 | O07 | “p> | 002-012 10 40-6 o21u01o21u01 HYDRAULIC PUMP 7 \@) | 8 2 2 = 6.0-7.2kgm a1uror9A oo no] cwactam coho =— a ae ean - — | 1 | Sexe be cam ote 010 ae [tre ao5= 010 38 2 Clearance between bearing LBRIO 0.06- 0.119 | 0.20 (ormaparaanO. ae a 3 apa Dacharoe | SERS [Drctarae rtomanee voce [omen] Dee | BER [rte tn mle 7ccecu Ako/em?) | “te/miny | _(&/min) 45~ 55°C LBR10 3,500 200 32 30 ee 40-76-SPOOL CONTROL VALVE 4 3 35 + 0.5kgm Sa 55 + O.5kom G8 0.9 £ O.tkgm | Section BB 5 4,5 + O.Skgm i ies 4.5 + 0.5kam ‘Section DD eat, Sa) 4.5 + 0.5kgn \ Section FF ‘Md 20PFO15 Section EE Unit: mm No. Check item Criteria Remedy ‘Standard size Repair limit Main relief valve pilot. Free Tenth | installed] taataled [> tnstalled i a pe ree length | (stl | Prorser ering 0.0. "| length oad i 2osxos| 29 | 126K9 | spring if - ; ——} ‘any damages ‘Main relief valve main e 2 | valve spring 23x72) 190 | 20k9 a eforme 3 | Spoot return spring 407%x206| 264 13kg found. 4 | Check valve spring 131x110] 6 0.2 kg — L 40-8 o21u012-SPOOL CONTROL VALVE |) oxo 35 205kn O_/e © 3 3 8 gue) # SR 9EOSKGM 2 4.540.5kgm Soe) 4.5 + 0.5kgm 20PFOIGK ~ oe og totkgn * 5.5 t 0.5kgm Unit: mm No. Check item Remedy Standard size Repair limit Se Free Tengah] Tnataled | —Trstaled Tetalled Fg | cere alee Chice 0.0. | _ length load _|Freelength | joad _| Replace poppet spring spring it x 9 6 ki __|asxes | 2s 12.6 ko Fae 2 relief valve main ~ jor deforma: valve spring 23.372 eo 2.0k9 [tion are : 5 — found 3. | Sooo! return spring 40.7%206| 254 13k9 4 | Check valve spring w1x110] 6 02ko 40-9HYDRAULIC CYLINDER SED 42 + 4.2kgm (Width across flats:36) (Offset) me) 85 45 kgm (Bucket, Ofet) 692 63k (Wie aros Natt) oom, 60 + 6.0kgm (Boom, arm, blade) * 21UF018 Unit: mm No. Cheek itern Criteria Remedy cylinder | Standard Tolerance | standard | Clearance size Ghat | Hole | clearance | timit Boom 0.025 | +0.152 | 0.087 so | 4 | eylinder © | -0087 | +0007 | -o208 | 9519 Clearance Arm’ 40 0.025 | +0132 | 0031 | aa 1 |between piston | cylinder -0.087 | +0.006 | -0219 t Replace rod and bushing |B 5 | bushing ws | Bucket fa 40132 | 0031 | oeig hing | +0006 | -0219 Offset a5 | 0.025 | +0132 | oa cop eylindsr -0.087 | +0.006 | —o219 Blade a 40.132 | 0.031 acs eylinder [+0008 | -o219 | Boom a5 | 40142 | 0130 40 . L_evtinder | -0.14 | +0080 | ~o282 | 1° Clearance Arm 40 | -008 | 40.142 | 0.130 10 between piston | evlinder -014 | +0000 | “o2e2 2 |rod (eylinder [Bucket 3s | -0.170 | *0142 | 0.220 10 a bottom) mount: | eytinder | +0080 | -0.351 ee ing pin and Offer “e170 | 40.142 ‘° bushing cylinder 38 -0203 | +0080 | a Blade ao | 0.170 | +0142 a eylinder [+0200 | +0.080 40-10 021U01WORK EQUIPMENT tonizo S 8 8 Section DD Section EE Section BB Section CC Section AA, Section KK Section J Section HH Section GG Section FF 40-12Section LL. Section MM Section NN Section 00 Section PP Section 0 Section RR Section SS Section TT Section UU Fo21u01011 2 g Unit: mm No. Check item Criteria Remedy ‘Standard Tolerance ‘Standard Clearance between link-bucked size | Grae] owe | clearance | timix 7 connecting pin and bushing |- 4 a 36 | ~at70 | =0.008 | oni8 =0209 | -0.052 | -0.206 ~ 2 Clearance between arm-bucket 38 0.170 | —0.003 0.118 connecting pin and bushing 0.209 | -0.052 | 0.206 ~ 3 Clearance between arm-link 35 0.170 | —0.003 0.118 connecting pin and bushing =0209 | -0052 | ~0.206 __| Replace Clearance between third. ~ | =0.170 | -0.003 0.118 pin or “eed bashing 40-0209 | -0052 | -0.206 ___| bushing Clearance between frst Boor “0.025 | 40.039 | 0.025 5 [retclinratienecomecine | 40 | 3064 | so eons | Clerance bewean ofietTink | 35 | 060 | +0083 | 0.160 mounting pin and bushing -0.193 | +0 0.226 Clearance between first boon | 50 0.025 | +0.039 0.025 7 | seeppd boom connecting pin 0.064 | 0 0.103 > [clearance between second | =0.170 | +0039 [0.170 | gomeinraasom connecting | 45 4 8 | beomtibeam conection “208 | “0 248 @ | Clearance between blade 0.170 | 40.142 0.250 mounting pin and bushing =0200 | +0080 | -0.351_| 40-13