Service manual New Holland E10SR Mini Crawler Excavator | 84363846

New Holland E10SR Mini Crawler Excavator (Preview)

2_SPECIFICATIONS.pdf
– 1. SPECIFICATIONS
— 2.1 COMPONENTS NAME 2-3
— 2.2 MACHINE DIMENSIONS 2-4
— 2.3 SPECIFICATIONS AND PERFORMANCE 2-5
— 2.4 MACHINE & COMPONENTS WEIGHT (DRY) 2-7
— 2.5 TRANSPORTATION DIMENSIONS AND WEIGHT 2-8
— 2.6 TYPE OF CRAWLER SHOES 2-12
— 2.7 TYPE OF BUCKETS (Reference Only) (Japanese standard bucket) 2-13
— 2.8 MACHINE LIFTING PROCEDURE 2-14
— 2.9 LIFTING CAPACITIES 2-15
— 2.10 ENGINE SPECIFICATIONS 2-17
— 2.10.1 SPECIFICATIONS 2-17
— 2.10.2 ENGINE PERFORMANCE CURVE 2-18
– 2.1 COMPONENTS NAME
– 2.2 MACHINE DIMENSIONS
– 2.3 SPECIFICATIONS AND PERFORMANCE
– 2.4 MACHINE & COMPONENTS WEIGHT (DRY)
— Unit : kg (lbs)
– 2.5 TRANSPORTATION DIMENSIONS AND WEIGHT
– 2.6 TYPE OF CRAWLER SHOES
– 2.7 TYPE OF BUCKETS (Reference Only) (Japanese standard bucket)
– 2.8 MACHINE LIFTING PROCEDURE
— (1) Manipulate each operating level to take the machine a posture as shown in the figure.
— (2) Operate the boom swing pedal to face the boom direct front.
— (3) Stop the engine, and make the safety lock lever to “LOCKED” position. Then take off the machine after confirmation for no abnormalities around the operator’s seat.
— (4) Install shackles to both bores (B) provided at both ends of the dozer blade, and put the wire ropes on them.
— (5) Put the wire ropes on the (A) portion of the boom.
— (6) Slightly lift the machine to confirm the balance, then lift up the machine.
– 2.9 LIFTING CAPACITIES
— 1. The lifting load shows the lower value either 87% of lifting capacity by hydraulic pressure, or 75% of tipping load.
— 2. The load point is on the bucket lift point, and the bucket cylinder is extended (bucket IN).
— 3. Weight of hooks, slings, and all other lifting equipment shall be considered a part of the load.
— 4. The values in the upper rows show the lifting capacity at a machine facing sideways, and values in the lower rows show a machine facing longitudinally.
— 5. Unit : ton,
— 6. Set hydraulic pressure 20.6MPa (2990 psi)
— (1) Long Arm
— (2) Long Arm
– 2.10 ENGINE SPECIFICATIONS
— 2.10.1 SPECIFICATIONS
— 2.10.2 ENGINE PERFORMANCE CURVE
3_ATTACHMENT DIM.pdf
– 3. ATTACHMENT DIMENSIONS
— 3.1 BOOM 3-3
— 3.1.1 BOOM DIMENSIONAL DRAWINGS 3-3
— 3.1.2 BOOM MAINTENANCE STANDARDS 3-4
— 3.2 ARM 3-8
— 3.2.1 ARM DIMENSIONAL DRAWINGS 3-8
— 3.2.2 ARM MAINTENANCE STANDARDS 3-10
— 3.3 BUCKET 3-14
— 3.3.1 BUCKET DIMENSIONAL DRAWINGS 3-14
— 3.3.2 DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION 3-15
— 3.3.3 DETAIL DIMENSIONAL DRAWINGS OF BOSS SECTION 3-16
— 3.4 DOZER 3-17
— 3.4.1 DOZER DIMENSIONAL DRAWINGS 3-17
— 3.4.2 DOZER MAINTENANCE STANDARDS 3-18
— 3.5 SWING 3-20
— 3.5.1 SWING BRACKET DIMENSIONAL DRAWINGS 3-20
— 3.5.2 SWING PORTION MAINTENANCE STANDARDS 3-21
– 3.1 BOOM
— 3.1.1 BOOM DIMENSIONAL DRAWINGS
— Boom Dimensional Drawings
— 3.1.2 BOOM MAINTENANCE STANDARDS
— Clearance of pin and bushing on boom section
— Clearance in thrust direction on boom section
– 3.2 ARM
— 3.2.1 ARM DIMENSIONAL DRAWINGS
— Arm dimensional drawings
— 3.2.2 ARM MAINTENANCE STANDARDS
—- (1) Clearance of pin and bushing
— Clearance of pin and bushing on arm section
— (2) Clearance in thrust direction on arm and cylinder installation section
— Clearance in thrust direction on arm section
– 3.3 BUCKET
— 3.3.1 BUCKET DIMENSIONAL DRAWINGS
— Bucket dimensional drawings
— Unit : mm (in)
— 3.3.2 DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION
— Dimension of lug section
— 3.3.3 DETAIL DIMENSIONAL DRAWINGS OF BOSS SECTION
— Dimension of boss section
– 3.4 DOZER
— 3.4.1 DOZER DIMENSIONAL DRAWINGS
— Dozer dimensional drawings
— 3.4.2 DOZER MAINTENANCE STANDARDS
— Dozer maintenance standards
— (1) Clearance of pin and bushing
— (2) Clearance in thrust direction on the dozer and cylinder installation section
– 3.5 SWING
— 3.5.1 SWING BRACKET DIMENSIONAL DRAWINGS
— Swing bracket dimensional drawings
— 3.5.2 SWING PORTION MAINTENANCE STANDARDS
—- (1) Clearance of pin and bushing
— Clearance of pin and bushing on swing portion
— (2) Clearance in thrust direction on swing bracket and cylinder installation section
— Clearance in thrust direction on swing portion
11_TOOLS.pdf
– 11. TOOLS
— 11.1 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS 11-3
— 11.1.1 Metric Coarse Thread Standard Tightening Torque Values. Make Certain to tighten all Capscrews & Nuts to proper torque values. 11-3
— 11.1.2 Metric Fine Thread Standard Tightening Torque values. Make certain to tighten all Capscrews & Nuts to proper torque values. 11-4
— 11.2 SCREW SIZE 11-5
— 11.2.1 CAPSCREW 11-5
— 11.2.2 CAPSCREW (SOCKET BOLT) 11-5
— 11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES 11-6
— 11.3.1 JOINTS FOR PIPING (O-RING SEALING TYPE) 11-6
— 11.3.2 HYDRAULIC HOSE (30 DEG. FLARE TYPE) 11-6
— 11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS 11-7
— 11.4.1 SLEEVE TYPE TUBE FITTINGS 11-7
— 11.4.2 PART NO. 11-7
— 11.5 PLUGS 11-8
— 11.5.1 PLUG FOR HYDREAULIC PIPE JOINT 11-8
— 11.5.2 PLUG FOR HYDRAULIC EQUIPMENT 11-9
— 11.6 SPECIAL SPANNERS FOR TUBES 11-10
— 11.7 APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS 11-11
– 11.1 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS
— 11.1.1 Metric Coarse Thread Standard Tightening Torque Values. Make Certain to tighten all Capscrews & Nuts to proper torque values.
— 11.1.2 Metric Fine Thread Standard Tightening Torque values. Make certain to tighten all Capscrews & Nuts to proper torque values.
– 11.2 SCREW SIZE
— 11.2.1 CAPSCREW
— 11.2.2 CAPSCREW (SOCKET BOLT)
– 11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES
— 11.3.1 JOINTS FOR PIPING (O-RING SEALING TYPE)
— 11.3.2 HYDRAULIC HOSE (30 DEG. FLARE TYPE)
– 11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS
— 11.4.1 SLEEVE TYPE TUBE FITTINGS
— 11.4.2 PART NO.
– 11.5 PLUGS
— 11.5.1 PLUG FOR HYDREAULIC PIPE JOINT
— 11.5.2 PLUG FOR HYDRAULIC EQUIPMENT
– 11.6 SPECIAL SPANNERS FOR TUBES
– 11.7 APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS
12_STD MAINTENANCE TT.pdf
– 12. STANDARD MAINTENANCE TIME TABLE
— 12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR 12-4
– PREFACE
— 1. Technicians : One more technicians who are qualified by Manufacturer are needed. The technicians need five years of more experience, and they have to complete the training in the operation of this machine.
— 2. Facilities : General jigs, tools, apparatus, testers to be provided.
— 3. Place : The workshop to be located on a flat land at which the work is able to perform and to which a service car or truck crane is accessible.
— 1. Standard maintenance time : Direct maintenance time plus spare time.
— 2. Direct maintenance time : Net time actually spent for maintenance.
— 3. Spare time : Time for transportation of the machine for maintenance, preparation for safety work, meeting for the work and physiological time for the needs of body.
— 1. Repairing time : Time for machining, sheet metal processing, welding, gas cutting, removing broken screw, taking care of parts and painting.
— 2. Items excluded from maintenance time because of uncertainty in time :
— 3. Indirect time : Time for field work, preparation of required parts, etc., before starting work, going to and from the site, waiting due to user’s convenience at the site and paper work for reports, bills, etc.
— 4. Special time : Working time at early morning, at mid night and on holidays shall be separately calculated.
— 5. Separate calculation : The cost for service cars, trucks with crane and truck cranes shall be separately calculated.
— 1. Standard machine.
— 2. A well maintained machine combined with standard attachments which has operated in a normal circumstances.
— 12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR
— 1. Units of working time : 6 minutes = 0.1 hour
— 2. Calculating method of standard maintenance time :
— 3. When more than one work are done,
— 4. O / H : The removing and installing time are not included.
— 5. Abbreviations in the table.
— No.
— GROUP
— REMARKS
— 01 Attachment(1/2)
— No.
— EQUIPMENT PORTION
— WORK TO
— BE DONE
— UNIT
— REMARKS
— UNIT : HOUR
— 01 Attachment(2/2)
— No.
— EQUIPMENT PORTION
— WORK TO
— BE DONE
— UNIT
— REMARKS
— UNIT : HOUR
— 02 Canopy & Guard (1/1)
— No.
— EQUIPMENT PORTION
— WORK TO
— BE DONE
— UNIT
— REMARKS
— UNIT : HOUR
— 03 Upper structure (1/4)
— No.
— EQUIPMENT PORTION
— WORK TO
— BE DONE
— UNIT
— REMARKS
— UNIT : HOUR
— 03 Upper structure (2/4)
— No.
— EQUIPMENT PORTION
— WORK TO
— BE DONE
— UNIT
— REMARKS
— UNIT : HOUR
— 03 Upper structure (3/4)
— No.
— EQUIPMENT PORTION
— WORK TO
— BE DONE
— UNIT
— REMARKS
— UNIT : HOUR
— 03 Upper structure(4/4)
— No.
— EQUIPMENT PORTION
— WORK TO
— BE DONE
— UNIT
— REMARKS
— UNIT : HOUR
— 04 Under carriage
— No.
— EQUIPMENT PORTION
— WORK TO
— BE DONE
— UNIT
— REMARKS
— UNIT : HOUR
13_MAINTENANCE STD.pdf
– 13. MAINTENANCE STANDARD AND TEST PROCEDURE
— 13.1 HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS 13-3
— 13.2 PERFORMANCE INSPECTION STANDARD TABLE 13-5
— 13.2.1 STANDARD VALUE TABLE 13-5
— 13.3 MEASURING ENGINE SPEED 13-7
— 13.3.1 ENGINE SPEED MEASUREMENT 13-7
— 13.4 MEASUREMENT OF HYDRAULIC PRESSURE 13-9
— 13.4.1 STANDARD FOR HYDRAULIC OIL PRESSURE MEASUREMENT 13-9
— 13.4.2 PRESSURE MEASUREMENT AND ADJUSTMENT 13-9
— 13.5 MEASURING TRAVEL PERFORMANCES 13-13
— 13.5.1 TRAVEL 13-13
— 13.5.2 TRAVEL DEVIATION 13-14
— 13.5.3 MOVEMENT DRIFT DUE TO GRAVITY 13-14
— 13.5.4 DRAIN RATE ON TRAVEL MOTOR 13-15
— 13.6 MEASURING SWING PERFORMANCES 13-16
— 13.6.1 SLEW TIME 13-16
— 13.6.2 OVERRUN WHEN SLEWING STOPS 13-16
— 13.6.3 SLEW DRIFT DUE TO GRAVITY 13-16
— 13.6.4 DRAIN RATE OF SLEW MOTOR 13-17
— 13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES 13-18
— 13.7.1 CYLINDER SPEED 13-18
— 13.7.2 GRAVITY DRIFT OF CYLINDERS 13-19
— 13.8 MEASURING SLEW BEARING PERFORMANCES 13-20
— 13.8.1 SLEW BEARING-BUCKET TIP PLAY 13-20
— 13.8.2 SLEW BEARING PLAY 13-20
— 13.9 MEASURING CRAWLER TENSION 13-21
— 13.9.1 CRAWLER TENSION 13-21
– 13.1 HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS
– (1)
— 1. For New Machine;
— 2. At Specific Self-Inspection (as per LOCAL RULES);
— 3. At Deterioration of Performance;
— 4. For Replacement of Major Components;
– (2)
— 1. Standard Values :
— 2. Standard Values for Repair :
— 3. Serviceability Limit :
– (3)
— 1. Evaluation for Measured Data :
— 2. Determination for Reconditioning, Adjustment or Replacement :
– (4)
— 1. Parts with Aging Effect :
— 2. Parts required Periodical Replacement :
— 3. Inspection & Replacement of Lubricants :
— 13.2 PERFORMANCE INSPECTION STANDARD TABLE
— 13.2.1 STANDARD VALUE TABLE
— 13.3 MEASURING ENGINE SPEED
— 13.3.1 ENGINE SPEED MEASUREMENT
– (1)
— 1. Diesel Speedometer (Measuring engine speed by means of applying a pick-up to one of injection pipes)
— 2. Surface Thermometer (Measuring the surface temperature getting contact of the probe with the surface of hydraulic oil tank and radiator)
— Engine Speed measurement (The above figure shows concept)
– (2)
– (3)
— 1. Apply the pick up of speedometer to one of convenient injection pipes. (Refer to above illustration “Engine Speed Measurement”.)
— 2. Measure the engine speed at idling with no load, and compare it to the figure in the STANDARD VALUE TABLE.
– (4)
— ADJUSTMENT OF ACCELERATION WIRE
— 13.4 MEASUREMENT OF HYDRAULIC PRESSURE
— 13.4.1 STANDARD FOR HYDRAULIC OIL PRESSURE MEASUREMENT
—- (1) Hydraulic Instruments
—- (2) Measuring cleanliness of hydraulic oil
— 13.4.2 PRESSURE MEASUREMENT AND ADJUSTMENT
– (1)
– (2)
— 1. After releasing pressure in the hydraulic oil tank, and setting a 49 MPa (7100 psi) pressure gauge to either of pressure detecting ports (G1, G2 PF1/4 with plug), operate the circuit to be measured to measure the relief pressure.
— 2. When the main relief pressure is being within the standard range, the measurement for the overload relief pressure may be omitted.
— 3. If the main relief pressure is lower than the standard range, tighten up the main relief valve by half turn [pressure increase by 6.1 MPa (880 psi)], then measure the pressure at overload relief valve.
— 4. After adjustment for the overload relief pressure, return back the main relief pressure within the standard range.
— Main hydraulic oil pressure measurement
— Position of relief valve
– (3)
– 1.
— a. Loosen the lock nut (2), and adjust the setting pressure turning the setscrew (1).
— Main relief valve
— b. After the adjustment, tighten up the lock nut holding the setscrew not to turn around.
— c. Again activate the relief valve to check the stable setting pressure.
— Overload relief valve
– 2.
— a. Remove the cap nut(1), and loosen the lock nut (2). Then adjust the setting pressure turning the setscrew (3).
— b. After the adjustment, tighten up the lock
— Relief valve (Slewing motor)
— (1) Measuring Conditions
— (2) Measurement
— Pilot oil pressure measurement
— (3) Pressure Adjustment
— 1. Loosen the lock nut (2), then turn the setscrew (1) to adjust the set pressure.
— 2. After the adjustment, lock the setscrew with the lock nut holding the setscrew not to allow its turning.
— 3. Again actuate the relief valve, and verify that the set pressure is being stable.
— Relief valve for pilot line
— 13.5 MEASURING TRAVEL PERFORMANCES
— 13.5.1 TRAVEL
– (1)
– (2)
— 13.5.2 TRAVEL DEVIATION
— 13.5.3 MOVEMENT DRIFT DUE TO GRAVITY
— 13.5.4 DRAIN RATE ON TRAVEL MOTOR
– (1)
— 1. Apply stopper pins for both travel sprockets of left and right.
— 2. Stop the engine, and release air in the hydraulic oil tank.
— 3. Connect a hose to the drain port of travel motor, and receive the drained oil in a container.
— 4. Apply a plug to the drain piping at tank side.
– (2)
— 13.6 MEASURING SWING PERFORMANCES
— 13.6.1 SLEW TIME
— 13.6.2 OVERRUN WHEN SLEWING STOPS
— 13.6.3 SLEW DRIFT DUE TO GRAVITY
— 13.6.4 DRAIN RATE OF SLEW MOTOR
– (1)
— 1. Stop the engine, and release air inside the hydraulic oil tank.
— 2. Disconnect the slew motor drain hose at the return side to the hydraulic oil tank. Then receive the drain oil to a container.
– (2)
— 13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES
— 13.7.1 CYLINDER SPEED
– (1)
– (2)
– (3)
– (4)
– (5)
– (6)
— 13.7.2 GRAVITY DRIFT OF CYLINDERS
– (1)
— 13.8 MEASURING SLEW BEARING PERFORMANCES
— 13.8.1 SLEW BEARING-BUCKET TIP PLAY
— 13.8.2 SLEW BEARING PLAY
— 13.9 MEASURING CRAWLER TENSION
— 13.9.1 CRAWLER TENSION
22_HYDRAULIC SYS.pdf
– 22. HYDRAULIC SYSTEM
— 22.1 SUMMARY 22-3
— 22.1.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT 22-3
— 22.2 HYDRAULIC CIRCUITS AND COMPONENT MODELS 22-4
— 22.2.1 STANDARD SPECIFICATION 22-5
— 22.3 HYDRAULIC CIRCUIT OPERATION 22-6
— 22.3.1 COLOR CODING STANDARDS 22-6
— 22.3.2 NEUTRAL CIRCUIT 22-6
— 22.3.3 TRAVEL OPERATING CIRCUIT 22-8
— 22.3.4 SLEW OPERATING CIRCUIT 22-10
— 22.3.5 BUCKET OPERATING CIRCUIT 22-12
— 22.3.6 BOOM OPERATING CIRCUIT 22-14
— 22.3.7 ARM OPERATING CIRCUIT 22-16
— 22.3.8 BOOM SWING OPERATING CIRCUIT 22-18
— 22.3.9 DOZER OPERATING CIRCUIT 22-20
— 22.3.10 RETRACTABLE CRAWLER OPERATING CIRCUIT 22-22
— 22.3.11 NIBBLER & BREAKER OPERATING CIRCUIT 22-24
— 22.3.12 TRAVEL / DOZER COMBINED OPERATING CIRCUIT 22-26
— 22.4 SCHEMATIC PIPING FOR HYDRAULIC SYSTEM 22-28
– 22.1 SUMMARY
— 22.1.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT
– 22.2 HYDRAULIC CIRCUITS AND COMPONENT MODELS
22_HYDRAULIC SYS_A3.pdf
– 22.2 HYDRAULIC CIRCUITS AND COMPONENT MODELS
— 22.2.1 STANDARD SPECIFICATION
– 22.3 HYDRAULIC CIRCUIT OPERATION
— 22.3.1 COLOR CODING STANDARDS
— 22.3.2 NEUTRAL CIRCUIT
— 1. Pilot Primary Pressure Circuit
— 2. Pilot Secondary Pressure Circuit
— 1. Variable Pump Circuit
— Newtral circuit
— 22.3.3 TRAVEL OPERATING CIRCUIT
—- 22.3.3.1 2nd Speed Operating Circuit (Independent-forward travel)
—- 1. Shifting signal for 2nd speed travel
—- 1. Circuit up to Travel Motor (4)
—- 2. Travel Motor
— Travel circuit : Travel foward operation at travel 2nd speed
— 22.3.4 SLEW OPERATING CIRCUIT
—- 22.3.4.1 Slew (left) Operating Circuit
—- 1. Slew Valve Spool Shifting
—- 1. Supply Circuit for Slewing Motor (3)
—- 2. Stewing Motor (3)
— Slewing circuit : Slewing left operation
— 22.3.5 BUCKET OPERATING CIRCUIT
—- 22.3.5.1 Bucket Digging Operation Circuit
—- 1. Bucket Spool Shifting
—- 1. Supply Circuit for Cylinder (7)
—– 22.3.5.2 Bucket Dumping Operating Circuit
—- 1. Bucket Spool Shifting
—- 1. Supply Circuit for Cylinder (7)
— Bucket circuit : Bucket digging operation
— 22.3.6 BOOM OPERATING CIRCUIT
—- 22.3.6.1 Boom Up Operating Circuit
—- 1. Boom Spool Shifting
—- 1. Supply Circuit for Cylinder (5)
—– 22.3.6.2 Boom Down Operating Circuit
—- 1. Boom Spool Shifting
—- 1. Supply Circuit for Cylinder (5) and Return Oil Circuit
— Boom circuit : Boom up operation
— 22.3.7 ARM OPERATING CIRCUIT
—- 22.3.7.1 Arm In Operating Circuit
—- 1. Shift for Arm Spool
—- 1. Supply Circuit for Cylinder (6)
—- 2. Return Line from Cylinder (6)
—– 22.3.7.2 Operating Circuit for Arm Out
— Arm circuit : Arm in operation
— 22.3.8 BOOM SWING OPERATING CIRCUIT
—- 22.3.8.1 Boom Swing (left) Operating Circuit
—- 1. Supply Circuit for Cylinder (8)
— Swing circuit : Boom swing left operation
— 22.3.9 DOZER OPERATING CIRCUIT
—- 22.3.9.1 Dozer Lowering Operating Circuit
—- 1. Supply Circuit for Cylinder (9)
— Dozer circuit : Dozer down operation
— 22.3.10 RETRACTABLE CRAWLER OPERATING CIRCUIT
—- 1. Supply circuit for cylinder (10)
— Retractable crawler operating circuit : Retractable crawler width expansion operating
— 22.3.11 NIBBLER & BREAKER OPERATING CIRCUIT
—- 22.3.11.1 Nibbler Close Operating Circuit
—- 1. Service Spool Shifting
—- 1. Supply Circuit for Nibbler Cylinder
—- 2. Return Line from Nibbler Cylinder
—– 22.3.11.2 Nibbler Open Operating Circuit
—– 22.3.11.3 Breaker Blow Operating Circuit
—- 1. Service spool shifting
—- 1. Supply Circuit for Breaker
—- 2. Return Line from Breaker
— Nibbler & breaker circuit : Nibbler close operation
— 22.3.12 TRAVEL / DOZER COMBINED OPERATING CIRCUIT
—- 22.3.12.1 Travel (1st speed forwarding) / Dozer Lowering Operating Circuit
—- (1) Pilot circuit
—- (2) Main Circuit
— Combined operation circuit : Travel (forward) 1st speed / Dozer down operation
– 22.4 SCHEMATIC PIPING FOR HYDRAULIC SYSTEM
— Schematic piping for hydraulic system
23_ELECTRICAL SYS.pdf
– 23. ELECTRICAL SYSTEM
— 23.1 HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION 23-3
— 23.1.1 ELECTRIC CIRCUIT DIAGRAM 23-3
— 23.1.2 HARNESS CONNECTION 23-3
— 23.2 ELECTRICAL EQUIPMENT & HARNESS 23-4
— 23.2.1 ELECTRICAL EQUIPMENT LIST 23-4
— 23.2.2 HARNESS & CABLE LIST 23-6
— 23.2.3 ELECTRIC CIRCUIT DIAGRAM 23-7
— 23.2.4 ARRANGEMENT DRAWING FOR COMPONENTS HARNESS 23-8
— 23.2.5 DETAIL OF HARNESS & CABLE 23-15
– 23.1 HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION
— 23.1.1 ELECTRIC CIRCUIT DIAGRAM
— (1) In the diagram, the number, size and color of wires are shown on the wiring line.
— 23.1.2 HARNESS CONNECTION
— 1. The figure for the connector pin arrangement is shown by putting the lock (nail) to upper portion, and looking from the fitting face.
— 2. The numbers in the connector show the wire No., and alphabetical letters show the wire color.
— 3. On the side face of connector, the connector name and serial number of the connector No. are indicated.
— 4. At the place indicated as “DOUBLE SPLICE”, Two wires are connected to one place.
— (2) The connector is to be connected with engaging the male (M) and female (F) connectors of the same number.
— (3) +<-- mark means the connector with diode. The direction for diode is shown by the arrow. --- (4) The AVSS wires are to be used for the size between 0.75 sq and 2 sq. AVS wires between 3 sq and 5 sq and others are AV wires, unless otherwise specified. --- (5) The wire size is 0.75 sq, unless otherwise specified. --- (6) The treatment for the harness end is to be as follows : --- (7) The length for the above (6)-3) is to be 30±10 mm. (1.2±0.4 in), and the length includes in the total length of wire shown in the diagram. - 23.2 ELECTRICAL EQUIPMENT & HARNESS -- 23.2.1 ELECTRICAL EQUIPMENT LIST -- 23.2.2 HARNESS & CABLE LIST 23_ELECTRICAL SYS_A3.pdf - 23.2 ELECTRICAL EQUIPMENT & HARNESS -- 23.2.3 ELECTRIC CIRCUIT DIAGRAM -- 23.2.4 ARRANGEMENT DRAWING FOR COMPONENTS HARNESS -- 23.2.5 DETAIL OF HARNESS & CABLE 24_COMPONENTS SYS.pdf - 24. COMPONENTS SYSTEM -- 24.1 HYDRAULIC COMPONENTS 24-3 --- 24.1.1 HYDRAULIC PUMP 24-3 --- 24.1.2 PILOT VALVE (ATT) 24-7 --- 24.1.3 CONTROL VALVE 24-11 --- 24.1.4 SLEWING MOTOR 24-29 --- 24.1.5 TRAVEL MOTOR 24-35 --- 24.1.6 SWIVEL JOINT 24-44 --- 24.1.7 CYLINDER 24-46 -- 24.2 ELECTRICAL EQUIPMENT 24-53 --- 24.2.1 ELCTRICAL EQUIPMENT LIST 24-53 --- 24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT 24-55 - 24.1 HYDRAULIC COMPONENTS -- 24.1.1 HYDRAULIC PUMP - 24.1.1.1 SUMMARY -- General view of hydraulic pump - 24.1.1.2 CONSTRUCTION -- Hydraulic pump-Sectional vie --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY - 24.1.1.3 OPERATION -- Valve plate and Cylinder barrel -- Operating Principle --- 24.1.2 PILOT VALVE (ATT) - 24.1.2.1 SUMMARY - 24.1.2.2 CONSTRUCTION -- Pilot valve-Sectional view --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY - 24.1.2.3 OPERATION -- Lever in neutral position -- When Lever is tilted -- Lever being held --- 24.1.3 CONTROL VALVE - 24.1.3.1 SPECIFICATION - 24.1.3.2 SPECIFICATIONS - 24.1.3.3 CONATRUCTION -- No. -- NAME -- Q'TY -- No. -- NAME -- Q'TY - 24.1.3.4 HYDRAULIC CIRCUIT DIAGRAM - 24.1.3.5 EXPLANATION OF OPERATION -- 1. Pump port (a): This delivers pressurized oil from pump. -- 2. Pump passage (parallel passage): This leads the oil from pump port (a) to directional section. -- 3. Bypass passage: This returns delivery oil to tank when directional valve is neutral position. -- 4. Tank port (b): This drains return oil which flows from bypass passage and actuator. -- 5. Main relief valve (1) -- P1 pressure regulating section -- P2 pressure regulating section --- 1. When the spool of directional valve is in neutral position (Valve is not operated.) -- Directional section of boom (At neutral position) --- 2. When the spool of directional valve is in operated position (Spool is moved.) -- Directional section of boom (Spool is moved.) --- 1. When the spool of directional valve is in neutral position (Valve is not operated.) -- Directional section of travel (At neutral position) --- 2. When the spool of directional valve is in operated position (Spool is moved.) -- Directional section of travel (Spool is moved.) --- 1. Operation when dozer is operated independently -- Dozer switching part --- 2. Operation when dozer/travel is operated simultaneously -- DOZER/TRAVEL SIMULTANEOUS OPERATION --- 1. When the service spool is in neutral position -- SERVICE CONFLUX (at neutral position) --- 2. When the service spool is in operated position (Spool is moved.) -- SERVICE CONFLUX (at spool is moved position) -- LOAD CHECK VALVE FUNCTION --- 1. Operation of Main Relief Valve (MRV) --- a. The pressure oil of pump passes through the inside of the piston placed in the pressure regulating valve and fills in "A" spring chamber inside of the piston through the orifice "B". -- Fig.1 OPERATION OF MRV --- b. When the pressure oil of the pump reaches to the set pressure of the spring, the pressure oil acts on the adjust valve through the piston and opens the adjust valve. -- Fig.2 OPERATION OF MRV --- c. The pressure in "A" spring chamber drops because the pressure regulating valve is open, consequently the pressure oil of the pump flows out directly to the tank passage through the drilled hole "E". -- Fig.3 OPERATION OF MRV --- d. When the pressure of the pump drops lower than the spring set pressure of the adjust valve, the adjust valve returns to the former position (Fig.1 OPERATION OF MRV) by the adjust valve spring force and the pressure in "A" spring chamber is equal t... --- 2. Operation of Overload Relief Valve (ORV) --- a. The pressure oil of the actuator port passes through the inside of the piston placed in the pressure regulating valve and fills in "A" spring chamber inside of the piston through the orifice "B". -- Fig.1 OPERATION OF ORV --- b. When the pressure oil of the actuator port reaches to the set pressure of the spring, the pressure oil acts on the adjust valve through the piston and opens the adjust valve. -- Fig.2 OPERATION OF ORV --- c. The pressure in "A" spring chamber drops because the pressure regulating valve is open, consequently the pressure oil of the port "P" flows out directly to the tank passage through the drilled hole "E". -- Fig.3 OPERATION OF ORV --- d. When the pressure of the actuator port drops lower than the spring set pressure of the adjust valve, the adjust valve returns to the former position (Fig.1 OPERATION OF ORV) by the adjust valve spring force and the pressure in "A" spring chamber i... --- 3. Operation No.2 of Overload Relief Valve (ORV) [Operation at suction] -- OPERATION OF ORV [OPERATION AT SUCTION] --- 4. Operation of anti-cavitation valve -- OPERATION OF ANTI-CAVITATION VALVE --- 24.1.4 SLEWING MOTOR - 24.1.4.1 SPECIFICATION -- General view of slewing motor - 24.1.4.2 CONSTRUCTION -- Slewing motor --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY - 24.1.4.3 OPERATION -- Operational principle -- Operational principle --- 24.1.5 TRAVEL MOTOR - 24.1.5.1 SPECIFICATION -- General view of travel motor - 24.1.5.2 CONSTRUCTION -- Basic construction of travel motor -- Reduction Unit --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY -- Hydraulic Motor --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY -- Body 1 assy --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY - 24.1.5.3 OPERATION DESCRIPTION - 24.1.5.3.1 REDUCTION UNIT -- Reduction unit operation - 24.1.5.3.2 HYDRAULlC MOTOR -- Structure of Hydraulic Motor -- Hydraulic motor operation - 24.1.5.3.3 BRAKE VALVE (COUNTER BALANCE VALVE) -- Hydraulic Valve Operation --- 24.1.6 SWIVEL JOINT - 24.1.6.1 GENERAL VIEW -- General view - 24.1.6.2 SPECIFICATION - 24.1.6.3 CONSTRUCTION -- Construction --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY - 24.1.6.4 FUNCTION -- 24.1.7 CYLINDER - 24.1.7.1 SPECIFICATION -- General view of cylinde - 24.1.7.2 CONSTRUCTION AND FUNCTION - 24.1.7.2.1 CONSTRUCTION -- Construction of boom cylinder --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY -- Construction of arm cylinder --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY -- Construction of bucket cylinder --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY -- Construction of swing cylinder --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY -- Construction of dozer cylinde --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY -- Construction of retractable crawler's cylinder --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY - 24.1.7.2.2 Function (Example for boom cylinder) -- Cylinder head assy --- a. Bushing (4) --- b. Wiper Ring (7) -- Piston assy --- a. Seal Ring (17) --- b. Slide Ring (16) --- c. Cushion Bearing (20) -- 24.2 ELECTRICAL EQUIPMENT --- 24.2.1 ELCTRICAL EQUIPMENT LIST --- Group --- Code --- Part Name --- Part No. --- Group --- Code --- Part Name --- Part No. ---- 24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT 32_ATTACHMENT.pdf - 32. ATTACHMENTS -- 32.1 REMOVING AND INSTALLING 32-3 --- 32.1.1 ATTACHMENT ASSEMBLY AND NAME 32-3 --- 32.1.2 BUCKET 32-4 --- 32.1.3 ARM 32-7 --- 32.1.4 BOOM 32-10 --- 32.1.5 SWING 32-13 --- 32.1.6 DOZER 32-15 -- 32.2 DISASSEMBLING AND ASSEMBLING COMPONENTS 32-16 --- 32.2.1 CYLINDER 32-16 - 32.1 REMOVING AND INSTALLING -- 32.1.1 ATTACHMENT ASSEMBLY AND NAME -- 32.1.2 BUCKET --- (1) Operate the operating lever and place the bucket on the ground, so the bucket and arm connecting pins are not loaded. --- (2) Move the O-rings (3) toward the bucket bosses using a spatula. -- To place Bucket on ground --- (3) In order to remove pin (K) which links arm and bucket, remove the ring (2) and the pin (1) by means of straight driver, and draw out pin (K). --- (4) Adjust the bucket by manipulating the operating lever so the pin (J) between the bucket link and the bucket is not loaded. --- (5) Remove the ring (2) and pin (1) then pull out the pin (J). --- (6) Remove bucket assembly. -- Assembly of pin (SECTION A-A) --- (1) Clean the welded part of the structures and check that there is no crack on the part. --- (2) Check that the dust seal is not damaged, and replace a faulty one if necessary. --- (3) Adjust the clearance between the bucket and the arm according to Item 32.1.2.3. --- (4) Replace the worn pins and bushings according to the Section "ATTACHMENT DIMENSIONS" of "SPECIFICATIONS". --- (5) When inserting the pin, coat the shaft with grease. -- Installation of bucket --- (1) Move O-ring (3) toward the bucket embossment using a spatula, to see gap (B). --- (2) When adjusting clearance (B), bring the non- adjusting side of the bucket in contact with the arm. --- (3) Measure clearance (B) and check that it is within 0.6mm (0.024in). --- (4) Recondition clearance (B) less than 0.6mm (0.02in), where it is more than 0.6mm (0.024in). --- (5) Several shims (10) of 0.6mm (0.024in) thickness are set in each of the three capscrews (8). The clearance can be decreased by removing 0.6mm (0.024in) if one each shim is removed. --- (6) After reconditioning by required shims, tighten 3- capscrews (8) evenly. By the above procedure, bushing (A) is pushed toward inside, and then clearance is reconditioned within 0.6mm (0.024in). --- (7) Operate the bucket and check again that the total of both clearances are within 0.6mm (0.024in). --- (8) Refit O-ring (3) to its original position. -- Recondition of clearance between bucket and arm --- 32.1.3 ARM ---- (1) Making the arm cylinder and bucket cylinder to the most contracting conditions, get touch the arm tip with the ground. ---- (2) Loosing the air plug on the hydraulic oil tank, release the pressure in the tank. ---- (3) Disconnect the 2 hoses connected to the bucket cylinder. Then apply a blinding plug to the openings. -- Arm removing Posture --- (4) Lift up the arm cylinder body with a nylon sling in order not to exert any load to the pin (E). --- (5) Remove the capscrew M10X65(3) and nuts (4) that are preventing the pin (E) from coming out. Then remove the pin (E) and shims. --- (6) Placing a square timber under the arm cylinder, get down the cylinder. --- (7) Install the pin (E) to the original position, and install the capscrew M10X65(3) and nuts (4) that prevents the pin (E) from coming out. Applying a rope to the pin (E) and the arm tip, slightly lift it up in order not exert any load to the pin (F). -- Sectional view of Installing Pin --- (8) Remove the capscrew M16X30(16) that is preventing the pin (F) connecting the arm and boom from coming out. Then pull off the pin (F). --- (9) Remove the arm assy paying attention to the stability of arm. -- Removal of Arm assy --- (10) Removal of Bucket Cylinder --- 1. Remove the sems-bolt M12X25(A11) that is preventing the rod pin (H) from coming out, then pull off the pin (H). --- 2. Remove the capscrew M10X60(A3) and nuts (A4) that are preventing the head pin (G) from coming out, then pull off the pin (G). --- 3. Apply a nylon sling to the tube of bucket cylinder, and remove the cylinder. -- Sectional view of Installing Pin --- (1) Make the welded area clean to inspect any cracks there. --- (2) Check the dust seal for damages, and replace the faulty dust seal to new one (See Fig. "Dust seal Installation"). --- (3) Referring to the Section "ATTACHMENT DIMENSIONS" of Specifications, replace the worn- out pin and bushing to new ones. -- Dust seal installation --- (4) Before installing the pin, apply grease to the shaft area. --- (5) Referring to right Fig., install the capscrew and nuts to prevent the pin from coming out. --- (6) Make sure to provide an appropriate clearance for thrust direction at the installation of pin referring to (See Fig. "Sectional view of Installing Pin"). --- (7) For the adjustment for clearance, insert resin (plastic) shim first, then adjust the clearance with steel shims. -- Tightening Procedures for Nuts -- Section view of Installing Pin --- 32.1.4 BOOM ---- (1) Get down the boom from which the arm was removed, and support the boom end with a stable stand. ---- (2) Disconnect all hoses from the bucket cylinder, arm cylinder and boom cylinder, and apply plugs to all the openings. ---- (3) Disconnect the wiring for working light at the connector. -- Removal of Boom Cylinder --- (4) Removal of Boom Cylinder --- 1. Temporarily lift up the boom cylinder with a nylon sling to prevent the boom cylinder from falling down. --- 2. Removing the capscrew and nuts that are preventing the rod pin (C) from coming out, remove the pin (C). --- 3. Retract the rod, then put the cylinder on a stable stand. --- 4. Removing the capscrew that is preventing the head pin (B) from coming out, remove the pin (B). --- 5. Remove the boom cylinder. -- Sectional view of Installing Pin --- (5) Removal of Boom assembly --- 1. Temporarily lift up the boom assembly in order not to exert any load to the boom foot pin (A). --- 2. Removing the capscrew that is preventing the boom foot pin (A) from coming out, pull off the pin (A). --- 3. Applying a sling to the boom assembly, remove the boom assembly. -- Removal of Boom assembly --- (6) Removal of Arm Cylinder --- 1. Removing the capscrew and nuts that are preventing the head pin (D) from coming out, remove the pin (D). --- 2. Applying a nylon sling to the tube of arm cylinder, remove the arm cylinder. -- Sectional view of Installing Pin --- (1) Make clean the welded area on each of structure to inspect any cracks there. --- (2) Check the dust seal for damages, and replace the faulty dust seal to new one (See Fig. "Dust seal installation"). --- (3) Referring to the Section "ATTACHMENT DIMENSIONS" of Specifications, replace the worn- out pin and bush to new ones. -- Dust seal installation --- (4) Before inserting the pin, apply grease to the shaft area. --- (5) Referring to right Fig., install the capscrew and nuts to prevent the pin from coming out. --- (6) Make sure to provide an appropriate clearance for thrust direction at the installation of pin referring to (See Fig. "Sectional view of Installing Pin"). --- (7) For the adjustment for clearance, insert resin (plastic) shim first, then adjust the clearance with steel shims. -- Tightening Procedures for Nuts -- Sectional view of Installing Pin --- 32.1.5 SWING ---- (1) To make the removing work easy, swing by around 30° for rightward. ---- (2) Remove the floor plate and left side cover. ---- 1. Removing the sems-bolt M10X30(B4) that is preventing the rod side pin (M) of swing cylinder (B1) from coming out, remove the pin (M). ---- 2. Install the boom foot pin (A) to the original position on swing bracket (A1), then temporarily lift it up. ---- 3. Removing the sems-bolt M10X30(A4) that is preventing the pin (L) from coming out, remove the pin (L). ---- 4. Remove the swing bracket (A1). -- Swing portion --- 1. Disconnect 2 connecting hoses for the swing cylinder. --- 2. Removing the sems-bolt M10X30(B4) that is preventing the head side pin (N) of swing cylinder from coming out, remove the pin (N). --- 3. Take out the swing cylinder (B1) from the front side. -- Removal of swing Bracket --- (1) Check the dust seal for damages, and replace the faulty dust seal to new one. --- (2) Referring to the Section "ATTACHMENT DIMENSIONS" of Specifications, replace the worn-out pin and bushing to new ones. --- (3) Before inserting the pin, apply grease to the shaft area. --- (4) Refer to below Fig. for the shim adjustment at pin installing portion. -- Sectional view of Pin Installing --- 32.1.6 DOZER ---- (1) Put a support of appropriate height under the mounting side of dozer body, and make the dozer at a stable condition not to exert any load to the pin (P). ---- (2) Disconnect the hydraulic hoses and apply a plug to the connecting portions. ---- (3) Apply a nylon sling to the dozer cylinder (C1), and lift it up slightly not to exert any load to the pin (Q) of rod side. ---- (4) Remove the capscrew M10X55(C2) and nuts M10(C3) that are preventing the pin (Q) from coming out, of rod side. Remove the pin (Q), and support the cylinder (C1) with a wood block, etc. ---- (5) Remove the capscrew M10X55(B2) and nuts M10(B3) that are preventing the dozer body fixing pin (P) from coming out, and remove the two pins (P). ---- (6) Gradually move the machine to backward to remove the dozer. ---- (7) If necessary, remove the dozer cylinder by means of removing the pin (R) of head side. -- Removing/Installing Dozer --- (1) Referring to the Section "ATTACHMENT DIMENSIONS" of Specifications, replace the worn- out bushings and dust seals to new ones. --- (2) Before installing pin (P), (Q) and (R), apply grease to their shaft area. --- (3) Referring to right Fig., install the nuts for capscrew to prevent the pin from coming out. -- Tightening Procedures for Nuts - 32.2 DISASSEMBLING AND ASSEMBLING COMPONENTS -- 32.2.1 CYLINDER -- List of Tools and Jigs -- Construction of boom cylinder --- 1. Fix the clevis portion of tube with a vice, and hold the other end with a wooden stand to hold the cylinder in level. --- 2. Drain hydraulic oil remained in the cylinder. -- Disassembling cylinder assy --- 3. Make straight the locking fin for the cylinder head (3). -- Unlocking cylinder head --- 4. Loosen the cylinder head (3). --- 5. Pull off the piston rod assy from the tube. -- Disassembling cylinder head --- 1. Fix the piston rod assy in level. --- 2. Disassembly of the piston -- Disassembling piston rod --- a. Remove the setscrew (19), then remove the steel ball (18). --- b. Remove the. piston (15) assy. --- c. Remove the cushion bearing (20) (for Boom Cylinder only). -- Removing piston assy --- 4. Remove the cylinder head (3) assy. -- Removing cylinder head assy --- 1. Remove the slide ring (16) from the piston (15). --- 2. Remove the seal ring assy (17). -- Disassembling piston assy --- 1. Remove the O-ings (8) (11) and back-up ring (9) from the outer periphery of cylinder head (3). Then remove the O-ring (10) and back-up ring (9) [for Boom Cylinder only]. -- Disassembling cylinder head assy --- 2. Removal of U-ring --- a. Remove the stopper (14). --- b. Remove the spacer (13). --- c. Remove the cushion ring (12). --- d. Remove the U-ring (5). --- e. Remove the back-up ring (6). -- Disassembling cylinder head assy --- a. Remove the U-ring (5). --- b. Remove the back-up ring (6). -- Disassembling cylinder head assy --- a. Remove the U-ring (5). -- Disassembling cylinder head assy --- 2. Remove the wiper ring (7). -- Removing wiper ring --- 3. Remove the bushing (4) using a removal jig. -- Removing bushing --- 1. Remove the dust seals (22) from the clevis portion of tube (1) and piston rod (2). -- Removing dust seal --- 2. Remove the pin bushing (21). -- Removing pin bushing --- 1. With the installing jig (B) shown Item 32.2.1.7, press the bushings (21) into the piston rod assy (2) and tube assy (1). -- Installing Pin Bushing --- 2. With the setting tool, install the dust seal (22). -- Installing Dust Seal --- 1. With installing jig (A) shown Item 32.2.1.7, press-fit the bushing (4). -- Assembling Cylinder Head --- 2. Installing U-Ring --- a. Install the back-up ring (6). --- b. Install the U-ring (5) paying attention for its installing direction. --- c. Install the cushion ring (12). --- d. Install the spacer (13). --- e. Install the stopper (14). -- Installing U-Ring --- a. Install the back-up ring (6). --- b. Install the U-ring (5). -- Installing U-ring --- a. Install the U-ring (5). -- Installing U-ring --- 2. Using the setting tool, install the wiper ring (7). -- Installing wiper ring --- 3. Install the back-up ring (9) and O-rings (8) (11). Then install the back-up ring (9) and O-ring (10)[for Boom Cylinder only]. -- Installing back-up ring and O-ring --- 1. Install the O-ring for the seal ring assy (17). -- Installing O-ring --- 2. Set the sliding jig (C) shown Item 32.2.1.7 on the piston (15), then quickly push the seal ring (17) onto the piston (15) with the pushing jig (D) shown Item 32.2.1.7. -- Assembling seal ring --- 3. Since the seal ring (17) is extremely stretched at the installation, reform it with the reforming jig (E) shown Item 32.2.1.7. -- Reforming seal ring --- 4. Install the slide ring (16). -- Installing slide ring --- 1. Fix the piston rod (2) in level, and install the cylinder head assy onto it. -- Installing head assy --- 2. Install the piston assy. --- a. Install the cushion bearing (20) (for Boom Cylinder only) and piston (15) on the piston rod(2), and tighten them up. --- b. Put the steel ball (18) into the threaded bore, and securely tighten it with the setscrew (19). And caulk the setscrew (19) with a punch at two points. -- Installing piston assy --- 1. Fix the tube in level, and install the piston rod assy into it. -- Installing piston rod --- 2. Install the cylinder head (3). -- Installing cylinder --- 3. Bend the locking, fin on the tube to lock the cylinder head. -- Locking cylinder head -- 1. Inspection item --- 1. Clearance between piston rod and rod bushing : --- 2. Bend of piston rod : -- Measuring method -- Unit : N-m(lbf-ft) --- a. Put the cylinder horizontally at unloaded condition. --- b. Apply pressure slowly and alternately through the ports at both ends to operate the piston rod 5 or 6 times. --- c. Check that the cylinder operates normally. -- Unloaded test --- a. Apply test pressure for 3 minutes each to the rod retraction side and to the rod extension side of the cylinder. --- b. Confirm that rod seals, cylinder head tightening part, and each weld are free from abnormalities, such as external leakage and permanent deformation. --- a. Disconnect the hose from the rod extension side of the cylinder. --- b. Apply test pressure to the rod retraction side of the cylinder for 3 minutes. --- c. Measure the leakage from the rod extension side. -- Leakage teat --- 1. Start the engine, and let it idling for about 5 minutes. --- 2. Repeat the step of extending and retracting the cylinder 4 or 5 times at slow speed of engine. --- 3. Perform the above 2) procedures at high idling speed, then move the piston rod to its stroke end at low idling speed to operate the relief valve. 33_UPPER SLEWING STR.pdf - 33. UPPER SLEWING STRUCTURE -- 33.1 REMOVING AND INSTALLING 33-3 --- 33.1.1 CANOPY 33-3 --- 33.1.2 GUARD (COVER AND SUPPORT) 33-4 --- 33.1.3 BATTERY 33-6 --- 33.1.4 CONTROL BOX 33-7 --- 33.1.5 AIR CLEANER 33-9 --- 33.1.6 GENERATOR 33-10 --- 33.1.7 STARTER 33-11 --- 33.1.8 MUFFLER 33-12 --- 33.1.9 FUEL LINE 33-13 --- 33.1.10 FUEL TANK 33-14 --- 33.1.11 HYDRAULIC OIL TANK 33-15 --- 33.1.12 PUMP 33-18 --- 33.1.13 RADIATOR 33-20 --- 33.1.14 ENGINE 33-22 --- 33.1.15 CONTROL VALVE 33-25 --- 33.1.16 PILOT VALVE 33-28 --- 33.1.17 SLEWING MOTOR 33-30 --- 33.1.18 SWIVEL JOINT 33-32 --- 33.1.19 UPPER FRAME 33-35 -- 33.2 DISASSEMBLING AND ASSEMBLING COMPONENTS 33-37 --- 33.2.1 HYDRAULIC PUMP 33-37 --- 33.2.2 CONTROL VALVE 33-47 --- 33.2.3 PILOT VALVE (Attachment) 33-76 --- 33.2.4 SWIVEL JOINT 33-88 --- 33.2.5 SLEWING MOTOR 33-98 - 33.1 REMOVING AND INSTALLING -- 33.1.1 CANOPY --- (1) Remove the floor mats (8) and (9). --- (2) Removing handrail (1) -- Floor mat and handrail removal --- (3) Removing canopy assembly --- (4) Install the canopy in reverse order of the removal. -- Removal of canopy assembly --- 33.1.2 GUARD (COVER AND SUPPORT) ---- (1) Removing cover assembly (Floor plate)(4) ---- (2) Removing right hand cover assembly (2) ---- (3) Removing left hand cover assembly (3) ---- (4) Removing control box ---- (5) Removing bonnet assembly (1) -- Cover assembly (2),(3),(4) and bonnet assembly (1) removal --- (6) Removing support assembly (5) --- (7) Removing support (6) --- (8) Removing support (7) -- Support (5),(6) and (7) removal --- 33.1.3 BATTERY ---- (1) Remove the cover assembly (3) of the left side (See Section 33.1.2.1-(3)). ---- (2) Open the cover under the seat. -- Battery removal preparation --- (1) Remove the band (1). --- (2) Removing the battery --- a. Pull out the battery to near side. --- b. Disconnect the negative side terminal of the cable. --- c. Then, disconnect the positive side terminal of the cable. -- Battery removal --- (4) Take out the battery (1) holding the straps attached to it. --- 33.1.4 CONTROL BOX ---- (1) Disconnect the negative terminal of battery. ---- (2) Release the inner pressure of hydraulic tank. ---- (3) Lift the bonnet to open. -- Disassembling and assembling of control box cover (19), (20), (5) --- a. Loosen sems bolt (9) M5X92, and (10) M5X107. --- b. Remove the covers (19), and (20). --- c. Disconnect the connector and ring terminal of harness. --- d. Disconnect 6 hoses from pilot valve. --- e. Loosen 3 sems bolts (29) M8X25, and 2 (34) M8X20 --- f. Remove the control box assembly (12). -- Disassembling and assembling of control box cover (12) --- a. Loosen sems bolt (9) M5X92, and (10) M5X107. --- b. Remove the covers (5), and (20). --- c. Disconnect the connector and ring terminal of harness. --- d. Disconnect 6 hoses from pilot valve. --- e. To remove the engine control cable (2), remove the beta pin (14) and nut (100). --- f. Loosen 4 sems bolts (26) M8X25. --- g. Remove the control box assembly (13). -- Disassembling and assembling of control box cover (13) -- Disassembling and assembling of engine control cable --- (1) Assemble the control box in reverse order of removal. --- 33.1.5 AIR CLEANER ---- (1) Remove the floor plate and the covers (See item 33.1.2) ---- (1) Open the bonnet and remove two M8X16 sems- bolts (5). ---- (2) Remove the clips (7). ---- (3) Disconnect the air hoses (2) and (3). ---- (4) Remove the air cleaner assy (1) with the bracket (4). -- Air cleaner removal --- 33.1.6 GENERATOR ---- (1) Remove the covers and the bonnet (See item 33.1.2). ---- (2) Remove the minus terminal side of the battery. ---- (1) Disconnect the connectors. ---- (2) Remove the capscrews (16) and (18). ---- (3) Remove the V-belt and the generator (1). -- Dynamo Assembly --- (1) Install in the reverse order of the removal. --- (2) V-belt tension -- V-belt tension --- 33.1.7 STARTER ---- (1) Remove the covers and the bonnet. ---- (2) Remove the minus side teminal of the battery. ---- (1) Remove the terminal B of the starter. ---- (2) Disconnect connector on the terminal S of the starter. ---- (3) Remove two fixing bolts and the starter. -- Starter removal --- 33.1.8 MUFFLER ---- (1) Swing approximately 30 degrees to the right. ---- (2) Remove the right side cover. ---- (3) Remove the under cover. ---- (1) Remove six nut (9) of muffler both side. ---- (2) Remove four M8X20 sems-bolts (7). ---- (3) Remove the muffler (1). -- Muffler disassembly --- No. --- Name --- Tool --- (mm) --- Torque --- N-m (lbf-ft) ---- 33.1.9 FUEL LINE ----- (1) Drain fuel from the tank (See item 33.1.10). ----- (2) Open the bonnet (1) (See item 33.2). ----- a. Remove M8X70 capscrew (19). ----- b. Remove the clips (13). ----- c. Pull out the hoses (3) and (4). ----- d. Remove the water separator (1). ----- 1. Remove M8X70 capscrew (19). ----- 2. Remove the clips (13). ----- 3. Disconnect the hoses (5) and (6). ----- 4. Remove the clips (14). ----- 5. Disconnect the hoses (7) and (22). ----- 6. Remove the filter (2). -- Fuel disassembly --- No. --- Name --- Tool --- (mm) --- Torque --- N-m (lbf-ft) ---- 33.1.10 FUEL TANK ----- (1) Swing approximately 30 degrees to the right to facilitate to drain fuel. ----- (2) Remove the bonnet (1) (See item 33.1.2). ----- (1) Open the cap (A10) and loosen the drain plug (A2) to drain fuel. ----- (2) Disconnect the hoses connected to the fuel outlet port tube (A1-1) and the return port tube (A1-2) of the tank (A1). ----- (3) Remove two M8X20 capscrews (B2) to remove the bracket (B1). ----- (4) Remove the tank (A1). -- Fuel tank disassembly --- No. --- Name --- Tool --- (mm) --- Torque --- N-m (lbf-ft) ---- 33.1.11 HYDRAULIC OIL TANK ----- (1) Prepare removal of the hydraulic oil tank in the method similar to the fore-mentioned fuel tank. ----- (2) Remove the front support and the rear support (See item 33.1.2). ----- (3) Remove the battery (See item 33.1.3) ----- (1) Depressurizing tank ----- (2) Remove the plug (A9) to drain hydraulic oil. ----- (3) Disconnecting suction hose (C3) ----- (4) Suction tube (A5) ----- (5) Remove the pilot return oil hose (A6) and (F12). ----- (6) Disconnect the drain oil hose fitting (D2) connected to the swivel. ----- (7) Disconnect the return oil hose (E3) from the solenoid valve. ----- (8) Disconnect the return oil hose (D1) from the slewing motor and the control valve. ----- (9) Remove three M10X25 sems-bolts (B8) for retaining the tank (A1). ----- (10) Remove the tank (A1), and the shims (B6) and (B7). -- Suction hose removal -- Hydraulic oil tank disassembly -- Hose removal --- (1) Clean the hydraulic tank, hose and fitting. --- (2) Assemble in the reverse order of the removal and tighten according to the Tightening Torque table shown below : -- Hydraulic oil tank assembly --- No. --- Name --- Tool --- (mm) --- Torque --- N-m (lbf-ft) ---- (3) After completing the installation, feed the specified hydraulic oil and check the oil level with the level gauge (A4). ---- (4) Releasing air ---- 1. Start the engine with the plug (A10) open. ---- 2. Run the engine in low idle condition for two to three minutes. Then extend and retract each cylinder a few times to release air from the circuit. -- Hydraulic oil tank pressurizing posture --- (5) Pressurizing hydraulic tank --- 1. Extend each cylinder till the stroke end as shown in right figure. --- 2. Tighten the plug (A10) in this condition. --- 3. Move the attachment to retract the cylinder rod to pressurize the tank. --- (4) Checking oil level again -- Engine stop posture --- 33.1.12 PUMP ---- (1) Remove the fuel tank (See item 33.1.10). ---- (2) Depressurize the tank and drain the hydraulic oil (See item 11). ---- (1) Disconnecting the hoses and fittings connected to the pump ---- a. Disconnect the pilot discharge oil hose (A4). ---- b. Remove the clip (14) and the suction hose (3). ---- c. Remove four M10X25 capscrew (16) and the suction tube (4). ---- d. Disconnect the main pup discharge oil hoses (1) and (2). -- Pilot hydraulic assembly -- Main pump hose removal --- (5) Remove two M12X15 capscrews (B3). --- (6) Remove the pump (B6). -- Pump Removal --- (1) Apply grease on the spline part of the pump input shaft. --- (2) Insert the pump spline part to the coupling. --- (3) Apply sealant on two M12X15 capscrews (B3) and install the pump. --- (4) Connect the main pump discharge oil hoses (1) and (2), and the pilot discharge oil hose (A4). -- Pump Installation -- Pump Instsllstion --- (5) Tighten four M10X25 capscrew (16) and install the suction tube (4). --- (6) Apply sealant on the tube of insert portion of the suction hose (3) and fix with the clip (14). --- (7) Restore each equipment removed in the preparation work to the orijinal state. --- (8) After starting hydraulic oil (approx. 10 L (2.6 gal)), release air and pressurize the tank (See item 33.1.11). --- 33.1.13 RADIATOR ---- (1) Remove the guards (covers and supports) (See item 33.1.2). ---- (1) Draining water form radiator ---- (2) Remove the band (A10) and then the connecting hose (A5) for the reserve tank (A3). ---- (3) Remove the radiator hoses (A1) and (A2) fixed by the clip (A11). ---- (4) Remove two M10X20 sems-bolts (B2) and two M10X25 sems-bolts (B3) fixing the radiator (B1). ---- (5) Lift up the radiator assy (B1) by two persons or by a crane. -- Radiator disassembly --- (1) Assemble in the reverse order of disassembly. --- (2) Install two M10X20 sems-bolts (B2) and two M10X25 sems-bolts (B3). --- (3) Install the clip (A11) for the radiator hose. --- (4) Feed cooling water (LLC). -- Tightening torque for related parts --- No. --- Name --- Tool --- (mm) --- Torque --- N-m (lbf-ft) ---- 33.1.14 ENGINE ----- (1) Remove guard (cover and support) (See item 33.1.2). ----- (2) Remove the air cleaner (See item 33.1.5). ----- (3) Remove the fuel tank (See item 33.1.10). ----- (4) Remove the hydraulic oil tank (See item 33.1.11). ----- (5) Remove the pump or the pump connecting hose (See item 33.1.12). ----- (6) Remove the radiator (See item 33.1.13). -- Fuel hose disconnection --- 1. Disconnect the hose (3) connecting to the water separator from the fuel tank. --- 2. Disconnect the hose (7) connecting to the fuel tank from the fuel filter. --- 1. Disconnect the connectors of the terminals B and S for the starter motor (M-1). --- 2. Disconnect the connector for the generator (E-2). --- 3. Disconnect the terminals for the water temperature switch (SW-6) and oil pressure switch (SW-7). --- 4. Disconnect the connectors for the glow plug (E-7). --- 5. Disconnect the connector for the engine stop solenoid. --- 6. Disconnect the terminal for the engine earth cable (H-4) at the engine side. -- Harness connector disconnection --- 1. Removing nuts for mounting engine --- 2. Lifting engine --- 3. Place the engine stably on the worktable for engine. --- (1) Perform installation in the reverse order of the removal. See the Figure below for the tightening torque and the sealant. -- Engine installation --- 33.1.15 CONTROL VALVE ---- (1) Remove guards (floor plate, cover and support) (See item 33.1.2) ---- (2) Depressurize the hydraulic oil tank (See item 33.1.11) -- Main hydraulic hose disconnection -- Pilot hydraulic hoses disconnection --- 1. Remove the pin (22) and pull off the pin (23). --- 2. Removing all the yokes connected to the control valve. -- Yoke disassembly --- 1. Removing three M8X20 sems-bolts (5). --- 2. Remove the control valve (1) with the brackets (2) and (3). --- 3. Remove each two M8X16 sems-bolt (4) for fixing the bracket. -- Control Valve Removal --- (1) Perform installation in the reverse order of the removal. --- (2) Install four M8X16 sems-bolts (4) and three M8X20 sems-bolts (5). --- (3) Tighten hoses and so on with the following torque : --- (4) Pressurize the hydraulic oil tank (See item 33.1.11) --- (5) Operate the attachment and check the performance. --- (6) Check oil leakage and hydraulic oil level. --- 33.1.16 PILOT VALVE ---- (1) Disconnect the minus terminal of the battery. ---- (2) Depressurize the hydraulic oil tank (See item 33.1.11). ---- (3) Remove the sems-bolts (9) and (10), and the cover assy (5) and (20). ---- (4) Disconnect the connectors and the terminals of harness. ---- (5) Loosen the sems-bolts (6) to remove the panel assembly (1). -- Cover removal (Right control box) --- (1) Disconnect each hose at the position with the mark * and attach plugs and tags to facilitate installation. --- (2) Shift the boot and remove four M6X30 capscrews (B4). --- (3) Remove the pilot valve (B1). -- Hose removal --- (1) Perform installation in the reverse order of the removal with the following tightening torque. --- (2) Pressurize the hydraulic oil tank (See item 33.1.11). --- (3) Operate the attachment and check the performance. --- (4) Check oil leakage and hydraulic oil level. --- 33.1.17 SLEWING MOTOR ---- (1) Remove the guards (floor plate, cover and support) (See item 33.1.2). ---- (2) Drain oil from the hydraulic tank (See item 33.1.11). ---- (3) Disconnect the cable for the dozer connected to the control valve at the position of the yoke (18). ---- (4) Removing travel lock cylinder (15). -- Cable and lock cylinder removal --- 1. Remove the link (17). --- 2. Remove the nut (16). --- 3. Disconnect the hose if necessary. --- (1) Disconnect three hoses (T), (AV) and (BV) connected to the slewing motor. --- (2) Disconnect the grease piping hose (G). --- (3) Remove six M10X35 capscrew (2). --- (4) Remove the slewing motor. -- Hose disconnection -- Slewing motor removal --- (1) Install in the reverse order of the removal according to the tightening torque shown below. --- a. When the cover (5) was removed, install it to the position. --- b. Apply Loctite #515 to whole the fitting surface of slew motor. --- c. Install two M20X35 capscrews for mounting the motor. --- d. Install the nut (16) for the lock cylinder. --- e. Connect hoses. -- Installation of cover -- Pinion and gear lubrication --- (6) Feed grease to the pinion and gear part of the slewing motor. --- (7) Pressurize the hydraulic oil tank (See item 33.1.11). --- (8) Check the slewing operation. --- (9) Check oil leakage and hydraulic oil level. --- 33.1.18 SWIVEL JOINT ---- (1) Lift the machine by approx. 30cm (12 inch) and insert support blocks at four places of the crawler shoes, namely, front, rear, right and left, to secure working space under the machine. ---- (2) Engage the slewing lock. ---- (3) Remove the slewing motor (See item 33.1.18). ---- (4) Remove the under cover (6). ---- (5) Take out the retractable crawler's cylinder (See the item for cylinder in section of TRAVEL SYSTEM). -- Lifting machine -- Undercover removal --- (1) Disconnect all the hoses connected to the swivel joionts. Install plug to the connecting ports and attach tags. -- Upper side hose disconnection -- Connecting port relation -- Lower side hose disconnection --- (2) Removing stopper -- Stopper removal --- (3) Removing swivel joint --- 1. Remove four M8X25 sems-bolts (2) --- 2. Remove the swivel joint (1) from the lower side. -- Swivel joint removal --- (1) Install the reverse order of the removal with the tightening torque shown below. --- 1. Install four M8X25 sems-bolts (2). --- 2. Install two M12X30 capscrew (8). --- 3. Connect hoses. --- (4) Pressurize the hydraulic oil tank. --- (5) Check the performance. --- 33.1.19 UPPER FRAME ---- (1) Remove the guards (floor plate, cover and support) (See item 33.1.2). ---- (2) Drain oil from the hydraulic oil tank (See item 33.1.11). ---- (3) Disconnect the upper side hose for the swivel joint (See item 33.1.18). ---- (4) Remove the the stopper for the swivel joint (See item 33.1.18). ---- (5) Remove the the attachment (See the "Boom" item of the section of ATTACHMENT). ---- (6) Remove the the swing bracket (See the "Swing" item of the section of ATTACHMENT). ---- (1) Providing match marks to slewing bearing ---- (2) Lifting upper frame temporarily -- Slewing bearing and upper frame --- (3) Removing bolt for mounting --- (4) Removing upper frame -- Lifting rear side --- (1) Perform installation in the reverse order of the removal. --- (2) Cleaning contact surface --- (3) Lifting method --- a. Apply wire ropes to the upper frame and lift up horizontally. --- b. Check the match marks provided at the disassembly. --- c. Slowly lower while aligning the match marks and watching the engaging condition between the slewing pinion gear and the internal gear of the inner race of slewing bearing. -- Slewing bearing installation --- (4) Installing slewing bearing and upper frame --- a. Apply Loctite #262 on a reamer bolt (10) and 14 M12X50 capscrews (7) and temporarily tighten. --- b. Tighten the reamer bolt and capscrews with the specified torque at the front, rear, right and left positions apart from each other by 180° alternately. -- Upper frame installation --- (5) Install each equipment removed in the above removal preparation to the original position and check the performance. - 33.2 DISASSEMBLING AND ASSEMBLING COMPONENTS -- 33.2.1 HYDRAULIC PUMP -- Hydraulic pump-Sectional view --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY --- Tool Name --- Size --- Q'ty ---- 1. The disassembling and assembling works are to be carried out in a clean place, providing clean containers to place the disassembled parts in. ---- 2. Bfore disassembling, make around the ports clean and remove the paint around each joint with a wire brush. ---- 3. Clean each of the disassembled parts with a washing oil. ---- 4. Put a matching mark on each of the mating parts so that they shall be installed to the original positions. ---- 5. Replace all the seals to new one at every disassembly. ---- 6. Check each part for abnormal wear and seizure, remove sharp edges and burrs with a sand paper, etc., if any. ---- 7. Avoid to adjust each adjusting screw, except the necessity. ---- 1. Removling the gear pump ---- 2. Removing the pressure adjusting setscrew (60). -- Removing the gear pump --- 3. Separating the body S(1) and the body H(2) --- a. Remove two (upper side) of four socket bolts (44), and screw two preliminary assembling bolts (M10X65) into the bores by about 10mm (0.4in). --- b. Slowly loosen the remaining two socket bolts (44). --- c. Loosen the preliminary assembling bolts (M10X65), and separate the body S and the body H. -- Separating body (S) and (H) --- 4. Remove the spring (15) and. spring holder (18) from the body S. --- 5. Remove the cylinder barrel (4) assy from the body S(1). --- 6. Remove the swash plate (10) and oscillating pin (12) from the body S(1). --- 7. Remove the stopper pin A(25) and coned disk spring (33) in order. --- 8. Remove the snap ring (34) from the shaft side of body S(1). --- 9. Remove the shaft (3) with bearing (30) from the body S(1). --- 10. Remove the spring guide (19) and valve plate (5) from the body H (2). --- 11. Disassembling cylinder barrel (4) assy --- a. Remove the shoe holder (8) with piston shoe assy (6) (7) and barrel holder (9) from the cylinder barrel (4) assy. --- b. Remove the piston shoe assy (6) (7) and barrel holder (9) from shoe holder (8). --- c. Remove the needle pins (11) from the cylinder barrel (4). --- d. Remove the snap ring (35), and remove the outer retainer (24), spring (14) and inner retainer (24) from cylinder barrel (4). --- 1. Installing shaft (3) -- Oil seal insertion Jig --- 2. Install four coned disk springs (33) to the stopper pin A(25), and install it to the body S(1). --- 3. Install the oscillating pin (12) to the swash plate (10), and install it in the spherical bore on the body S(1). --- 4. Assembling cylinder barrel (4). --- a. Install the retainer (24), spring (14), retainer (24) and snap ring (35) to the cylinder barrel (4). --- b. Install the needle pins (11) to the cylinder barrel (4). --- c. Install the barrel holder (9) to the cylinder barrel (4). --- d. Install the piston shoe assy (6) (7) to the shoe holder (8), and install it to the cylinder barrel (4). --- 5. Install the cylinder barrel assy to the body S. --- 6. Install the spring (15) to the spring holder (18). --- 7. Install the spring guide (19) to the body H(2). --- 8. Positioning the valve plate (5) to the spring pin (56) on the body H(2), install with care, --- 9. Install the joint (66) to the shaft (3). --- 10. Install the packing (13) to the mating face of the body S(1). --- 11. Install two preliminary installing socket bolts (M10X65) to the upper part, and tighten them up with care. And when the gap between the mating faces becomes 5 to 10mm (0.20 to 0.39in), change them to four socket bolts (44) and tighten them up. --- 12. Install the pressure adjusting setscrew (60). --- 13. Installing gear pump --- a. Install the steel ball (67) and O-ring (71) to the connecting portion of gear pump for piston pump assy. Then temporarily tighten the socket bolts (68) with washer (4), fixing the gear pump kit (65). --- b. Install the another two socket bolts (68) with washers (4). -- Installing gear pump --- 14. Assembling confirmation --- Trouble --- Possible Causes --- Remedy ---- 33.2.2 CONTROL VALVE --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY ---- (1) All hydraulic equipment is machined in precision and consequently the clearance of each part is very small. Therefore when disassembling and assembling, place the machine in the clean area to prevent it from the entry of dust, earth and sand. ---- (2) Before disassembly, prepare the valve construction drawing to understand the construction clearly. ---- (3) When removing the control valve from the machine, never forget to cap every port to prevent dust, etc. from entering. And before disassembly, recheck that every post is capped and clean the outer surface of the assembly. ---- (4) When it is required to leave it in the removed condition, apply rust preventives or seal them to protect them from rusting. ---- (5) The control valve should be transported or moved holding the main body. Especially, after removing the pilot cover, carefully handle it paying attention not to touch the exposed surfaces. ---- (6) Even when the movement is not smooth, never strike it. ---- (7) In addition, after assembly of equipment, various tests {relief setting, leak test, flow resistance (pressure loss) test} are required, but these tests require hydraulic test equipment. --- Tools --- Q'TY --- Remarks ---- a. At first, using 4mm Allen wrench and loosen and remove 2 bolts with washer (10). ---- b. Remove pilot cover A1 (8). ---- c. The spring section of the slewing spool appears. And pull out the spool assembly horizontally along the hole of spool from valve body. ---- d. Remove the opposite bolts with washer (10) to remove the pilot cover B1 (9). ---- e. Other pilot spool can be pulled out by the same procedure. -- TYPE OF SWITCHING BY HYDRAULIC PILOT --- a. At first, using 4mm Allen wrench and loosen and remove 2 socket bolts (12). --- b. Remove the cap for return spring (11). --- c. The spring section of the swing spool appears. And holding the spring section, pull out the spool assembly slowly and horizontally along the hole of spool from valve body. --- d. Other manual switching pilot spool can be pulled out by the same procedure. -- TYPE OF MANUAL SWITCHING --- a. Using 6mm Allen wrench and loosen and remove the retainer of check valve (10). --- b. Remove the check valve return spring (8) and the check valve (7) from the body (1). --- c. Other switching sections have different item numbers but they can be pulled out by the same procedure. -- REMOVAL OF CHECK VALVE (LOAD CHECK VALVE) -- REMOVAL OF MRV, ORV -- REMOVAL OF ANTI-CAVITATION VALVE -- REMOVAL OF RELIEF PLUG -- REMOVAL OF PRESSURE ADJUSTMENT PLUG -- REMOVAL OF SWITCHING SECTION PLUG -- REMOVAL OF LINK ATTACHING SIDE SECTION --- 1. Using 13mm spanner or socket wrench, loosen 3 M8 nuts which are used for mounting switching section body located on the both ends of control valve. --- 2. To separate the control valve into individual section, remove 3 assembling bolts from end of control valve.During disassembling, do not fall and lose O-rings which are installed on the mating surface between each switching section. -- BODY OF CONTROL VALVE --- a. Fix hexagonal section of opposing flats in 22mm of pressure adjusting section (5) to vise lightly. --- b. Using 19mm spanner and loosen and remove locknut (8). --- c. Using 4mm Allen wrench and loosen and remove adjusting screw (7). --- d. Using tweezers and so on and pull out the spring (9) of regulating valve. --- e. Using 19mm spanner and loosen and remove regulating valve section (4). --- f. Other parts can also be removed by the following procedure. -- DISASSEMBLING OF MAIN RELIEF VALVE (P1, P2) --- a. Fix hexagonal section of opposing flats in 22mm of pressure adjusting section (5) to vise lightly. --- b. Using 19mm spanner and loosen and remove locknut (8). --- c. Using 4mm Allen wrench and loosen and remove adjusting screw (7). --- d. Using tweezers and so on and pull out the spring (9) of regulating valve. --- e. Using 19mm spanner and loosen and remove regulating valve section (4). --- f. Other parts can also be removed by the following procedure. -- DISASSEMBLING OF OVER LOAD RELIEF VALVE --- a. Fix hexagonal section of opposing flats in 22mm of anti-cavitation section (2) to vise lightly. --- b. Using 8mm Allen wrench and remove plug (3). --- c. Using tweezers, magnet and so on and pull out the spring (4). --- d. Lastly, remove anti-cavitation valve from anti-cavitation section. -- DISASSEMBLING OF ANTI-CAVITATION VALVE --- a. Apply air pressure through hole of relief valve (1), and remove relief plug (1) from retainer (2) of relief valve. --- b. As a consequence of removal of relief plug (1), the removal of inside plain washer (4) and spring washer (3) become possible. -- DISASSEMBLING OF RELIEF VALVE --- (1) The unevenness of tightening torque and the contamination by dust during assembly may cause a failure. And observe the tightening torque specified in the description. --- (2) When assembling, check up on the valve construction drawing, identify the number of part, and ensure that there is no installation error and omission of part, etc. --- (3) After cleaning the parts required to use with cleaning solvent, immerse them in hydraulic oil as required and reassemble them. --- (4) Before applying Loctite, clean and decrease the surface sufficiently, and apply it to two threads of screw top. --- (5) When you perform the installation and assembly work by using two or more bolts/nuts, do not tighten each bolt to the specified torque at a time. --- (1) Replace seals with new ones when assembling. --- (2) Ensure that seals are free from deformation and flaw coming about when handling them. --- (3) Apply grease or hydraulic oil to the seals and seal fitting section to make the sliding smooth, unless otherwise specified. --- (4) Do not stretch the seals too much. Otherwise they may be permanently deformed. --- (5) Pay attention not to roll the O-ring when fitting. Because it is difficult for the twisted O-ring to be restored naturally after fitting, and it may cause oil leakage. --- Tools --- Q'TY --- Remarks ---- 1. The numbers in ( ) in explanation and figure is the reference numbers. ---- 2. For tightening torque of each screw thread, refer to this manual. ---- 1. Put each body section in assembly order facing the mating surface upward. ---- 2. Prepare surface plate, and direct actuator port downward and place each body section in order. ---- 3. Insert 3 M8 assembling bolts through each body section from the side face and tighten M8 nuts lightly. Then, make the port faces of each body even with each other by striking body with plastic hammer lightly. And tighten nuts while stopping rotati... -- ASSEMBLY OF BODY -- ARRANGEMENT OF EACH SECTION -- INSTALLATION OF MRV, ORV -- INSTALLATION OF ANTI-CAVITATION VALVE -- INSTALLATION OF RELIEF PLUG --- a. Fix control valve on the workbench, or press it on the workbench with several people. --- b. Direct the umbrella part off the check valve (7) downward, and insert it straight in the center portion of upper surface of control valve body (1).Put spring (8) of check valve in the shaft of check valve (7) from above. --- c. Check that O-ring (9) is securely fitted and screw in the retainer (10) of check valve and tighten it to the specified torque with 6mm Allen wrench. --- a. Fix control valve on the workbench, or press it on the workbench with several people. --- b. Direct the umbrella part off the check valve (7) downward, and insert it straight in the center portion of upper surface of control valve body (1).Put spring (8) of check valve in the shaft of check valve (7) from above. --- c. Check that O-ring (9) is securely fitted and screw in the retainer (10) of check valve and tighten it to the specified torque with 6mm Allen wrench. -- INSTALLATION OF CHECK VALVE (LOAD CHECK VALVE) --- a. Check that spool holes of each spool assembly and switching section are free from dust and so on and O-ring (7) is securely fitted to flange bottom of switching section, and insert each spool assembly in spool hole of switching section. --- b. Install pilot cover A1 (8) to flange of switching section from the spring side of inserted spool assembly securely, and using 4mm Allen wrench, and tighten sems bolts (10) to the specified torque. --- c. Similarly for spring of spool assembly and pilot cover B1 (9) on other side, after checking that O-ring (7) is securely installed to the flange bottom of switching section and install it so as to be fitted to flange, and using 4mm Allen wrench, an... --- d. The spools for other hydraulic pilot switching type can be installed by the same procedure. -- HYDRAULIC PRESSURE SWITCHING TYPE --- a. Check that spool holes of each spool assembly and switching section are free from dust and so on, and insert each spool assembly in spool hole of switching section. --- b. Install return spring cover (11) from the spring side of inserted spool assembly securely, and using 4mm Allen wrench, and tighten hexagon socket head screw (12) to the specified torque. --- c. And, install O-ring (3), backup ring (4), and O-ring retainer (5) to projected spool in order from the other side of switching section, and tighten cross recessed head machine screw (6) to the specified torque with Phillips screwdriver. --- d. The spools for other hydraulic pilot switching type can be installed by the same procedure. -- MANUAL SWITCHING TYPE -- INSTALLATION OF PRESSURE ADJUSTING PLUG -- INSTALLATION OF SWITCHING PLUG --- a. As a general rule, the part replacement with new one for every one year is recommended, but it is possible to replace parts earlier according to the service environment (like dust adhered on spool) and frequency of use. --- b. When it is stored for long period (6 months or more) before actually equipping on the machine, replace the seal with new one because the spool seal may be deformed or spool seal may be stuck. --- a. The replacement is not required where the sliding surface is not damaged, not bent due to unexpected force applied to link mounting section or not broken. --- a. If seat is damaged or failed due to foreign matters included in hydraulic oil, the cast body seat should be replaced with new one. --- b. After disassembled once, O-ring on plug should be replaced with new one. --- a. When the set value drops or abnormal pressure is indicated during operation, it is necessary to reset. --- a. If seat should be damaged or failed due to foreign matters included in hydraulic oil, the cast body seat should be replaced with new one. --- a. If seat should be damaged or failed due to foreign matters included in hydraulic oil, the cast body seat should be replaced with new one. --- a. Where the parts removed from the body (main relief valve, overload relief valve and every plug) are assembled again, O-rings and so on fitted on the parts should be replaced with new ones. --- b. When body was individually disassembled, replace O-ring fitted to mating surface with new one. -- Inspection of parts --- Phenomenon --- Cause --- Corrective action ---- 33.2.3 PILOT VALVE (Attachment) -- Pilot valve (Attachment) --- Item --- Thread size --- Tightening Torque Table --- N-m (lbf-ft) --- Item --- NAME --- Q'TY --- Item --- NAME --- Q'TY --- Item --- NAME --- Q'TY ---- (1) Since all the parts are very precisely manufactured, carefully handle them without causing collision with each other or dropping. ---- (2) Perform the wark carefully without hammering or using excessive force even if the part is sticking. Otherwise burrs may be produced or the part is damaged, leading to oil leakage or performance deterioration. ---- (3) When leaving the parts in the disassembled condition, always take rust preventive and dust protective measures. Otherwise rust may be produced on the parts due to humidity or dust. -- Handle lever disassembly -- Adjusting nut (312) removal -- Joint (301) removal -- Plate (151) removal -- Spring (221) removal -- Push rod (212) removal -- Pressure reducing valve disassembly -- Pressure reducing valve disassembly -- Pulling out plug (211) -- Seal (213) removal --- (1) General cautions for assembling work are almost similar to that for disassembling work. --- (2) Remove metal chips or foreign substances from all the parts and ensure that the parts have no burrs or flaw prior to assembly. Remove burrs or flaw if any, using oil stone. --- (3) Replace the O-rings and back-up rings with new ones in principle. --- (4) Be careful not to damage the O-rings and back-up rings when fitting them. (Apply a small amount of grease to fit them smoothly.) --- (5) Apply grease to the parts to be installed in order to prevent them from dropping. --- (6) Tighten screws at the torque specified in tightening torque tabe. Watch the torque using a torque wrench. --- (7) After finishing the assembly, screw blind plugs in all the ports to prevent dust intrusion. -- Assembling spool (201) -- Assembling spool (201) -- Installing spool (221) -- Installing seal (213) -- Installing push rod (212) -- Installing plug assembly -- Installing plug assembly -- Installing joint (301) -- Installing joint (301) -- Applying grease --- Phenomenon --- Possible Cause --- Corrective action ---- 33.2.4 SWIVEL JOINT --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY -- Exploded view of swivel joint --- Tool --- Remark ---- 1. Loosen bolt (13) and spring washer (14), then remove flange (3). ---- 2. Take out O-ring (8), snap ring (11) and thrust ring (4). ---- 3. Remove shaft (1) from the body (2). ---- 4. Remove dust seal (10) from the shaft (1). ---- 5. Remove seal, etc. from the inside of the body (2). ---- 1. Insert seals in the body. ---- 2. Install dust seal (10) to shaft (1). ---- 3. Install shaft (1) to body (2). ---- 4. Fit thrust ring (4) and snap ring (11). ---- 5. Fit O-ring (8) and install flange (3). ---- 6. Install spring washer (14) and bolt (13). --- Check Interval --- Place Checked --- Check Procedure --- Remedy --- Portion --- Judgment Criteria --- Remedy --- Portion --- Judgment Criteria --- Remedy ---- 1. Connect a pipe (3) between the hydraulic pump (2) and the shaft (1) side port. ---- 2. Connect a pressure gauge to the body (4) side. ---- 3. Increase the pressure gradually to 20.5MPa (2970 psi) adjusting the relief valve (6), then perform 1 minute leak test. --- Phenomenon --- Cause --- Corrective action ---- 33.2.5 SLEWING MOTOR -- Slewing motor --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY --- No. --- NAME --- Q'TY --- Tool --- Remark ---- 1. Remove the capscrew(44). ---- 2. Remove the valve housing (25) assy, then remove the spring (17), pin (19) and balancing plate (16). ---- 3. Remove the valve (15). ---- 4. Remove the valve plate (13) and valve drive (23). ---- 5. Remove the Geroller (22) and main drive (21). ---- 6. Remove the wear plate (11). ---- 7. Remove the retaining ring (7) with a snap ring plier. ---- 8. Pull out the pinion gear (2) with a press machine or plastic hammer. ---- 9. Remove the X-ring (6). ---- 10. Remove the ball bearing (4) of the rear side, tapping the inner race of bearing with a minus screw driver, etc. and plastic hammer. ---- 11. Remove the ball bearing (3) of the front side, tapping the inner race of bearing with a minus screw driver, etc. and plastic hammer. ---- 1. Install the ball bearing (4) of the rear side to the bearing housing (1), with a plastic hammer or press machine. ---- 2. Install the ball bearing (3) of the front side to the bearing housing (1), with a plastic hammer or press machine. ---- 3. Install the X-ring (6) to the housing (1). ---- 4. Press the pinion gear (2) into the bearing housing (1), with a press machine. ---- 5. Install the retaining ring (7) to the pinion gear (2). ---- 6. Install the shaft face seal (10) to the wear plate (11). ---- 7. Insert the main drive (21) into the inner spline on pinion gear (2). ---- 8. Attaching the O-ring (12) to the wear plate (11), install the Geroller (22). ---- 9. Install the valve draive (23) to the Geroller (22). ---- 10. Attaching the O-ring (12) to the valve plate (13), iinstall it to the Geroller (22). ---- 11. Install the valve (15). ---- 12. Insert the steel ball (26), spring (29) and O-ring (28) into the valve housing (25), and tighten up them with the plug (27). ---- 13. Install the spring (17) and pin (19) to the valve housing (25). ---- 14. Install the inner face seal (18) and outer face seal (20) to the balancing plate (16). ---- 15. Aligning the cut on balancing plate (16) with the pin (19), install it to the valve housing (25). ---- 16. Installing valve housing (25). ---- a. Attaching the O-rings (14) and (24) to the valve housing (25). ---- b. Insert a slender bar such as a screw driver from the B port side on valve housing to hold the balancing plate (16) not to come off, then install the valve housing (25) to the valve (15). ---- 3. Tighten up the capscrew (44). --- Portion --- Judgement Criteria --- Remedy --- Troubles --- Possible Causes --- Remedy 34_TRAVEL SYS.pdf - 34. TRAVEL SYSTEM -- 34.1 REMOVING AND INSTALLING 34-3 --- 34.1.1 NAME OF TRAVEL SYSTEM PARTS 34-3 --- 34.1.2 CRAWLER 34-3 --- 34.1.3 LOWER ROLLER 34-6 --- 34.1.4 FRONT IDLER 34-10 --- 34.1.5 IDLER ADJUSTER 34-14 --- 34.1.6 SPROCKET 34-16 --- 34.1.7 TRAVEL MOTOR 34-18 --- 34.1.8 SLEWING BEARING 34-20 --- 34.1.9 RETRACTABLE CRAWLERS 34-23 -- 34.2 DISASSEMBLING AND ASSEMBLING COMPONENTS 34-26 --- 34.2.1 TRAVEL MOTOR 34-26 - 34.1 REMOVING AND INSTALLING -- 34.1.1 NAME OF TRAVEL SYSTEM PARTS -- Name and location of parts --- 34.1.2 CRAWLER ---- 1. Lift the one side of machine with attachment, and place support under lower frame to support machine. -- Crawler removing posture --- 2. Loosen grease nipple for crawler adjuster, discharging grease in cylinder, and release tension of crawler. -- Loosing crawler tension --- 3. Put steel pipes in the rubber crawler, turn the sprocket in the reverse direction slowly and when the rubber crawler has floated off the idler stop the rotating. --- 4. Slide the rubber crawler sideways, and remove it. -- Removing rubber crawler --- 1. Engage the rubber crawler with the sprocket and mount it on the idler. --- 2. Put steel pipes in the rubber crawler, turn the sprocket in the reverse direction slowly and then the rubber crawler has floated off the idler, stop the rotating. --- 3. Slide the rubber crawler to the position to be set on idler exactly. -- Installing rubber crawler --- 4. Confirm that the rubber crawler is engaged securely with the sprocket, idler and lower roller. --- 5. Tighten the grease nipple for the crawler adjuster, and adjust tension by feeding grease. -- Feeding grease -- Crawler tension -- Rubber crawler assy -- Rubber crawler shoe -- Unit : mm (in) --- 34.1.3 LOWER ROLLER ---- (1) Slightly loosen capscrews (M12X25) (2) fastening lower roller assembly (1) to the lower frame. ---- (2) As same as the case for removal of the crawler, loosen the grease nipple for crawler adjusting within one turn to discharge the grease, and release the tension on the crawler. -- Lower roller assembly --- (3) Lift the lower frame good enough to remove the lower roller, using the attachment. --- (4) After lifting the lower frame to a proper height, place square lumber under the lower frame to stabilize the machine. --- (5) Remove the capscrews (2) fastening the lower roller, and remove the lower roller assembly. -- Crawler removing posture --- (1) Coat the mounting capscrews (2) with Loctite #262 in advance. --- (2) Lower the machine in full contact with the ground and tighten the capscrews (2) as specified. --- (3) Tighten the grease nipple of the crawler adjuster. -- Lower roller construction --- (1) Loosen the plug (7) to drain oil. --- (2) Remove the seals (5). --- (3) Removing snap ring (6) -- Removing seal(5) and snap ring(6) --- (4) Put the lower roller on the supporting stand, and push out the shaft (2) together with the bearings (3). -- Removing shaft(2) and bearing --- (1) Apply molybdenum grease to the shaft (2), and install the bearings (3). --- (2) Apply molybdenum grease to the lower roller (1), and press the shaft (2) together with the bearings into the place. -- Installing shaft / bearing --- (3) Install the snap ring (6). --- (4) For the seal (5), first enclose grease into the lip portion of the seal body (5a). Then push the seal body (5a) and sleeve (5b) into the place evenly with the specialized pushing jig paying attention not to give any distortion on the lip. --- (5) With the same procedure of the above, install the seal (5) of the opposite side. -- Installing seal --- (6) Fill in 75 cc (4.6 cu-in) of the gear oil SAE #90 through the bore of plug on the roller (1). --- (7) Tighten up the plug (7). -- Assembling lower roller -- Lower roller --- 34.1.4 FRONT IDLER ---- (1) Removing the crawler assy. ---- (2) Remove idler together with idler adjuster assy, rolling it, using a crowbar or equivalent. -- Removing idler --- (3) Loosen capscrews (M10X30)(3), and separate idler assy (1) from idler adjuster assy (2). -- Disassembling idler assy --- (1) Install idler assy (1) to the idler adjuster assy (2) by means of capscrews (3) in the reverse order of removing the idler assy. Coat the threaded part of capscrews (3) with Loctite #262 beforehand. --- (2) The assembly of the idler and idler adjuster is to be installed to the lower frame so that the grease feeding plug (4) of idler is positioned to outside, and the grease feeding port of the grease nipple (5) of idler adjuster assy is facing to out... --- (3) Following procedures of Item 34.1.2, install the crawler assy, and adjust the crawler tension. -- Installing idler -- Idler assy construction --- (1) Remove the plug (8) and drain the oil --- (2) Push out the spring pin (6) applying the pin extruding jig to it and lightly tapping the jig with a hammer, then remove the collar (12) (13). -- Extruding pin --- (3) Remove the seals (4) and retaining rings (7). --- (4) Supporting the idler (1) with the supporting stand, apply the shaft extruding jig to the shaft (5), and push out it together with the bearing (11) using a pressing machine. -- Extruding shaft --- (1) Apply molybdenum grease to the shaft (5), and install the bearings (11). --- (2) Applying molybdenum grease to the idler (1), press the shaft (5) together with the bearings into the idler. --- (3) Install the retaining ring (7). -- Shaft / Bearing installation --- (4) For the seal (4), first enclose grease into the lip portion of the seal body (4a). Then push the seal body (4a) and sleeve (4b) into the place evenly with the specialized pushing jig paying attention not to give any distortion on the lip. --- (5) Install the opposite seal (4) with the same procedure. -- Installing seal --- (6) Install the collar (12) to the shaft (5), and fix it with tapping the spring pin (6) in. Install the collar (13) of the opposite side with the same procedure. -- Tapping pin --- (7) Fill in 30 cc (1.8 cu-in) of the gear oil SAE #90 through the bore for plug on the idler (1). --- (8) Tighten up the plug (8). -- Pin's gap direction -- Idler assy --- 34.1.5 IDLER ADJUSTER ---- (1) Idler adjuster assy assembled with idler assy (1), is removed from the lower frame . Do this work by referring to "34.1.4.1.(1)" Removing front idler. ---- (2) Loosen capscrews (M10X30)(3) and remove idler assy (1), from idler adjuster assy (2). -- Disassembling idler assy --- (1) Installation is done in the reverse order of removal: --- (2) Before installing the idler adjuster to the crawler frame, assemble it with the idler assy. For the procedure, refer to "34.1.4.1.(2)" Installing front idler. -- Idler adjuster assy --- (1) Pull the piston (1) out of grease cylinder (2) --- (2) Remove the oil seal (10), Q-ring (8) and back-up ring (9) from the grease cylinder (2). --- (1) Install the back-up ring (9), O-ring (8) and oil seal (10) to the grease cylinder (2). --- (2) Fill up the grease cylinder (2) with grease. Remove the grease nipple (7) from the grease cylinder (2). Then release air in the cylinder through the bore of grease nipple pushing the piston (1) with hand. --- (3) Attach the grease nipple (7) to the grease cylinder (2). -- Assembling idler adjuster -- Idler adjuster assy --- 34.1.6 SPROCKET ---- (1) Remove the crawler assy. ---- (2) Place square lumber under the lower frame so the sprocket is off the ground. ---- (3) Loosen capscrew (M10X25) for the mounting of the sprocket by means of a socket wrench key and remove the sprocket. -- Free sprocket from load --- (1) Check the fixing parts of the travel motor and the sprocket, eliminate burrs and dirt thoroughly, and install the sprocket. --- (2) Apply Loctite #262 to the sprocket mounting capscrews and fasten the sprocket temporarily. -- Removing sprocket --- 3. Remove the square lumber under the lower frame and tighten socket bolts with specified torque to fix sprocket and travel motor. --- 4. Install crawler -- Tightening socket bolts -- Sprocket --- 34.1.7 TRAVEL MOTOR ---- (1) Remove the crawler assy. ---- (2) Place square lumber under the lower frame so the sprocket is off the ground. ---- (3) Remove the capscrews (A5) located inside the lower frame and remove the cover (A8). ---- (4) Loozen the air plug of hydraulic oil tank and release air in the tank. -- Free sprocket from load --- (5) Disconnect the joint of hydraulic piping connected with the travel motor, and plug the joints in order to prevent outflow of oil and entering of dust. --- (6) Remove capscrew (M10X20)(B4) that fasten the travel motor to the lower frame. On that occasion, put a matching mark between the lower frame and the travel motor. --- (7) Place a wire sling in a part near the sprocket of the travel motor for balancing, and remove the unit out of the lower frame. -- Removing cover / travel motor --- (1) If there are burrs and dirt on fitting part with which the travel motor are fastened, eliminate it beforehand. Place a wire sling in the travel unit with the same way as in the removing, and install it to the lower frame. --- (2) Coat the threaded part of the capscrew (M12X20)(B4) with Loctite #262 and tighten them. -- Removing / Installing travel motor --- (3) Reconnect the hydraulic pipings as before, and tighten the joints with specified torque. -- Installing hydraulic pipings (RH-travel motor) --- (4) Install the cover (A8) located inside the lower frame, and tighten capscrews (A5). (See Fig. "Removing cover/travel motor" on previous page.) --- (5) Remove the square lumber supporting the lower frame and install the crawler. --- (6) Check the oil level in the reduction gear of travel motor [See Item (7) mentioned below] and replace or replenish oil as required. --- (7) Checking oil level in reduction gear -- Checking oil level --- a. Stop the machine so the drain plug comes right under the machine. --- b. Remove the level plug and check the oil level and contamination. The oil level is proper if it is close to the plug bore. Replenish oil when deficient. -- Installing travel motor --- 34.1.8 SLEWING BEARING ---- (1) Remove the upper slewing structure. (See detail of "Upper Slewing Structure") ---- (2) Remove capscrews (B) that fix the inner race of slewing bearing (A) -- Slewing bearing --- (3) Remove the grease in the inner race of slewing bearing. --- (4) Fix lifting-bolts to slewing bearing (A), and lift it by crane. -- Lifting slewing bearing --- 1. Before installing the slewing bearing, clean thoroughly the bearing and the mating surface of the lower frame to be free from dirt, oil and other foreign materials. --- 2. Lift up the bearing and place it on the lower frame, aligning the S-mark stamped on the inner race. --- 3. Coat the threads of the capscrews (B) with Loctite #262 and tighten all capscrews temporarily. --- 4. Tighten the capscrews (B) at 180° intervals alternately, and tighten them up to a specified- torque. --- 5. After installing the slewing bearing on the lower frame, install upper slewing structure. -- Location of "S" mark to install slewing bearing -- Cross-section of slewing bearing --- (1) Remove seal A (8) fitted in the groove in the inner circumference on top of outer race (2) and seal B (9) fitted in the groove in the outer circumference under inner race (1), from the bearing, and place the bearing level on a square lumber. --- (2) Remove taper pin (7), using a hammer and an extrusion rod. --- (3) Remove plug (6), using an puller bolt made use of the threaded bore in the center of the plug. --- (4) After removing plug (6), take out balls (3) and spacers (4) (5) from the bore in order, while rotating outer race (2) slightly. -- Disassembling slewing bearing -- Removing balls / spacers -- Installing balls --- (1) Degrease thoroughly the groove for seal A (8) located in the inner circumference of outer race (2) and the groove for seal B (9) located in the outer circumference of inner race (1). Coat the grooves with adhesive Cyano Bond PO-1, fit seal B (9),... --- (2) Lift and lower outer race (2) slowly till the top surface of inner race (1) matches the bottom of the sealing groove of outer race (2). Place an adjusting washer under outer race (2) in order to support the outer race so the track surface of ball... --- (3) Forward, balls (3) and spacers (4) (5) coated with the specified grease (Shell Alvania EP2) alternately through the hole for plug (6) in outer race (2). --- (4) Install plug (6) to outer race (2), confirming the direction and the position of the bore for taper pin (7). --- (5) Push taper pin (7) into bore, and caulk the head of the taper pin with a punch. --- (6) Coat seal A (8) with adhesive Cyano Bond PO-1 and place it into groove of outer race (2). --- (7) Confirm that grease nipple (10) is useful. Apply grease (NLGI-2 EP type) and confirm that the outer race rotates smoothly and that the lip of the seal is not scored. -- Installing spacer --- 34.1.9 RETRACTABLE CRAWLERS ---- (1) Preparation for Removal ---- 1. Lift up the machine by around 30 cm (1 ft) to secure the working space under the machine, and set a stable supporting stand at four positions, left and right of front and rear of crawler shoes. ---- 2. Release air in the hydraulic oil tank. ---- 3. Remove the under cover (6). -- Lift up the machine --- (2) Remove the capscrew (A6) that is fixing the cover (A3). --- (3) Disconnect the hydraulic hose connected to the adjusting cylinder (A1), and apply a plug to openings. --- (4) Remove the sems-bolt (A9) and (A10) that are fixing the brackets (A7) and (A8). --- (5) Remove the pins (A2). --- (6) Remove the nuts (14) and (15) for the stopper bolt (12). -- Removing under cover -- Stopper bolt (12) -- Removing adjusting cylinder --- (7) Preparation to remove Crawler Frame Assy --- 1. Lifting up the machine with the attachment and dozer, support the lower frame (machine body) applying stable supporting stands under the lower frame to make the crawler frame free. --- 2. Disconnect the hydraulic piping connected to the travel motor at the joint portion, and plug the joint portion to prevent oil outflow and dust invasion. -- Removing Crawler Assy --- (8) Lift up the crawler assy with a crane, remove the crawler assy with pulling it with a lever block or alike one to sideward. --- (9) Remove the adjusting cylinder (A1) together with the cover (A3), bracket (A7), etc. -- Removing / Installing Adjusting Cylinder --- (1) Apply grease on the surface of square pillars before insertion. -- Crawler Frame --- (2) Insert the crawler frame assy utilizing a lever block, etc., paying attention not to grate the square pillars. -- Installing Crawler Assy --- (3) Confirm the installing length of stopper bolts (12) for both left and right (Refer to Fig.) --- (4) Apply grease to the pin (A2). --- (5) Installation of sems-bolt (A9) and (A10) --- (6) Reconnect the hydraulic pipings for the adjusting cylinder and hydraulic motor as they had been, and tighten them with the specified torque. -- Installing Stopper Bolts (12) -- Installing Adjustable Crawler Frame Width --- (7) Pressurize the hydraulic oil tank, then confrim the smooth operation of adjusting cylinder and travel motor without any leakages. - 34.2 DISASSEMBLING AND ASSEMBLING COMPONENTS -- 34.2.1 TRAVEL MOTOR -- Travel motor assembly-Sectional View -- Travel motor reduction unit -- Hydraulic Motor -- Body 1 assy --- (1) Carry out disassembly and assembly on a clean site. Disassembled parts should be kept in a clean tray. --- (2) Before proceeding to disassembly, clean surfaces around the ports. Remove remained painting materials from every connecting parts with wire brush. --- (3) Wash disassembled parts with washing oil. --- (4) Leave match-marks on the surface of parts so as to reassemble correctly. --- (5) Do not reuse sealing parts or snap rings. Replace them with new ones at every disassembly. --- (6) Make sure there is no abnormal abrasion or seizure. Remove sharp edges and burrs by sandpaper. --- 1. Remove the plug (131) from the cover (102) and drain out the lubricating oil. -- Plug (131) removal --- 2. Put a minus screw driver or the like into the gap on the body (101) to remove the O-snap ring (113). --- 3. Remove the O-ring (102). -- O-snap ring (113) removal --- 4. Remove the O-ring (130). -- O-ring (130) removal --- 5. Remove the snap ring (125) from the top of the shaft (203), and then the S2 gear (109). -- Snap ring (125) removal --- 6. Remove the carrier II (104) assy. -- Removing carrier II (104) assy --- 7. Disassembling carrier II (104) assy. --- a. Remove the snap ring (137) from the B2 pin (111). --- b. Remove the thrust washer (121), the B2-gear (107), the needle (117) and the thrust washer (121) one after another. -- Snap ring (137) removal --- c. Remove the snap ring (123), and then the S1 gear (108). -- Snap ring (123) removal --- 8. Remove the snap ring (137) from the B1 pin of the body 2 (202), and then the thrust plate (114). -- Snap ring (137) removal --- 9. Remove the B1 gear (106), the needle (116), the ring (138) and the thrust washer (134) from the B1 pin in sequence. -- B1 gear (106) removal --- 10. Fasten the reduction unit flange and the hydraulic motor flange by a C-cIamp or a hydraulic press and then remove the snap ring (122) (See the sketch below). -- Snap ring (122) removal --- 11. Pull out the reduction unit body from the hydraulic motor together with the steel balls with retainer and the inner ring (1 set) of the bearing (120). -- Bearing (120) removal --- 12. Remove the seal ring (112) together with the O-ring (129) from the body (101). -- Seal ring (112) removal --- 13. Remove the steel balls with retainer and the inner ring (1 set) of the bearing (120) from the body 2 (202) of hydraulic motor. --- 14. Remove the floating seal (118) and the O-ring (119). -- Bearing (120) removal --- 1. Fix the hydraulic motor by a vice and remove the cap screws (222). -- Cap screw (222) removal --- 2. Remove the body 1 (201) from the body 2 (202). --- 3. Remove the valve plate (205) and the O-rings (217) and (218) from the body 1 (201). -- Body (1) and (2) disassembly --- 4. Pull out the cylinder barrel (204) assy from the body 2 (202). -- Removing cylinder barrel (204) assy --- 5. Disassembling cylinder barrel (204) assy --- a. Remove the piston shoe assy (206) and (207). --- b. Remove the shoe holder (208), the barrel holder (209) and the pin (212). -- Disassembling cylinder barrel (204) assy --- 6. Remove the snap ring (221) from the cylinder barrel (204), and the retainer (214) and the spring (213) are removed. -- Snap ring (221) removal -- Cylinder barrel (204) disassembly --- 7. Remove the swash plate (210) from the body 2 (202). -- Swash plate (210) removal --- 8. Remove two balls (220) from the body 2 (202). -- Ball (220) removal --- 9. Remove the shaft (203) from the body 2 (202). -- Shaft (203) removal --- 10. Remove the control piston (211) from the body 2 (202). --- 11. Remove the cylindrical pin (224) from the body 2 (202). -- Control piston (211) removal --- 12. Remove the plugs (312) [both sides], the pins (321) [both sides] and the shuttle spool (306) [one side] from the body 1 (301). --- 13. Remove the plugs (311) with the O-rings (318) [both sides], the spring (309) [one side], and the 2- speed spool (305) [one side] from the body 1 (301). -- Removing spool (305 and 306) --- 14. Remove the plugs (310) with the O-rings (319) [both sides], the springs (308) [both sides], the rings (314) [both sides] and the spool (302) assy [one side] from.the body 1 (301). -- Removing spool (302) --- 1. Insert the spool (302) assy [one side], the rings (314) [both sides] and the springs (308) [both sides] into the body 1 (301) in this order, and tighten the plugs (310) [both sides] provided with the O-rings (319). -- Installing spool (302) --- 2. Insert the 2-speed spool (305) [one side] and the spring (309) [one side] into the body (301), and tighten the plugs (311) [both sides] provided with the O-rings (318). --- 3. Insert the shuttle spool (306) [one side] and the pins (321) [both sides] into the body (301), and tighten the plugs (312) [both sides]. -- Installing spool (305) and (306) --- 4. Press in the bearing (216) and the spring pin (223) if they are removed from the body (301). --- 5. Install the Q-rings (217) and (218). -- Installing bearing, O-ring etc. --- 6. Press in the oil seal (219) to the body (202). -- Oil seal (219) installation --- 7. Install the cylindrical pin (224) to the body (202). -- Cylindrical pin (224) installation --- 8. Press in the bearing (215) to the shaft (203) if it is removed. -- Bearing (215) installation --- 9. Install the control piston (211) to the body 2 (202). -- Control piston (211) installation --- 10. Install the shaft (203) to the body 2 (202). -- Shaft (203) installation --- 11. Install two balls (220) to the body 2 (202). -- Ball (220) installation --- 12. Install the swash plate (210) to the body 2 (202). -- Swash plate (210) installation --- 13. Install the retainer (214), the spring (213) and the retainer (214) to the cylinder barrel (204) in this order, and fix by the snap ring (221). -- Installing parts to cylinder barrel (204) -- Snap ring (221) installation --- 14. Assembling shoe holder (208) install the piston (206) and the shoe (207) assy to the shoe holder (208) to complete the shoe holder assy. -- Shoe holder (208) assembly --- 15. Assembling cylinder barrel (204) --- a. Insert three pins (212) to the cylinder barrel (204). -- Pin (212) installation --- b. Install the barrel holder (209). --- c. Further install the shoe holder assy (208) to complete the cylinder barrel assy (204). -- Cylinder barrel (204) assy --- 16. Insert the cylinder barrel (204) assy into the body 2 (202) till the shoe (207) contacts with the swash plate (210). -- Installing cylinder barrel (204) assy --- 17. Install the valve plate (205) to the body 1 (301). --- a. Install so that the copper surface of the valve plate (205) is directed upward [cylinder barrel (204) side]. --- b. Apply hydraulic oil on the slide surface (copper surface) of the valve plate (205). --- c. Apply grease on the reverse side of the valve plate (steel surface) to prevent it from dropping. -- Valve plate (205) installation --- 18. Feed approximately 100 cc (6 cu in) of hydraulic oil to the body 2 (202). --- 19. Combine the bodies 1 (201) and 2 (202). -- Combining bodies (202) and (301) --- 20. Fasten the bodies 1 (201) and 2 (202) with the capscrews (222). -- Tighten capscrews (222) --- 1. Install the floating seat (118) and the O-ring (119) to the hydraulic motor body 2 (202). -- Floating seat (118) installation --- 2. Install the inner race of the bearing (120) and the steel balls with the retainer to the body 2 (202) in this order. --- a. Do not mistake the direction of the inner race and the retainer when installing (See sectional drawing). --- b. Be careful not to loss steel balls because they may come off from the retainer. -- Bearing (120) inner race installation -- Bearing (120) retainer installation --- 3. Insert the seal ring (112) provided with the O-ring (129) to the body (101). -- Seal ring (112) installation --- 4. Assemble the hydraulic motor and the body (101). -- Body (101) assembly --- 5. Installing bearing (120) --- a. Install the steel balls with the retainer to the body (101). --- b. Install the retainer to the body 2 (202) of hydraulic motor. -- Bearing (120) installation --- 6. Fix the bearing (120) with the snap ring (122). -- Snap ring (122) installation --- 7. Install the thrust washers (134), the ring (138), the needle (116) and the B1 gear (106) to the B1 pin portion of the hydraulic motor in sequence. -- B1 gear (106) installation --- 8. Install the thrust plate (114) and fix it with the snap ring (137). -- Thrust plate (114) fixing --- 9. Assembling carrier II (104) --- a. Press in the B2 pins (111) if they are removed. --- b. Insert the S1 gear (108) and fix it with the snap ring (123). -- S1 (108) gear fixing --- c. Install the thrust washer (121), B2 gear (107), the needle (117) and the thrust washer (121) in sequence. --- d. Fix them with the snap ring (137). -- Snap ring (137) installation --- 10. Install the carrier II (104) assy. -- Installing carrier II (104) assy --- 11. Install the S2 gear (109) to the shaft (203) and fix with the snap ring (125). -- S2 gear (109) fixing --- 12. Install the O-ring (130) to the body (101). -- O-ring (101) installation --- 13. Feed 330 cc (20 cu-in) of; lubricating oil and install the cover (102). -- Cover (102) installation --- 14. Install the O-snap ring (113) and fix the cover (102). -- O-snap ring (113) installation --- 15. Tighten the two plugs (131). -- Plug (131) installation --- 1. Mating part of sprocket A --- 2. When installing the motor to the machine body and when mounting the sprocket to it, push it in gently utilizing the mounting bolts without striking it with a hammer. --- 3. Use specified types of the motor mounting and sprocket mounting bolts and tighten them with the specified torque (equivalent to or higher than 10.9 T). --- 1. Two piping ports (PF1/4) are provided. A drain pipe is connected to only one of them, another being plugged. When piping it, use the port at which the casing is filled up with hydraulic oil. Fill in 100 cc (6 cu-in)of hydraulic oil and perform piping --- 2. The back pressure of drain (allowable pressure in the hydraulic motor casing) is restricted by the oil seal. Therefore, the allowable working pressure of the drain pipe casing is restricted to 0.29MPa (43 psi) or less and the surge 0.98MPa (142 ps... --- 1. Use API Grade CD, SAE30 for lubricating oil (The machine was shipped from the factory with Idemitsu Apolloil Diesel Motive S-330 filled). --- 2. The gear oil may be any of the recommended brands. Avoid mixing different brands. Use the same brand as much as possible. --- 3. Oil is filled up at shipping. Replenish oil according to the following steps: (Ail plugs are sealed with O- rings.) --- a. Remove the plug at the oil feeding. --- b. Fill in lubricating oil to LEVEL. --- c. Tighten the plug. --- 4. Volume of lubricating oil: 330 cc (20 cu-in) 42_TROUBLE.pdf - 42. TROUBLESHOOTING (HYDRAULIC SYSTEM) -- 42.1 GENERAL PRECAUTIONS 42-3 --- 42.1.1 CONFIRM ACTUAL TROUBLED CONDITIONS AT SITE 42-3 -- 42.2 TROUBLE DIAGNOSIS : HYDRAULIC 42-5 -- 42.3 TROUBLESHOOTING 42-8 --- 42.3.1 ATTACHMENT OPERATION 42-8 --- 42.3.2 TRAVEL OPERATION 42-10 --- 42.3.3 SLEWING OPERATION 42-13 --- 42.3.4 PUMP 42-14 - 42.1 GENERAL PRECAUTIONS -- 42.1.1 CONFIRM ACTUAL TROUBLED CONDITIONS AT SITE -- Make field investigation --- 1. Model name and serial number. --- 2. Kind of attachment. --- 3. Operating time on the hour-meter. --- 4. Record of troubles. --- 5. History of the trouble and additional modifications. -- Verifying background of trouble occurred. --- 1. Verify defective part. --- 2. Reproduce the troubled conditions. --- 3. Where the defective part can not be verified, surmise the possible causes systematically. --- 4. Verify the surmised cause. --- 5. Report estimated repairing method, procedures and term to the user. -- Diagnosing trouble by means troubleshooting. --- 1. Explain the cause of trouble to the user. --- 2. Handling of damaged parts - 42.2 TROUBLE DIAGNOSIS : HYDRAULIC - 42.3 TROUBLESHOOTING -- 42.3.1 ATTACHMENT OPERATION --- 42.3.1.1 Incapable of attachment operation --- 42.3.1.2 Attachment force small --- 42.3.1.3 Attachment speed low -- 42.3.2 TRAVEL OPERATION --- 42.3.2.1 Incapable of travel operation --- 42.3.2.2 Traction force small --- 42.3.2.3 Travel speed low --- 42.3.2.4 Incapable of shifting 1st / 2nd speed --- 42.3.2.5 Deviation in single (independent) operation -- 42.3.3 SLEWING OPERATION --- 42.3.3.1 Incapable of slewing operation --- 42.3.3.2 Slewing speed low --- 42.3.3.3 Slewing force small -- 42.3.4 PUMP --- 42.3.4.1 Malfunction of pump 43_TROUBLE ELECT.pdf - 43. TROUBLESHOOTING (ELECTRICAL SYSTEM) -- 43.1 TROUBLE DIAGNOSIS : ELECTRICAL 43-3 -- 43.2 TROUBLESHOOTING 43-4 --- 43.2.1 GENERAL 43-4 --- 43.2.2 ATTACHMENT OPERATION 43-7 --- 43.2.3 TRAVEL OPERATION 43-7 - 43.1 TROUBLE DIAGNOSIS : ELECTRICAL - 43.2 TROUBLESHOOTING -- 43.2.1 GENERAL -- 43.2.2 ATTACHMENT OPERATION -- 43.2.3 TRAVEL OPERATION 44_TROUBLE ENGINE.pdf - 44. TROUBLESHOOTING (ENGINE) -- 44.1 TROUBLE DIAGNOSIS : ENGINE 44-3 -- 44.2 TROUBLESHOOTING 44-6 --- 44.2.1 STARTING TROUBLE 44-6 --- 44.2.2 E/G ROTATION TROUBLE 44-8 --- 44.2.3 OUTPUT DROPS DOWN 44-9 --- 44.2.4 OTHER TROUBLE 44-10 - 44.1 TROUBLE DIAGNOSIS : ENGINE - 44.2 TROUBLESHOOTING -- 44.2.1 STARTING TROUBLE -- 44.2.2 E/G ROTATION TROUBLE -- 44.2.3 OUTPUT DROPS DOWN -- 44.2.4 OTHER TROUBLE 51_ENGINE.pdf - 51. ENGINE TNV(0BTNV-G00200)_A4.pdf - Table of Contents - Introduction - Yanmar Warranties -- Yanmar Limited Warranty --- What is Covered by this Warranty? --- How Long is the Warranty Period? --- What the Engine Owner Must Do: --- To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor: --- What Yanmar Will Do: --- What is Not Covered by this Warranty? --- Warranty Limitations: --- Warranty Modifications: --- Questions: --- Retail Purchaser Registration -- Emission System Warranty -- Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only --- Your Warranty Rights and Obligations: ---- California --- Manufacturer’s Warranty Period: --- Warranty Coverage: --- Warranted Parts: --- Exclusions: --- Owner’s Warranty Responsibilities: - Safety -- Safety Statements -- Safety Precautions - General Service Information -- Component Identification -- Location of Labels --- Engine Nameplate (Typical) -- EPA / ARB Emission Control Regulations - USA Only -- Emission Control Labels --- EPA / ARB Labels -- The 97/68/EC Directive Certified Engines -- Engine Family -- Function of Major Engine Components -- Function of Cooling System Components -- Diesel Fuel --- Diesel Fuel Specifications ---- Additional Technical Fuel Requirements ---- Bio-Diesel Fuels --- Filling the Fuel Tank --- Priming the Fuel System -- Engine Oil --- Engine Oil Specifications --- Service Categories ---- Definitions ---- Additional Technical Engine oil Requirements: --- Engine Oil Viscosity --- Checking Engine Oil --- Adding Engine Oil --- Engine Oil Capacity (Typical) -- Engine Coolant --- Engine Coolant Specifications ---- Additional Technical Coolant Specifications: ---- Alternative Engine Coolant --- Filling Radiator with Engine Coolant --- Engine Coolant Capacity (Typical) -- Specifications --- Description of Model Number --- Engine Speed Specifications --- Engine General Specifications -- Principal Engine Specifications --- 2TNV70 --- 3TNV70 --- 3TNV76 -- Engine Service Information -- Tightening Torques for Standard Bolts and Nuts -- Abbreviations and Symbols --- Abbreviations --- Symbols -- Unit Conversions --- Unit Prefixes --- Units of Length --- Units of Volume --- Units of Mass --- Units of Force --- Units of Torque --- Units of Pressure --- Units of Power --- Units of Temperature - Periodic Maintenance -- Introduction -- Precautions --- The Importance of Periodic Maintenance --- Performing Periodic Maintenance --- Yanmar Replacement Parts --- Required EPA / ARB Maintenance - USA Only --- EPA / ARB Installation Requirements - USA Only -- Periodic Maintenance Schedule -- Periodic Maintenance Procedures --- After Initial 50 Hours of Operation ---- Replace Engine Oil and Engine Oil Filter ---- Check and Adjust Cooling Fan V-Belt --- Every 50 Hours of Operation ---- Drain Fuel Filter / Water Separator ---- Check Battery --- Every 250 Hours of Operation ---- Drain Fuel Tank ---- Replace Engine Oil and Engine Oil Filter ---- Check and Clean Radiator Fins ---- Check and Adjust Cooling Fan V-Belt ---- Check and Adjust the Governor Lever and Engine Speed Control ---- Clean Air Cleaner Element --- Every 500 Hours of Operation ---- Replace Air Cleaner Element ---- Replace Fuel Filter ---- Clean Fuel Filter / Water Separator --- Every 1000 Hours of Operation ---- Drain, Flush and Refill Cooling System with New Coolant ---- Adjust Intake / Exhaust Valve Clearance --- Every 1500 Hours of Operation ---- Inspect, Clean and Test Fuel Injectors ---- Inspect Crankcase Breather System --- Every 2000 Hours of Operation ---- Check and Replace Fuel Hoses and Engine Coolant Hoses ---- Lap the Intake and Exhaust Valves - Engine -- Before You Begin Servicing -- Introduction -- Cylinder Head Specifications --- Adjustment Specifications --- Cylinder Head --- Intake / Exhaust Valve and Guide --- Push Rod --- Valve Spring --- Rocker Arm and Shaft -- Camshaft and Timing Gear Train Specifications --- Camshaft --- Idler Gear Shaft and Bushing --- Timing Gear Backlash -- Crankshaft and Pistons Specifications --- Crankshaft --- Crankshaft Reconditioning --- Thrust Bearing --- Piston --- Piston Ring --- Connecting Rod ---- Connecting Rod Small End ---- Connecting Rod Big End ---- Connecting Rod Distortion --- Tappet -- Cylinder Block Specifications --- Cylinder Block -- Special Torque Chart --- Torque for Bolts and Nuts -- Special Service Tools -- Measuring Instruments -- Cylinder Head --- Cylinder Head Components --- Disassembly of Cylinder Head ---- Removal of Intake Manifold / Valve Cover ---- Removal of Glow Plugs ---- Removal of Rocker Arm Assembly ---- Disassembly of Rocker Arm Assembly ---- Removal of Cylinder Head ---- Removal of Intake / Exhaust Valves ---- Removal of Valve Guides --- Cleaning of Cylinder Head Components --- Inspection of Cylinder Head Components ---- Inspection of Push Rods ---- Inspection of Rocker Arm Assembly ---- Inspection of Valve Guides ---- Inspection of Cylinder Head ---- Inspection of Intake and Exhaust Valves ---- Inspection of Valve Springs --- Reassembly of Cylinder Head ---- Reassembly of Valve Guides ---- Reassembly of Intake and Exhaust Valves ---- Reassembly of Cylinder Head ---- Reassembly of Rocker Arm Assembly ---- Reassembly of Intake Manifold / Valve Cover --- Measuring and Adjusting Valve Clearance ---- 3-Cylinder Engines -- Cylinder Block --- Crankshaft and Camshaft Components --- Disassembly of Cylinder Block Components --- Disassembly of Camshaft and Timing Components ---- Removal of Timing Gear Case Cover ---- Checking Timing Gear Backlash ---- Measuring Idler Gear-to-Crankshaft Gear Backlash ---- Measuring Idler Gear-to-Camshaft Gear Backlash ---- Removal of Timing Gears ---- Removal of Oil Pan ---- Removal of Camshaft ---- Removal of Gear Case --- Disassembly of Crankshaft and Piston Components ---- Removal of Pistons ---- Removal of Crankshaft --- Inspection of Crankshaft and Camshaft Components ---- Replacement of Crankshaft Oil Seals ---- Crankshaft Bearing Oil Clearance ---- Inspection of Cylinder Block ---- Inspection of Pistons, Piston Rings and Wrist Pin ---- Inspection of Connecting Rod ---- Inspection of Tappets ---- Inspection of Crankshaft --- Reconditioning the Crankshaft ---- Inspection of Camshaft ---- Inspection of Camshaft Bushing and Bores ---- Inspection of Idler Gear and Shaft --- Honing and Boring --- Reassembly of Crankshaft and Piston Components ---- Reassembly of Pistons ---- Installation of Crankshaft ---- Installation of Pistons --- Reassembly of Camshaft and Timing Components ---- Installation of Gear Case ---- Installation of Camshaft ---- Installation of Timing Gears ---- Installation of Gear Case Cover ---- Installation of Oil Pan ---- Final Assembly of Engine - Fuel System -- Before You Begin Servicing -- Introduction --- Fuel Injection Pump --- Stop Solenoid -- Fuel System Specifications --- Special Torque Chart --- Test and Adjustment Specifications -- Special Service Tools -- Measuring Instruments -- Fuel System Diagram -- Fuel System Components -- Fuel Injection Lines --- Removal of High-Pressure Fuel Injection Lines --- Installation of High-Pressure Fuel Injection Lines --- Removal of Fuel Return Line --- Installation of Fuel Return Line -- Fuel Injection Pump --- Removal of Fuel Injection Pump --- Installation of Fuel Injection Pump -- Checking and Adjusting Fuel Injection Timing --- Checking Fuel Injection Timing --- Adjusting Fuel Injection Timing -- Fuel Injectors --- Removal of Fuel Injectors --- Testing of Fuel Injectors ---- Fuel Injector Test Results --- Disassembly and Inspection of Fuel Injectors --- Adjusting Fuel Injector Pressure --- Reassembly of Fuel Injectors --- Installation of the Fuel Injectors - Cooling System -- Before You Begin Servicing -- Introduction -- Cooling System Diagram -- Engine Coolant Pump Components -- Engine Coolant System Check -- Engine Coolant Pump --- Disassembly of Engine Coolant Pump --- Cleaning and Inspection ---- Temperature Switch ---- Thermostat ---- Radiator Cap --- Reassembly of Engine Coolant Pump - Lubrication System -- Before You Begin Servicing -- Introduction -- Oil Pump Service Information --- Engine Oil Pressure --- Outer Rotor Outside Clearance --- Outer Rotor Side Clearance --- Outer Rotor to Inner Rotor Tip Clearance --- Inner Rotor and Gear Boss Clearance -- Lubrication System Diagram -- Checking Engine Oil Pressure -- Trochoid Oil Pump --- Oil Pump Components --- Disassembly of Oil Pump --- Cleaning and Inspection ---- Check Outer Rotor Outside Clearance ---- Outer Rotor to Inner Rotor Tip Clearance ---- Check Outer Rotor Side Clearance ---- Check Inner Rotor and Gear Boss Clearance --- Reassembly of Oil Pump - Starter Motor -- Before You Begin Servicing -- Introduction -- Starter Motor Information -- Starter Motor Specifications -- Starter Motor Troubleshooting -- Starter Motor Components -- Starter Motor --- Removal of Starter Motor --- Disassembly of Starter Motor --- Cleaning and Inspection ---- Armature ---- Field Coil ---- Brush Holder ---- Solenoid Switch ---- Pinion Clutch Assembly --- Reassembly of Starter Motor --- Check Pinion Projection Length --- No-Load Test --- Installation of Starter Motor - Alternator -- Before You Begin Servicing -- Introduction -- Standard and Optional Dynamo Information -- Standard and Optional Alternator Information -- Alternator Specifications -- Dynamo Specifications -- Alternator Troubleshooting -- Alternator Components -- Alternator Wiring Diagram -- Alternator Standard Output -- Alternator --- Removal of Alternator --- Disassembly of Alternator --- Reassembly of Alternator --- Installation of Alternator -- Dynamo Component Location -- Dynamo Wiring Diagram -- Operation of Dynamo -- Dynamo Standard Output -- Testing of Dynamo --- Testing Stator Coil Continuity --- Testing Stator Coil Short-to-Ground --- Testing Dynamo Regulated Output -- Dynamo --- Removal of Dynamo --- Disassembly of Dynamo --- Reassembly of Dynamo --- Installation of Dynamo - Electric Wiring -- Electric Wiring Precautions -- Electric Wire Resistance -- Battery Cable Resistance -- Electrical Wire Sizes - Voltage Drop -- Conversion of AWG to European Standards - Troubleshooting -- Special Service Tools -- Troubleshooting By Measuring Compression Pressure --- Compression Pressure Measurement Method --- Standard Compression Pressure --- Engine Speed and Compression Pressure (Use for Reference) --- Measured Value and Troubleshooting -- Quick Reference Table For Troubleshooting