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Hyundai HX130LCR Manual

Hyundai HX130LCR Manual

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Service manual (41 pages)

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SECTION 1 GENERAL

Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1

Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10

SECTION 2 STRUCTURE AND FUNCTION

Group 1 Pump Device ------------------------------------------------------------------------------------------------------ 2-1

Group 2 Main Control Valve -------------------------------------------------------------------------------------------- 2-20

Group 3 Swing Device ----------------------------------------------------------------------------------------------------- 2-47

Group 4 Travel Device ------------------------------------------------------------------------------------------------------ 2-61

Group 5 RCV Lever ---------------------------------------------------------------------------------------------------------- 2-74

Group 6 RCV Pedal ---------------------------------------------------------------------------------------------------------- 2-81

SECTION 3 HYDRAULIC SYSTEM

Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------ 3-1

Group 2 Main Circuit -------------------------------------------------------------------------------------------------------- 3-2

Group 3 Pilot Circuit --------------------------------------------------------------------------------------------------------- 3-5

Group 4 Single Operation ------------------------------------------------------------------------------------------------ 3-14

Group 5 Combined Operation ----------------------------------------------------------------------------------------- 3-26

SECTION 4 ELECTRICAL SYSTEM

Group 1 Component Location ----------------------------------------------------------------------------------------- 4-1

Group 2 Electrical Circuit ------------------------------------------------------------------------------------------------- 4-3

Group 3 Electrical Component Specification ----------------------------------------------------------------- 4-22

Group 4 Connectors --------------------------------------------------------------------------------------------------------- 4-33

SECTION 5 MECHATRONICS SYSTEM

Group 1 Outline ----------------------------------------------------------------------------------------------------------------- 5-1

Group 2 Mode selection System ------------------------------------------------------------------------------------- 5-3

Group 3 Automatic Deceleration System ----------------------------------------------------------------------- 5-6

Group 4 Power Boost System ----------------------------------------------------------------------------------------- 5-7

Group 5 Travel Speed Control System --------------------------------------------------------------------------- 5-8

Group 6 Automatic Warming Up Function ---------------------------------------------------------------------- 5-9

Group 7 Engine Overheat Prevention Function ------------------------------------------------------------- 5-10

Group 8 Variable Power Control System ------------------------------------------------------------------------ 5-11

CONTENTS

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Summary of Contents for Hyundai HX130LCR

Page 1: Table Of Contents
CONTENTS SECTION 1 GENERAL Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10 SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device ------------------------------------------------------------------------------------------------------ 2-1 Group 2 Main Control Valve -------------------------------------------------------------------------------------------- 2-20 Group 3 Swing Device ----------------------------------------------------------------------------------------------------- 2-47 Group 4 Travel Device ------------------------------------------------------------------------------------------------------ 2-61 Group 5 RCV Lever ---------------------------------------------------------------------------------------------------------- 2-74 Group 6 RCV Pedal ---------------------------------------------------------------------------------------------------------- 2-81 SECTION 3 HYDRAULIC SYSTEM...
Page 2 Group 9 Attachment Flow Control System -------------------------------------------------------------------- 5-12 Group 10 Intelligent Power Control System --------------------------------------------------------------------- 5-13 Group 11 Anti-Restart System ------------------------------------------------------------------------------------------ 5-15 Group 12 Self-Diagnostic System ------------------------------------------------------------------------------------- 5-16 Group 13 Engine Control System ------------------------------------------------------------------------------------- 5-49 Group 14 EPPR Valve ------------------------------------------------------------------------------------------------------- 5-50 Group 15 Monitoring System --------------------------------------------------------------------------------------------- 5-55 Group 16 Fuel Warmer System ---------------------------------------------------------------------------------------- 5-94 SECTION 6 TROUBLESHOOTING...
Page 3 The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your HYUNDAI distributor for the latest information.
Page 4 Revised edition mark(①②③…) Any additions, amendments or other changes will When a manual is revised, an edition mark is be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.
Page 5 3. CONVERSION TABLE Method of using the Conversion Table The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. Example Method of using the Conversion Table to convert from millimeters to inches Convert 55mm into inches.
Page 6 Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457...
Page 7 Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189 8.454 8.718 8.982 9.246...
Page 8 kgf·m to lbf·ft 1kgf·m = 7.233lbf·ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9...
Page 9 kgf/cm to lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
Page 10 TEMPERATURE Fahrenheit-Centigrade Conversion. A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
Page 11: Section 1 General
SECTION 1 GENERAL Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10...
Page 12 SECTION 1 GENERAL GROUP 1 SAFETY FOLLOW SAFE PROCEDURE Unsafe wor k practices are dangerous. Understand service procedure before doing work; Do not attempt shortcuts. WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job. 13031GE01 WARN OTHERS OF SERVICE WORK Unexpected machine movement can cause serious injury.
Page 13 PREPARE FOR EMERGENCIES Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance ser vice, hospital, and fire department near your telephone. 13031GE04 PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal or debris;...
Page 14 KEEP RIDERS OFF EXCAVATOR Only allow the operator on the excavator. Keep riders off. Riders on excavator are subject to injury such as being struck by foreign objects and being thrown off the excavator. Riders also obstruct the operator's view resulting in the excavator being operated in an unsafe manner.
Page 15 SUPPORT MACHINE PROPERLY Always lower the attachment or implement to the ground before you work on the machine. If you must wor k on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load.
Page 16 BEWARE OF EXHAUST FUMES Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in a building, be positive there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.
Page 17 SERVICE MACHINE SAFELY Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
Page 18 AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.
Page 19 PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3.
Page 20 DISPOSE OF FLUIDS PROPERLY Improperly disposing of fluids can harm the environment and ecology. Before draining any fluids, find out the proper way to dispose of waste from your local environmental agency. Use proper containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.
Page 21: Group 2 Specifications
GROUP 2 SPECIFICATIONS GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENT 1. MAJOR COMPONENT Main control valve Fuel tank Hydraulic tank Main pump After treatment device Engine Radiator Oil cooler Turning joint Swing motor Battery Bucket Tooth Arm cylinder Boom Boom cylinder Counterweight Dozer blade cylinder Sprocket...
Page 22 2. SPECIFICATIONS HX130LCR 4.30 m (14' 1") BOOM and 2.26 m (7' 5") ARM I (I') B (L) Description Unit Specification Operating weight kg (lb) 12700 (28000) Bucket capacity (SAE heaped), standard 0.40 (0.52) Overall length 6860 (22' 6") Overall width, with 500 mm shoe 2490 (8' 2")
Page 23 HX130LCRD I (I') B (L) 130ZF2SP03 Description Unit Specification Operating weight kg (lb) 13400 (29500) Bucket capacity (SAE heaped), standard 0.40 (0.52) Overall length 7600 (24' 11") Overall width, with 500 mm shoe 2490 (8' 2") Overall height 2750 (9' 0") Overall height of guardrail 3165 (10' 5") Superstructure width...
Page 24 HX130LCR 2-PIECE BOOM Without dozer I (I') B (L) 130ZF2SP06 Specification Description Unit 1.96 m (6' 5") Arm 2.26 m (7' 5") Arm Operating weight kg (lb) 13060 (28790) 13090 (28860) Bucket capacity (SAE heaped), standard 0.40 (0.52) Overall length 7100 (23' 3")
Page 25 With dozer I (I') B (L) 130ZF2SP07 Specification Description Unit 1.96 m (6' 5") Arm 2.26 m (7' 5") Arm Operating weight kg (lb) 13220 (29150) 13250 (29110) Bucket capacity (SAE heaped), standard 0.40 (0.52) Overall length 7840 (25' 9") 7830 (25' 8") Overall width, with 500 mm shoe 2490 (8' 2")
Page 26 3. WORKING RANGE 4.30 m (14' 1") MONO BOOM 130ZF2SP04 2.81 (9' 3") Arm Description 1.96 m (6' 5") Arm 2.26 m ( 7' 5") Arm 7410 mm (24' 4") 8220 mm (27' 0") Max digging reach 7690 mm (25' 3") 7250 mm (23' 9") 8080 mm (26' 6") Max digging reach on ground...
Page 27 4.556 m (14' 11") 2-PIECE BOOM 130ZF2SP08 Description 1.96 m (6' 5") Arm 2.26 m ( 7' 5") Arm Max digging reach 7715 mm (25' 4") 8000 mm (26' 3") Max digging reach on ground 7570 mm (24' 10") 7860 mm (25' 9") Max digging depth 4920 mm (16' 2") 5215 mm (17' 1")
Page 28 4. WEIGHT HX130LCR HX130LCRD Item Upper structure assembly 6950 15320 Main frame weld assembly 1231 2710 Engine assembly Main pump assembly Main control valve assembly Swing motor assembly Hydraulic oil tank assembly Fuel tank assembly Counterweight 2000 4410 Cab assembly...
Page 29 The difference between the weight of a work tool attachment must be subtracted. Consult your Hyundai dealer regarding the lifting capacities for specific work tools and attachments. Failure to comply to the rated load can cause possible personal injury or property damage.
Page 30 Outrigger Model Type Length Length Weight (kg) Width Front Rear Front Rear HX130LCR Mono 4300 1960 2000 : Rating over-front : Rating over-side or 360 degree Lift-point radius (B) At max. reach 1.5 m (4.9 ft) 3.0 m (9.8 ft) 4.5 m (14.8 ft)
Page 31 Dozer Outrigger Model Type Length Length Weight (kg) Width Front Rear Front Rear HX130LCR Mono 4300 2260 2000 Down : Rating over-front : Rating over-side or 360 degree Lift-point radius (B) At max. reach Lift-point 1.5 m (4.9 ft) 3.0 m (9.8 ft) 4.5 m (14.8 ft)
Page 32 Outrigger Model Type Length Length Weight (kg) Width Front Rear Front Rear HX130LCR Mono 4300 2260 2000 : Rating over-front : Rating over-side or 360 degree Lift-point radius (B) At max. reach Lift-point 1.5 m (4.9 ft) 3.0 m (9.8 ft) 4.5 m (14.8 ft)
Page 33 Outrigger Model Type Length Length Weight (kg) Width Front Rear Front Rear HX130LCR Mono 4300 2810 2000 : Rating over-front : Rating over-side or 360 degree Lift-point radius (B) At max. reach 1.5 m (4.9 ft) 3.0 m (9.8 ft) 4.5 m (14.8 ft)
Page 34 Outrigger Model Type Length Length Weight (kg) Width Front Rear Front Rear HX130LCR 2PCS 4556 1960 2350 Down : Rating over-front : Rating over-side or 360 degree Lift-point radius (B) At max. reach 1.5 m (4.9 ft) 3.0 m (9.8 ft) 4.5 m (14.8 ft)
Page 35 Dozer Outrigger Model Type Length Length Weight (kg) Width Front Rear Front Rear HX130LCR 2PCS 4556 1960 2350 : Rating over-front : Rating over-side or 360 degree Lift-point radius (B) At max. reach Capacity Reach Lift-point 1.5 m (4.9 ft) 3.0 m (9.8 ft)
Page 36 Outrigger Model Type Length Length Weight (kg) Width Front Rear Front Rear HX130LCR 2PCS 4556 2260 2350 : Rating over-front : Rating over-side or 360 degree At max. reach Lift-point radius (B) 1.5 m (4.9 ft) 3.0 m (9.8 ft) 4.5 m (14.8 ft)
Page 37 Work tools and ground conditions have effects on machine performance. Select an optimum combination according to the working conditions and the type of work that is being done. Consult your Hyundai dealer for information on selecting the correct boom-arm-bucket combi- nation. 1-25...
Page 38 (in) ※ 600 (24) 700 (28) 500 (20) Operating weight kg (lb) 12700 (28000) 12850 (28330) 13000 (28660) HX130LCR Ground pressure kgf/cm (psi) 0.42 (5.95) 0.35 (5.02) 0.31 (4.35) Overall width mm (ft-in) 2500 (8' 2") 2600 (8' 6") 2700 (8' 10")
Page 39 4) 4) SELECTION OF TRACK SHOE SELECTION OF TRACK SHOE Suitable track shoes should be selected according to operating conditions. Method of selecting shoes Method of selecting shoes Confirm the category from the list of applications in table table 2 2, then use table table 1 1 to select the shoe.
Page 40 8. SPECIFICATIONS FOR MAJOR COMPONENTS 8. SPECIFICATIONS FOR MAJOR COMPONENTS 1) 1) ENGINE ENGINE Item Specification Model Perkins 854F Type 4-cycle turbocharged charge air cooled diesel engine Cooling method Water cooling Number of cylinders and arrangement 4 cylinders, in-line Firing order 1-3-4-2 Combustion chamber type Direct injection type...
Page 41 3) 3) GEAR PUMP GEAR PUMP Item Specification Type Fixed displacement gear pump single stage Capacity 15cc/rev Maximum pressure 40 kgf/cm (570 psi) Rated oil flow 30ℓ/min (7.9 U.S. gpm / 6.6 U.K. gpm) 4) 4) MAIN CONTROL VALVE MAIN CONTROL VALVE Item Specification Type...
Page 42 Ground pressure Link quantity Overall width Standard 500 mm (20") 0.42 kgf/cm (5.95 psi) 2500 mm ( 8' 2") HX130LCR 600 mm (24") 0.35 kgf/cm (5.02 psi) 2600 mm ( 8' 6") Option 700 mm (28") 0.31 kgf/cm (4.35 psi) 2700 mm ( 8' 10")
Page 43 ※ ※ Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of major components.
Page 44: Section 2 Structure And Function
SECTION 2 STRUCTURE AND FUNCTION Group 1 Pump Device ------------------------------------------------------------------------------------------------------ 2-1 Group 2 Main Control Valve -------------------------------------------------------------------------------------------- 2-20 Group 3 Swing Device ----------------------------------------------------------------------------------------------------- 2-47 Group 4 Travel Device ----------------------------------------------------------------------------------------------------- 2-61 Group 5 RCV Lever ---------------------------------------------------------------------------------------------------------- 2-74 Group 6 RCV Pedal ---------------------------------------------------------------------------------------------------------- 2-81...
Page 45: Group 1 Pump Device
SECTION 2 STRUCTURE AND FUNCTION GROUP 1 PUMP DEVICE 1. STRUCTURE The pump device consists of main pump, regulator and gear pump. VIEW A Qmax adjusting screw Qmin adjusting screw A1 pump regulator A2 pump regulator a4 P1 (Dr1) (Dr1) a1(PH1) a2(PH2) Gear pump...
Page 46 MAIN PUMP (1/2) The main pump consists of two piston pumps (A1 and A2) and valve block. 533 789 733 732 532 214 548 531 702 792 534 901 808 954 724 717 723 402 151 981 983 130ZF2MP02 111 Drive shaft (F) 272 Pump casing (R) 711 O-ring 113 Drive shaft (R)
Page 47 MAIN PUMP (2/2) 711 326 728 125 468 118 825 04 A1 pump side A2 pump side 130ZF2MP03 04 Gear pump 128 Bearing spacer 711 O-ring 115 Idler shaft 262 Cover 728 O-ring 117 Gear No. 2 326 Gear case 825 Retainer ring 118 Gear No.
Page 48 REGULATOR (1/2) 412 753 612 897 874 874 726 646 438 730 643 708 645 728 801 924 SECTION B-B 413 497 VIEW C (A1 pump) VIEW C (A2 pump) 079 753 755 466 755 656 496 KR76-9N01-V (A1 pump) 130ZF2MP04 KR76-9N02-V (A2 pump) Port...
Page 49 REGULATOR (2/2) 653 654 734 836 651 652 601 624 629 630 628 802 623 887 757 753 627 SECTION A-A 140Z92MP05 079 EPPR valve assembly 624 Spring seat (C) 724 Square ring 412 Hexagon socket screw 625 Outer spring 725 O-ring 413 Hexagon socket screw 626 Inner spring...
Page 50 GEAR PUMP 354 351 307 310 308 434 466,725 SECTION Z-Z 130ZF2MP06 307 Poppet 353 Drive gear 466 Plug 308 Seat 354 Driven gear 700 Square ring 309 Ring 355 Filter 710 O-ring 310 Spring 361 Front case 725 O-ring 311 Adjusting screw 433 Flange socket bolt 732 O-ring...
Page 51 2. FUNCTION MAIN PUMP The pumps may be classified roughly into the rotary group performing a rotary motion and working as the major part of the whole pump function: the swash plate group that varies the delivery rates: and the valve cover group that changes over oil suction and discharge : and the PTO group that transfers drive shaft of gear pump.
Page 52 Valve block group The valve block group consists of valve block (312), valve plate (313, 314) and spring pin(886). The valve plate having two kidmey ports is fixed to the valve block and feeds and collects oil to and from the cylinder block. The oil changed over by the valve plate is connected to an external pipeline by way 140Z92MP07...
Page 53 REGULATOR Regulator consists of the negative flow control, total horse power control and power shift control function. Negative flow control By changing the pilot pressure Pi, the pump tilting angle (delivery flow) is regulated arbitrarily, as shown in the figure. This regulator is of the negative flow control in which the delivery flow Q decreases as the pilot pressure Pi rises.
Page 54 Flow reducing function ① B(E) Pi(From MCV) Large diameter Servo piston Small diameter chamber chamber 140Z92MP12 As the pilot pressure Pi rises, the pilot piston (643) moves to the right to a position where the force of the pilot spring (646) balances with the hydraulic force. The groove (A) in the pilot piston is fitted with the pin (875) that is fixed to lever 2 (613).
Page 55 Flow increasing function ② 651 652 B(E) Pi(From MCV) Large diameter Servo piston Small diameter chamber chamber 140Z92MP13 As the pilot pressure Pi decreases, the pilot piston (643) moves to the left by the action of the pilot spring (646) and causes lever 2 (613) to rotate around the fulcrum of point B. Since the pin (897) is pressed against the large hole section (C) of lever 2 by the action of the return spring (654) via the spool (652), pin (874), and feedback lever (611), the feedback lever rotates around the fulcrum of point D as lever 2 rotates, and shifts the spool to the left.
Page 56 Adjustment of flow control characteristic ③ The flow control characteristic can be adjusted with the adjusting screw. Adjust it by loosening the hexagon nut (801) and by tightening (or loosening) the hexagonal socket head screw (924). Tightening the screw shifts the control chart to the right as shown in the figure.
Page 57 Total horsepower control The regulator decreases the pump tilting angle (delivery flow) automatically to limit the input torque within a certain value with a rise in the delivery pressure P1 of the self pump and the delivery pressure P2 of the companion pump.
Page 58 Overload preventive function ① 621 652 623 612 601 B(E) Small diameter Large diameter Servo piston chamber chamber 140Z92RG03 When the self pump delivery pressure P1 or the companion pump delivery pressure P2 rises, it acts on the stepped part of the compensating piston (621). It presses the compensating rod (623) to the right till the force of the outer spring (625) and inner spring (626) balances with the hydraulic force.
Page 59 Flow reset function ② 621 652 612 601 B(E) Small diameter Large diameter Servo piston chamber chamber 140Z92RG04 As the self pump delivery pressure P1 or the companion pump delivery pressure P2 decreases, the compensating rod (623) is pushed back by the action of the springs (625 & 626) to rotate lever 1 (612) around point E.
Page 60 Low tilting angle (low flow) command preferential function ③ As mentioned above, flow control and horsepower control tilting angle commands are transmitted to the feedback lever and spool via the large-hole sections (C & F) of levers 1 and 2. However, since sections C and F have the pins (Ø4) protruding from the large hole (Ø8), only the lever lessening the tilting angle contacts the pin (897) ;...
Page 61 Adjustment of inner spring Adjust it by loosening the hexagon nut (802) and by tightening (or loosening) the adjusting stem C (627). Tightening the screw increases the flow and then the input horsepower as shown in the figure. ※ Adjusting value Adjustment of input horsepower Speed Tightening...
Page 62 Power shift control 621 652 623 612 601 B(E) Small diameter Large diameter Servo piston chamber chamber 140Z92RG05 The set horsepower valve is shifted by varying the command current level of the proportional pressure reducing valve attached to the pump. Only one proportional pressure redu- cing valve is provided.
Page 63 Adjustment of maximum and minimum flows Adjustment of maximum flow ① Adjust it by loosening the hexagon nut (808) and by tightening (or loosening) the set screw (954). The maximum flow only is adjusted without changing other control charac- teristics. Speed 140Z92MP23 Adjustment of max flow...
Page 64: Group 2 Main Control Valve
GROUP 2 MAIN CONTROL VALVE 1. STRUCTURE Mark Port name Port size Tightening torque Make up for swing motor UNF 1 3/16 18 kgf·m (130 lbf·ft) Travel left pilot port (BW) Travel left pilot port (FW) Travel right pilot port (FW) Travel right pilot port (BW) Pa20 Boom up pilot port...
Page 65 53 56 77 34 65 62 31 49 48 46 47 50 56 53 61 30 50 53 56 69 11 43 79 72 28 63 29 80 44 26 Housing-P1 Load check-poppet Housing-P2 Load check-poppet Spool-straight travel Signal-poppet Spool-travel (LH, RH) Travel straight-sleeve Spool-swing Travel straight-piston...
Page 66 2. HYDRAULIC CIRCUIT (Pump) (Pump) OPTION-C (DOZER) OPTION-B BUCKET P04(Boom up pilot) Pc42 OPTION-A & ARM Pc41 Pc40 REGENERATION CUT Pd40 Pd41(Shuttle) Pc42 ARM 1 BOOM 2 & ARM 2 Pa21 SWING ARM 2 PRIORITY Pd41 SWING Pb21 Pb20 Pa20 BOOM 1 Pa21 (Boom priority)P03...
Page 67 3. FUNCTION CONTROL IN NEUTRAL P1 SIDE The hydraulic fluid from pump A2 flows into the main control valve through the inlet port "P1", pass the straight travel spool into the P1 bypass passage and P1parallel passage. The hydraulic fluid from the pump A2 is directed to the tank through the bypass passage of spools : travel left, boom 1, arm 2, arm regeneration &...
Page 68 P2 SIDE The hydraulic fluid from pump A1 flows into the main control valve through the inlet port "P2", into the P2 bypass passage and P2 parallel passage. The hydraulic fluid from the pump A1 is directed to the tank through the bypass passage of spools : travel right, swing, boom 2 &...
Page 69 TRAVEL OPERATION TRAVEL FORWARD OPERATION P1 Bypass passage From RCV TRAVEL RIGHT TRAVEL LEFT From RCV Tank passage P2 Bypass passage 14092MC18 TRAVEL BACKWARD OPERATION P1 Bypass passage From RCV TRAVEL RIGHT TRAVEL LEFT From RCV Tank passage P2 Bypass passage 14092MC17 During the travel forward operation, the hydraulic fluid of the pump A2 is supplied to the travel left motor and the hydraulic fluid of the pump A1 is supplied to the other travel right motor.
Page 70 TRAVEL STRAIGHT FUNCTION P2 Parallel passage P1 port Orifice P2 Bypass passage Check valve Tank port T1 Straight travel spool P2 port P1 Bypass passage P1 Parallel passage 14092MC19 This function keeps straight travel in case of simultaneous operation of other actuators (boom, arm, bucket, swing) during a straight travel.
Page 71 BOOM OPERATION BOOM UP OPERATION During boom up operation, the pilot secondary pressure from RCV is supplied to the port Pa20 of the spring side and shifts the boom 1 spool in the left direction. The bypass passage is shut off by the movement of the boom 1 spool and the hydraulic oil fluid from pump A2 is entered P1 parallel passage and then passes through the load check, bridge passage and boom holding valve then flows into the port A2.
Page 72 BOOM DOWN OPERATION During the boom lowing operation, the pilot pressure from RCV is supplied to the port Pb20 of the spring opposite side and shifts the boom 1 spool in the right direction. The bypass passage is shut off by the movement of the boom 1 spool and the hydraulic fluid from the pump A2 enters the parallel passage and is directed to the port B2 through the load check.
Page 73 HOLDING VALVE OPERATION HOLDING OPERATION At neutral condition, the pilot piston chamber is connected to drain port through the pilot port. And the piston "B" is supported with spring "B". Also, the pressured fluid from actuator entered to inside of the holding valve through the periphery hole of check, crevice of the check and the plug and the periphery hole of plug.
Page 74 RELEASE HOLDING OPERATION The pilot pressure is supplied to the pilot port for release holding valve and shifts the piston "B" in the left direction against the spring "B", and shifts the poppet in the left direction through piston "B" and piston "A" against spring "B" and shifts the spool in the left side. At same time, the return fluid from actuator returns to the drain port through the periphery hole of check, crevice of the check and the plug, the periphery hole of the plug, in side of holding valve, crevice of the poppet and the poppet seat, the periphery hole of the poppet seat, crevice of...
Page 75 BUCKET OPERATION BUCKET IN OPERATION During the bucket in operation, the pilot secondary pressure from RCV is supplied to port Pa5 of the spring side and shifts the bucket spool in the left direction. The bypass passage is shut off by the movement of the bucket spool and the hydraulic fluid from pump A2 entered P1 parallel passage and is directed to the port A5 through the check 1.
Page 76 BUCKET OUT OPERATION During the bucket out operation, the pilot secondary pressure from RCV is supplied to port Pb5 of the spring opposite side and shifts the bucket spool in the right direction. The bypass passage is shut off by the movement of the bucket spool and the hydraulic fluid from pump A2 entered P1 parallel passage and is directed to the port B5 through the check 1.
Page 77 BUCKET IN OPERATION WITH BOOM OPERATION When combined operation, mostly same as previous page but the fluid from P1 bypass passage is empty. So only the fluid from P1 parallel passage is supplied to the bucket cylinder. Also, parallel passage is installed the orifice of bucket limiter for supplying the fluid from pump A2 to the boom operation prior to the bucket operation.
Page 78 SWING OPERATION SWING LEFT & RIGHT OPERATION During the swing left operation, the pilot secondary pressure from the RCV is supplied to the port Pd2 of the spring side and shift the swing spool in left direction. The bypass passage is shut off by the movement of the swing spool and the hydraulic fluid from pump A1 flows into swing spool through the P2 parallel passage.
Page 79 SWING LEFT OPERATION WITH ARM OR BOOM OPERATION When combined operation, mostly same as previous page but the fluid from P2 bypass passage is empty. So only the fluid from parallel passage is supplied to the swing motor. Also, parallel passage is installed the orifice of swing logic valve for supplying the fluid from pump A1 to the boom or the arm operation prior to the swing operation.
Page 80 ARM OPERATION ARM IN OPERATION During arm in operation, the pilot secondary pressure from the RCV is supplied to the port Pc40 of spring opposite side and shifts arm 1 spool in the right direction. The bypass passage is shut off by the movement of the arm 1 spool and the hydraulic oil from the pump A1 flows into the arm cylinder head side through P2 parallel passage, the load check valve, bridge passage and the port C4.
Page 81 ARM REGENERATION The return flow from the arm cylinder rod side is pressurized by self weight of arm and so, returns to port D4. The pressurized oil returning to port D4 enters the arm regeneration & breaker spool through the arm holding valve and the arm 1 spool. It is supplied the arm cylinder head through internal passage.
Page 82 ARM OUT OPERATION During arm out operation, the pilot secondary pressure from RCV is supplied to the port Pd40 of spring side and shifts arm 1 spool in the left direction. The bypass passage is shut off by the movement of the arm 1 spool and the hydraulic fluid from pump A1 flows into arm 1 spool through the P2 parallel passage.
Page 83 SWING PRIORITY FUNCTION During swing priority operation, the pilot secondary pressure is supplied to the port Pc3 of the spring side of the swing priority spool and shift swing priority spool in the right direction. The hydraulic fluid from P2 parallel passage flows into the parallel passage of arm 1 side through swing priority spool and the path "A"...
Page 84 DOZER OPERATION Dozer down operation P2 Parallel passage Dozer spool From dozer RCV DOZER Tank passage 14W92MC30 Dozer up operation P2 Parallel passage Dozer spool DOZER From dozer RCV Tank passage 14W92MC31 During the dozer down operation, the pilot pressure from the dozer control valve is supplied into the port Pc6 of the spring side and it shifts the dozer spool in the left direction.
Page 85 NEGATIVE RELIEF VALVE OPERATION When no function is being actuated on P1 side, the hydraulic fluid from the pump A2, flows into the tank passage through the P1 bypass passage and orifice. The restriction caused by this orifice thereby pressurizes. This pressure is transferred as the negative control signal pressure Pn1 to the pump A2 regulator.
Page 86 OPERATION OF MAIN RELIEF VALVE The pressurized oil passes through the orifice (A) of the plunger is filled up in chamber A of the inside space, and seats the plunger against the housing securely. Socket Chamber A Piston A Poppet Hole A Spring Piston B...
Page 87 The pressure at port P becomes lower than set pressure of the spring, the poppet is seated by spring force. Then the pressure at port P becomes equal to set pressure of the spring and the plunger is seated to the socket. Socket Poppet Spring...
Page 88 OPERATION OF OVERLOAD RELIEF VALVE FUNCTION AS RELIEF VALVE The pressurized oil passes through the piston A and orifice A is filled up in chamber A of the inside space and seat the plunger against the socket and the socket against the housing securely. Piston A Socket Chamber A Poppet...
Page 89 Opening of the poppet causes the pressure in chamber A to fall and the plunger to open. As the result the pressurized oil at port P runs into tank passage (T). Tank passage Chamber A Poppet Housing Tank passage Plunger 14W92MC43 The pressure at port P becomes lower than set pressure of the spring, the poppet is seated by spring force.
Page 90 MAKE-UP FUNCTION When negative pressure exists at port P, the oil is supplied through tank passage (T). When the pressure at tank passage (T) becomes higher than that of at port P, the socket moves in the right direction. Then, sufficient oil passes around the socket from tank passage (T) to port P and fills up the space.
Page 91: Group 3 Swing Device
GROUP 3 SWING DEVICE 1. STRUCTURE (TYPE 1) Swing device consists swing motor, swing reduction gear. Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve. Reduction gear Relief valve Oil level gauge & oil supply port Oil level &...
Page 92 SWING MOTOR VIEW X 17 18 21 20 29 30 3 2 11 10 1 16 19 18 38 25 26 24 23 41 31 40 23 24 26 25 38 130ZF2SM22 Casing 15 Parking piston 29 Plug Oil seal 16 Spring 30 O-ring Shaft...
Page 93 REDUCTION GEAR 2 25 26 27 8 7 15 11 12 14 13 21 15 20 18 19 32 23 9 6 31 24 1 10 16 17 24 22 125LCR2SM23 Ring gear 11 Planetary gear No. 2 21 Carrier pin No. 1 Drive shaft 12 Needle bearing No.
Page 94 STRUCTURE (TYPE 2) Swing device consists swing motor, swing reduction gear. Swing motor include mechanical parking valve, relief valve, make up valve and time delay valve. Time delay valve Relief valve Oil level gauge & R/G grease fill port(PT 1/4) Oil supply port R/G Oil drain port(PT 1/2) R/G Air bleed port(PT 1/4)
Page 95 SWING MOTOR DETAIL K 11 10 9 22 7 37 30 32,33 130ZF2SM02 8 13 12 15 14 17 2 3 4 Body 16 Brake piston 31 Anti-rotating valve Oil seal 17 O-ring 32 Time delay valve Roller bearing 18 O-ring 33 Wrench bolt Snap ring 19 Brake spring...
Page 96 REDUCTION GEAR 29 5 1 10 27 12 13 Oil drain Grease port VIEW A 130ZF2SM03 Casing 12 No.2 pin 23 Stop ring Drive shaft 13 No.2 bushing 24 No. 1 sun gear Cover plate 14 No.2 sun gear 25 Stop ring Spacer 15 No.1 carrier assy 26 Side plate No.1...
Page 97 2. PRINCIPLE OF DRIVING ※ Descriptions are based on the type 1 of the swing motor. 1) GENERATING THE TURNING FORCE The high hydraulic supplied from a hydraulic pump flows into a cylinder block (8) through valve casing (22) of motor and valve plate (20). The high hydraulic is built as flowing on one side of Y-Y line connected by the upper and lower sides of piston (12).
Page 98 MAKE UP VALVE In the system using this type of motor, there is no counter balance functioning valve and there happens the case of revolution exceeding hydraulic supply of motor. To prevent the cavitation caused by insufficient oil flow there is a make up valve to fill up the oil insufficiency. A make up valve is provided immediately before the port leading to the hydraulic oil tank to secure feed pressure required when the hydraulic motor makes a pumping action.
Page 99 RELIEF VALVE Sleeve Poppet Poppet seat Spring Spring seat Shim Piston Stopper Plug O-ring O-ring 145WF2SM25 Construction of relief valve The valve casing contains two cartridge type relief valves that stop the regular and reverse rotations of the hydraulic motor. The relief valves relieve high pressure at start or at stop of swing motion and can control the relief pressure in two steps, high and low, in order to insure smooth operation.
Page 100 Ports (P,R) at tank pressure. ① A2 m h 145WF2SM26 When hydraulic oil pressure (P×A ) reaches the preset force (F ) of spring (4), the poppet (2) ② moves to the right as shown. Fsp+Pg×A ×A Fsp+Pg×A 145WF2SM27 2-56...
Page 101 The oil flows into chamber (g) via orifice (m) and (n). When the pressure of chamber (g) reaches ③ the preset force (F ) of spring (4), the piston (7) moves left and stop the piston (7) hits the bottom of stopper (8).
Page 102 BRAKE SYSTEM Control valve swing brake system This is the brake system to stop the swing motion of the excavator during operation. In this system, the hydraulic circuit is throttled by the swing control valve, and the resistance created by this throttling works as a brake force to slow down the swing motion. Deceleration Stop Work...
Page 103 Operating principle ② When one of the RCV lever (1) is set to the operation position, the each spool is shifted to left or right and the pilot oil flow is blocked. Then the pilot oil go to SH of the time delay valve (35). This pressure moves spool (5) to the leftward against the force of the spring(8), so pilot pump charged oil (P3) goes to the chamber G through port PG.
Page 104 When all of the RCV lever (1) are set the neutral position, the spool (5) returns to right. Then, the parking piston (15) is moved lower by spring force and the return oil from the chamber G flows back to tank port. At this time, the brake works.
Page 105: Group 4 Travel Device
GROUP 4 TRAVEL DEVICE 1. CONSTRUCTION Travel device consists travel motor and gear box. Travel motor includes brake valve, parking brake and high/low speed changeover mechanism. Parts number Reduction gear Travel motor VIEW A 130ZF2TM20 Port Port name Port size VA, VB Valve port PF 3/4...
Page 106 2. STRUCTURE 49 40 43 42 41 44 64 69 68 67 66 65 62 17 18 21 20 19 22 23 53 55,56 28 24 2 29 71 70 59 77 88 3 63 7 10 11 14 15 13 16 26 27 6 8 130ZF2TM21 Casing...
Page 107 3. OPERATION MOTOR High pressure oil delivered form hydraulic pump is led to inlet port that is provided in the brake valve portion and, through the rear cover (30) and valve plate (24), led to cylinder block (12). The oil flow and direction of shaft rotation are indicated in table. Shaft rotation Left Shaft rotation Right (Counterclockwise)
Page 108 PARKING BRAKE Parking brake is released when high pressure oil selected by the brake valve portion that is connected directly to the rear cover (30), is applied to the parking piston (19). Otherwise the braking torque is always applied. This braking torque is generated by the friction between the separated plates (18), inserted into the casing (1), and friction plates (17), coupled to cylinder block (12) by the outer splines.
Page 109 CAPACITY CONTROL MECHANISM Figure typically shows the capacity control mechanism. When high speed pilot line is charged with the pressure P that overcome the spring (44), the spring (44) is compressed and spool (40) shifts to the right to connect the port P and port C. Then, the highest pressure is selected by the check valve (50) from inlet and outlet pressure of the motor and high speed pilot line pressure and pushes shifter piston (4).
Page 110 OVERLOAD RELIEF VALVE Structure This valve is screwed in the motor rear cover (30) and consists of : plug (38-1) that is screwed and fixed in the rear cover (30), poppet (38-8) and supports the poppet seat (38-9), spring (38-2) that is operating relief valve setting pressure and supports the spring seat (38-3), that is inserted in the sleeve (38-4), piston (38-5) that reduce the shock.
Page 111 Operation Two pieces of overload valves are located at cross-over position in the counterbalance circuit of brake valve and have the following functions : When hydraulic motor starts, keep the driving pressure below predetermined value and while ① accelerating, bypasses surplus oil to return line. When stopping the motor, keep the brake pressure, that develops on the outlet side of motor, ②...
Page 112 BRAKE VALVE Structure The brake valve portion mainly consists of the following parts: Spool ① By shifting the spool (31), the discharged oil from hydraulic motor is automatically shut off or restricted according to the condition and give the effect of holding, accelerating, stopping and counterbalance operations.
Page 113 Operation Holding operation ① When the control valve is at neutral position, VA and VB ports are connected to the tank, and the spring (33) located on both spool ends holds the spool (31) at central position. Therefore, the passages from VA to MA and VB to MB are closed, which result in closing MA and MB ports connected to hydraulic motor.
Page 114 Accelerating operation ② When VA and VB ports are connected respectively to pump and tank by operating the control valve, hydraulic oil from pump is forwarded through VA port to push open the check valve provided inside spool (31), and oil flows to motor via MA port to rotate the motor. Therefore, the pressure increases and negative brake is released by the pressure supplied from pump.
Page 115 Stopping operation ③ Returning the control valve to neutral position while running the motor, the oil supply is cut off and VA and VB ports are connected to the tank line. Then the pressure of the pilot chamber located on both spool ends become equal, and the spool (31) returns to the neutral position by spring (33) force.
Page 116 Counterbalance operation ④ Counterbalance operation is required to decelerate slowly the hydraulic motor while absorbing inertia force. In case the hydraulic oil is gradually decreased from pump to VB port, the drive shaft of hydraulic motor tends to rotate faster than that matched to the volume of oil supply. Consequently, the pilot chamber pressure on MB to VB side decreases and the spring (33) force moves the spool (31) leftwards towards neutral position.
Page 117 REDUCTION GEAR Reduction unit slows down the rotating speed of motor and converts motor torque to strong rotating force. This reduction unit utilizes two stages, planetary reduction system. Planetary reduction system consists of sun gear, planetary gears, (planetary) carriers, and ring gear.
Page 118: Group 5 Rcv Lever
GROUP 5 RCV LEVER 1. STRUCTURE The casing has the oil inlet port P (primary pressure) and the oil outlet port T (tank). In addition the secondary pressure is taken out through ports 1, 2, 3 and 4 provided at the bottom face. ※...
Page 119 TYPE M2 Null TYPE M2 Switches Type One touch decel Horn Single Simultaneous operation Power boost Breaker operation Hydraulic circuit Pilot ports Port Port size Pilot oil inlet port Pilot oil inlet port Pilot oil return port Pilot oil return port Left swing port Bucket out port PF 3/8...
Page 120 CROSS SECTION Case Bushing Spool Shim Spring Spring seat Spring Plug Push rod 10 O-ring 11 Rod seal 12 Plate 13 Spacer 14 Boot 15 Joint assembly 16 Swash plate 17 Adjusting nut 18 Bushing 19 Plug 20 Handle assembly 21 Handle bar 22 Nut 23 Boot...
Page 121 2. FUNCTIONS FUNDAMENTAL FUNCTIONS The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This function is carried out by providing the spring at one end of the main control valve spool and apply- ing the output pressure (secondary pressure) of the pilot valve to the other end.
Page 122 OPERATION The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown below and the attached operation explanation drawing. The diagram shown below is the typical application example of the pilot valve. 2-70 Pilot valve Main pump Hydraulic motor...
Page 123 Case where handle is in neutral position Port 1 Port 3 300L2RL03 The force of the spring (5) that determines the output pressure of the pilot valve is not applied to the spool (3). Therefore, the spool is pushed up by the spring (7) to the position of port (1, 3) in the operation explanation drawing.
Page 124 Case where handle is tilted Port 1 Port 3 300L2RL04 When the push rod (9) is stroked, the spool (3) moves downwards. Then port P is connected with port (1) and the oil supplied from the pilot pump flows through port (1) to generate the pressure.
Page 125: Group 6 Rcv Pedal
GROUP 6 RCV PEDAL 1. STRUCTURE The casing (spacer) has the oil inlet port P (primary pressure), and the oil outlet port T (tank). In addition the secondary pressure is taken out through ports 1,2, 3 and 4 provided at the bottom face. Port Port Port size...
Page 126 CROSS SECTION The construction of the RCV pedal is shown in the below drawing. The casing has vertical holes in which reducing valves are assembled. The pressure reducing section is composed of the spool (7), spring (5) for setting secondary pressure, return spring (9), stopper (8), and spring seat (6).
Page 127 2. FUNCTION FUNDAMENTAL FUNCTIONS The pilot valve is a valve controls the spool stroke, direction, etc of a main control valve. This function is carried out by providing the spring at one end of the main control valve spool and applying the output pressure (secondary pressure) of the pilot valve to the other end.
Page 128 OPERATION The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown below and the attached operation explanation drawing. The diagram shown below is the typical application example of the pilot valve. 36072SF01 Pilot valve Main pump Hydraulic motor...
Page 129 Case where pedal is in neutral position 130ZF2RP03 The force of the spring (5) that determines the output pressure of the pilot valve is not applied to the spool (7). Therefore, the spool is pushed up by the spring (9) to the position of 1 and port 2. Then, since the output port is connected to tank port T only, the output port pressure becomes equal to tank pressure.
Page 130 Case where pedal is tilted 130ZF2RP04 When the push rod (13) is stroked, the spool (7) moves downwards. Then port P is connected with port 1, and the oil supplied from the pilot pump flows through port 1 to generate the pressure. When the pressure at port 1 increases to the value corresponding to the spring force set by tilting the handle, the hydraulic pressure force balances with the spring force.
Page 131: Section 3 Hydraulic System
SECTION 3 HYDRAULIC SYSTEM Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 3-1 Group 2 Main Circuit --------------------------------------------------------------------------------------------------------- 3-2 Group 3 Pilot Circuit ---------------------------------------------------------------------------------------------------------- 3-5 Group 4 Single Operation ------------------------------------------------------------------------------------------------ 3-14 Group 5 Combined Operation ----------------------------------------------------------------------------------------- 3-26...
Page 132: Group 1 Hydraulic Circuit
SECTION 3 HYDRAULIC SYSTEM GROUP 1 HYDRAULIC CIRCUIT 1. HYDRAULIC CIRCUIT (1/2) ,MU) ,Pi1) ,Pi2) ,e1) ,P4) OP-C SPRING 4k [RETURN] [ROD] [HEAD] [BUCKET OUT] [BUCKET IN] ,Rs) OP-B BUCKET P2(BW) P1(FW) P1(BW) P2(FW) ,T3) [HYD.TANK] ,T2) [BOOM PRI'] [HYD.TANK] [HEAD] [ROD] ,A1)
Page 133 2. HYDRAULIC CIRCUIT (2/2) <SINGLE ACTING> <PROPOTIONAL RCV DOUBLE ACTING & ROTATING> ( 59 ,C) ( 2 ,Po5) ( 2 ,Pc40) Pc42 OPTION-B [PEDAL [BREAKER] [FLOW ( 21 ,A1) SAFETY] ( 2 ,Pc40) CONFLUX] Pc42 Pd41 ( 2 ,Pd40) Pb21 [BREAKER] [FLOW ( 21 ,A1)
Page 134: Group 2 Main Circuit
GROUP 2 MAIN CIRCUIT The main hydraulic circuit consists of suction circuit, delivery circuit, return circuit and drain circuit. The hydraulic system consists of one main pump, one control valve, one swing motor, four cylinders and two travel motors. The swash plate type variable displacement axial piston pump is used as the main pump and is driven by the engine at ratio 1.0 of engine speed.
Page 135 2. RETURN CIRCUIT Check valve(2) 1.5kgf/cm Full flow filter Oil cooler Main control valve Actuators Check valve(1) 3.0kgf/cm Bypass relief valve Bypass relief valve 1.5kgf/cm 1.5 kgf/cm 21073CI01 All oil returned from each actuator returns to the hydraulic tank through the main control valve. The bypass check valves are provided in the return circuit.
Page 136 3. DRAIN CIRCUIT Travel motor Swing motor Main pump From return line Turning joint Dr#, dr# Drain filter Hydraulic oil tank Check valve 1.5kgf/cm 21093CI02 Besides internal leaks from the motors and main pump, the oil for lubrication circulates. These oil have to be fed to the hydraulic tank passing through drain filter.
Page 137: Group 3 Pilot Circuit
GROUP 3 PILOT CIRCUIT Remote control valve Remote control valve RCV pedal (RH lever) (LH lever) Safety lock Swing parking brake solenoid valve Travel speed solenoid valve Arm regeneration solenoid valve • • Power boost solenoid valve • Boom priority EPPR valve •...
Page 138 1. SUCTION, DELIVERY AND RETURN CIRCUIT Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT LEFT TRAVEL TRAVEL STRAIGHT...
Page 139 2. SAFETY VALVE (SAFETY LEVER) Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) BUCKET OPTION B Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT LEFT TRAVEL TRAVEL STRAIGHT Dr#, dr#...
Page 140 3. BOOM PRIORITY SYSTEM Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT TRAVEL LEFT TRAVEL STRAIGHT Dr#, dr# SWING...
Page 141 4. TRAVEL SPEED CONTROL SYSTEM Pi1(Pump) Pi2(Pump) P2(BW) P1(FW) P1(BW) P2(FW) OPTION C (DOZER) TURNING JOINT OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT TRAVEL...
Page 142 5. MAIN RELIEF PRESSURE CHANGE SYSTEM Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT TRAVEL LEFT TRAVEL STRAIGHT...
Page 143 6. ARM REGENERATION CUT SYSTEM Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 Arm regeneration BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT LEFT TRAVEL TRAVEL...
Page 144 7. SWING PARKING BRAKE RELEASE Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET SPRING 4k Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 VB(CCW) VA(CW) Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT LEFT...
Page 145 8. SWING PRIORITY SYSTEM Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT LEFT TRAVEL TRAVEL STRAIGHT Dr#, dr# SWING...
Page 146: Group 4 Single Operation
GROUP 4 SINGLE OPERATION 1. BOOM UP OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL...
Page 147 2. BOOM DOWN OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING RELIEF Pb20 VALVE Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT...
Page 148 3. ARM IN OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET MAKE UP VALVE RELIEF VALVE Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL...
Page 149 4. ARM OUT OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET RELIEF VALVE MAKE UP VALVE Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL...
Page 150 5. BUCKET IN OPERATION Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT LEFT TRAVEL...
Page 151 6. BUCKET OUT OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT LEFT TRAVEL...
Page 152 7. DOZER UP OPERATION Pi1(Pump) Pi2(Pump) MAKE UP VALVE TURNING RELIEF JOINT OPTION C VALVE (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL...
Page 153 8. DOZER DOWN OPERATION Pi1(Pump) Pi2(Pump) RELIEF VALVE MAKE UP VALVE TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL...
Page 154 9. SWING OPERATION Pi1(Pump) Pi2(Pump) TURNING OPTION C JOINT (DOZER) OPTION B BUCKET SPRING 4k Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 VA(CW) VB(CCW) Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT LEFT TRAVEL TRAVEL...
Page 155 SWING CIRCUIT OPERATION PARKING BRAKE BRAKE OFF BRAKE RELEASE VALVE BRAKE ON SPRING 4k MAKE UP VALVE MOTOR BRAKE VALVE MAKE UP PORT(MU) ANTI-INVERSION VALVE VB(CCW) VA(CW) TO / FROM MAIN CONTROL VALVE 140L3HC18A MOTOR BRAKE VALVE Motor brake valve for the swing motor limits to cushion the starting and stopping pressure of swing operation and controls the swing motor operating pressure.
Page 156 10. TRAVEL FORWARD AND REVERSE OPERATION Pi1(Pump) Pi2(Pump) P2(BW) P1(FW) P1(BW) P2(FW) OPTION C (DOZER) TURNING JOINT OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT...
Page 157 TRAVEL CIRCUIT OPERATION OVERLOAD RELIEF VALVE TRAVEL MOTOR DEVICE COUNTER BALANCE VALVE TURNING JOINT TO/FROM MAIN CONTROL VALVE 140L3HC19A Valves are provided on travel motors to offer the following functions. COUNTER BALANCE VALVE When stopping the motor of slope descending, this valve to prevent the motor over run. OVERLOAD RELIEF VALVE Relief valve limit the circuit pressure below 350 kgf/cm (4980 psi) to prevent high pressure...
Page 158: Group 5 Combined Operation
GROUP 5 COMBINED OPERATION 1. OUTLINE Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT...
Page 159 2. COMBINED SWING AND BOOM UP OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL...
Page 160 3. COMBINED SWING AND ARM OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT...
Page 161 4. COMBINED SWING AND BUCKET OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT...
Page 162 5. COMBINED SWING AND TRAVEL OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 ARM 1 Pc42 REGEN Pa21 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT LEFT 130ZF3HC27 When the swing and travel functions are operated simultaneously, the swing spool and travel spools in the main control valve are moved to the functional position by the pilot oil pressure from the...
Page 163 6. COMBINED BOOM AND TRAVEL OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT...
Page 164 7. COMBINED ARM AND TRAVEL OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT...
Page 165 8. COMBINED BUCKET AND TRAVEL OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) OPTION B BUCKET Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL RIGHT...
Page 166 9. COMBINED BOOM UP AND BUCKET OPERATION Pi1(Pump) Pi2(Pump) TURNING JOINT OPTION C (DOZER) BUCKET OPTION B Pc41 Pc40 Pd40 Pd41 ARM 1 Pc42 REGEN Pc40 Pc41 Pa21 Pa20 BOOM 2 ARM 2 Pd41 Pb21 SWING Pb20 Pa20 BOOM 1 Patt TRAVEL TRAVEL...
Page 167: Section 4 Electrical System
SECTION 4 ELECTRICAL SYSTEM Group 1 Component Location ----------------------------------------------------------------------------------------- 4-1 Group 2 Electrical Circuit ------------------------------------------------------------------------------------------------- 4-3 Group 3 Electrical Component Specification ----------------------------------------------------------------- 4-22 Group 4 Connectors --------------------------------------------------------------------------------------------------------- 4-33...
Page 168: Group 1 Component Location
SECTION 4 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 1. LOCATION 1 Switch panel Switch panel CN-16B CN-16 & 16A 130ZF4EL01 Cigar lighter 14 Emergency engine stop switch 28 Swing fine switch Aircon and heater switch 15 DC/DC converter 29 Swing lock switch Remote controller 16 Remote controller unit 30 Machine control unit...
Page 169 2. LOCATION 2 BOOM SAFETY VALVE BOOM 4 CARTRIDGE SAFETY VALVE SOL VALVE MAIN PUMP Patt MAIN CONTROL VALVE SHUTTLE BLOCK 130ZF4EL02 Work lamp 13 Power relay 28 Nega-control pressure sensor Fuel sender 14 Alternator 29 Flow control EPPR valve Fuel filler pump 15 Travel alarm buzzer 30 Relay drive unit...
Page 170: Group 2 Electrical Circuit
GROUP 2 ELECTRICAL CIRCUIT ELECTRICAL CIRCUIT (1/4, SERIAL NO. : -#0333) ECM BATT RY (12V COIL) PVG CONTROLLER CN-231 (12V OUT) 8.0W 145 CABIN LAMP 8.0R R/DRYER 8.0R MASTER SW WASHER P/P AAVM CAMERA FUSE BOX 8.0R 2-PCS SOL AC COMP HORN ANTI-RESTART BEACON LAMP...
Page 171 ELECTRICAL CIRCUIT (2/4, SERIAL NO. : -#0333) CS-67 => HARNESS-RH SIDE FRONT CAMERA HARNESS SIDE<= CIGARLIGHT Service Tool DC/DC CONVERTER 0.8Br CS-1 12V SOCKET HOUR METER SMT CAN 1.0Gr 0.75G 0.75V CN-10 DESTINATION CS-26A CL-1 0.8Or 1.0Gr 2.0V DOOR S.W CABIN LIGHT RY 0.8BW 0.75Y...
Page 172 ELECTRICAL CIRCUIT (3/4, SERIAL NO. : #0334-) (12V COIL) CN-231 PVG CONTROLLER (12V OUT) 8W 104 8.0W CABIN LAMP 8.0R R/DRYER WASHER P/P 8.0R MASTER SW AAVM CAMERA FUSE BOX 8.0R BEACON LAMP AC COMP HORN ANTI-RESTART POWER RY CS-74A CN-95 MASTER SW 8.0W...
Page 173 ELECTRICAL CIRCUIT (4/4, SERIAL NO. : #0334-) CS-67 FRONT CAMERA HARNESS SIDE<= CIGAR LIGHTER => HARNESS-RH SIDE Service Tool DC/DC CONVERTER 0.8Br HOUR METER CS-1 12V SOCKET SMT CAN 1.0Gr 0.75G CN-10 DESTINATION 0.75V CS-26A CL-1 0.8Or DOOR S.W 1.0Gr 12 2.0V 0.8BW CABIN LIGHT RY...
Page 174 MEMORANDUM HYUNDAI HEAVY INDUSTRIES CO., LTD CONSTRUCTION EQUIPMENT DIV.
Page 175 1. POWER CIRCUIT The negative terminal of battery is grounded to the machine chassis. When the start switch is in the OFF position, the current flows from the positive battery terminal as shown below. OPERATING FLOW Battery Battery relay[CR-1] Circuit breaker [CN-60] Master switch [CS-74A] I/conn [CN-231 (2)] Fuse box [No.1]...
Page 176 POWER CIRCUIT CN-231 FUSE BOX POWER RY CS-74 MASTER SW CN-95 CIRCUIT BREAKER CN-60 CR-105 85 87 87a CR-1 CN-GND 1.0G BATTERY BATT RY (12VX2) EQUALIZER RY CS-74B MASTER SW CN-56A CN-48 0.8RW BATT.24V IG 24V 0.8Y CAN1 HI HOUR METER CS-1 CAN1 LO 1.0Gr...
Page 177 2. STARTING CIRCUIT OPERATING FLOW Battery (+) terminal Battery relay [CR-1] Circuit breaker [CN-60] Master switch [CS-74A] I/conn [CN-231 (2)] Fuse box [No.2] I/conn [CN-36-1 (7)] Master switch [CS-74B] I/conn [CN-5 (36)] Start switch [CS-2A (1)] When start key switch is in ON position Start switch ON [CS-2A (2)] I/conn [CN-5 (39)] Battery relay [CR-1]...
Page 178 STARTING CIRCUIT CN-231 FUSE BOX POWER RY ANTI-RESTART RY AC COMP RY CS-74 MASTER SW CN-95 CIRCUIT BREAKER CN-60 CR-1 1.2B 1.2G BATTERY (12VX2) BATT RY CS-74 CN-94 0.75W KEY IG 0.75RW START REQUEST MASTER SW 0.75LW START CNTL OUT - 0.75WG START CNTL OUT + CR-23A...
Page 179 3. CHARGING CIRCUIT When the starter is activated and the engine is started, the operator releases the starting switch to the ON position. Charging current generated by operating the alternator flows into the battery through the battery relay [CR-1]. The current also flows from the alternator to each electrical component and controller through the fuse box.
Page 180 CHARGING CIRCUIT CN-231 FUSE BOX CS-74 MASTER SW CN-95 CIRCUIT BREAKER CN-60 CN-56A 0.8RW BATT.24V 0.8VOr IG 24V 0.8B CR-1 CAN1 HI 1.2B CAN1 LO CAN2 HI BATTERY CAN2 LO BATT RY (12VX2) RS-232 RX RS-232 TX AUX LEFT AUX RIGHT AUX GND CLUSTER CR-23...
Page 181 4. HEAD AND WORK LIGHT CIRCUIT OPERATING FLOW Fuse box (No.16) I/conn [CN-36-2 (4)] Head light relay [CR-13 (30, 86)] Fuse box (No.17) I/conn [CN-36-2 (5)] Work light relay [CR-4 (30, 86)] Fuse box (No.11) I/conn [CN-36-1 (16)] Membrane controller [CN-376 (1)] Head light switch ON Head light switch ON [CN-376 (13)] Head light relay [CR-13 (85) →...
Page 182 HEAD AND WORK LIGHT CIRCUIT FUSE BOX CR-13 1.0Br CN-376 0.75OrL 1.0Br IG 24V 1.0ROr TRAVEL ALARM 0.75G WIPER 0.75YR WORK LIGHT HEAD LAMP RY CABIN LIGHT CL-4 1.0B 1.0ROr CAN HI (2) HEAD LAMP WASHER CL-3 INT.WIPER 0.75G 1.0B HEAD LIGHT 1.0ROr BEACON...
Page 183 5. BEACON LAMP AND CAB LIGHT CIRCUIT OPERATING FLOW Fuse box (No.19) Beacon lamp relay [CR-85 (30, 86)] Fuse box (No.18) I/conn [CN-36-2 (6)] Cab light relay [CR-9 (30, 86)] Fuse box (No.11) I/conn [CN-36-1 (16)] Membrane controller [CN-376 (1)] Beacon lamp switch ON Beacon lamp switch ON [CN-376 (15)] I/conn [CN-36-1 (9)]...
Page 184 BEACON LAMP AND CAB LIGHT CIRCUIT FUSE BOX CR-85 1.2Gr 0.8WOr 87 85 0.8W 0.8B BEACON LAMP RELAY CN-376 0.75OrL IG 24V CR-9 TRAVEL ALARM 1.0R 87 85 WIPER 2.0V WORK LIGHT 0.75OrW 0.75OrW CABIN LIGHT CABIN LAMP RELAY CAN HI (2) WASHER INT.WIPER HEAD LIGHT...
Page 185 6. WIPER AND WASHER CIRCUIT OPERATING FLOW Start switch ON Fuse box (No.11) I/conn [CN-36-1 (16)] Membrane controller [CN-376 (1)] Fuse box (No.6) I/conn [CN-36-1 (11)] I/conn [CN-5 (18)] I/conn [CN-17 (5)] Wiper motor controller [CN-141 (7)] Wiper motor [CN-21 (4)] Fuse box (No.21) I/conn [CN-36-1 (4)] I/conn [CN-5 (16)]...
Page 186 WIPER AND WASHER CIRCUIT FUSE BOX CN-376 0.75OrL IG 24V TRAVEL ALARM 0.75G WIPER WORK LIGHT CABIN LIGHT CN-22 0.75RY 0.75VW CAN HI (2) 0.75WG WASHER WASHER PUMP 0.75VB INT.WIPER DO-5 0.75RY HEAD LIGHT 0.75VW BEACON CAN LO (2) DIODE 0.75B 0.75B MEMBRANE CONTROLLER...
Page 187 CONTROLLER CIRCUIT FUSE BOX CN-435 CR-106 CR-5 CN-BATT CN-126A CN-93B 2.0Y GLOW PLUG 1 61A 0.75L 2.0L CAN-A_Hi GLOW PLUG 2 60A 0.75Y 2.0Y CAN-A_Lo GLOW PLUG 3 58A 2.0L GLOW PLUG 4 57A CN-94 0.75W KEY IG POWER BATT+(A) SERVICE TOOL 2.5R BATT+(B)
Page 188 MONITORING CIRCUIT FUSE BOX CD-45 0.75V 0.75B 0.75GrW CN-94 0.75W KEY IG BATT+(A) CN-126A BATT+(B) BATT+(C) 0.75L MAIN RY CAN-A_Hi 0.75Y BATT-(1) CAN-A_Lo BATT-(2) BATT-(3) 0.75Y CAN 1 LOW 0.75L CAN 1 HIGH POWER AIR TEMP SIG SERVICE TOOL AIR TEMP GND LAMBDA PUMP LAMBDA ADJUST LAMBDA HEATING...
Page 189 ELECTRIC CIRCUIT FOR HYDRAULIC (1/2) FUSE BOX DOZER & ADJUST BOOM SW QUICK CLAMP SW BUZZER CN-5 CD-6 SUPPLY RETURN TRAVEL PS CD-7 SUPPLY CN-263 RETURN WORK PS 2-PCS SOL CD-35 SEE : 130ZF4EL14 SUPPLY RETURN ARM IN_OUT BUCKET IN PS CD-24 SUPPLY CD-70...
Page 190 ELECTRIC CIRCUIT FOR HYDRAULIC (2/2) FUSE BOX SWING SWING SWING PARKING PARKING PARKING SOL A3 SOL A1 SOL A2 CS-67 CN-3 QUICK CLAMP SW CN-8 CS-73A SWING FINE SW CS-73 EPPR EPPR VALVE VALVE SOL A2 SOL A1 SEE : SEE : 130ZF4EL13 CN-140 P/P VALVE...
Page 191: Group 3 Electrical Component Specification
GROUP 3 ELECTRICAL COMPONENT SPECIFICATION Part name Symbol Specifications Check ※ Check specific gravity 1.280 over : Over charged 12V × 100Ah Battery (2EA) 1.280 ~ 1.250 : Normal 1.250 below : Recharging Rated load : ※ Check coil resistance(M4 to M4) Normal : About 50Ω...
Page 192 Part name Symbol Specifications Check ※ Check resistance Temperature 50˚C : 804Ω sensor 80˚C : 310Ω (hydraulic) 100˚C : 180Ω CN-1 CD-8 CS-2C ※ Check contact Air cleaner N.O TYPE High level : ∞Ω pressure switch Low level : 0Ω CD-10 ※...
Page 193 Part name Symbol Specifications Check ※ Check resistance CN-66 CN-68 CN-70 Solenoid valve 24V 1A Normal : 15~25Ω CN-88 CN-135 CN-140 (for terminal 1-2) CN-149 CN-237 CN-262 CN-263 CN-367 CN-368 CN-369 CN-370 CN-419 CN-420 CN-421 ※ Check resistance 700mA Normal : 15~25Ω EPPR valve (for terminal 1-2) CN-75 CN-133 CN-242...
Page 194 Part name Symbol Specifications Check ※ Check contact Normal Switch Ⅰ : 0 Ω(for terminal 6-10) (DPF) 0 : ∞Ω(for terminal 6-4, 6-10) Ⅱ : ∞Ω(for terminal 6-10) CS-100 Head lamp, 24V 65W ※ Check disconnection Work lamp, (H3 Type) Normal : 1.2Ω...
Page 195 Part name Symbol Specifications Check ※ Check operation Horn 22~28V 2A Supply power(24V) to each terminal and connect ground. CN-20 CN-25 ※ Check contact Normal : 1.0Ω ON : 0Ω(for terminal A-B) 24V 15A Safety switch (N.C TYPE) ∞Ω(for terminal A-C) OFF : ∞Ω(for terminal A-B) CS-20 CS-4...
Page 196 Part name Symbol Specifications Check ※ Check disconnection Wiper motor 24V 2A Normal : 7Ω(for terminal 2-6) CN-21 ※ Check voltage DC/DC 24V 3A 24V (for terminal 1-2) Converter 12V (for terminal 1-3) CN-138 ※ Check coil resistance Normal : About 1MΩ Cigar lighter 24V 5A 1.4W ※...
Page 197 Part name Symbol Specifications Check ※ Check contact Air conditioner 24V 79W compressor Normal : 13.4Ω CN-28 ※ Check contact Start relay 24V 300A Normal : 0.94Ω(for terminal 1-2) CR-23 ※ Check resistance Blower motor 24V 14A Normal : 2.5Ω(for terminal 1-2) ※...
Page 198 Part name Symbol Specifications Check ※ Check disconnection Normal : 0Ω CN-60 : 60A Circuit breaker CN-95 : 90A (connect ring terminal and check CN60 CN-95 resist between terminal 1 and 2) ※ Check disconnection Master switch 6~36V Normal : 0.1Ω CS-74 Breaker pedal switch...
Page 199 Part name Symbol Specifications Check AIR INLET TEMP Air inlet temperature AIR INLET GND sensor CN-150 DOC inlet DOC INLET TEMP GND temperature DOC INLET TEMP SIG sensor CN-152 DPF INLET TEMP SIG DPF inlet DPF INLET TEMP GND temperature CN-153 sensor DPF PS SUPPLY...
Page 200 Part name Symbol Specifications Check 5V, 8mA Accel dial CN-142 Accel dial LED CN-267 Temperature sensor (A/C incar, A/C ambient, water) CN-429 SIG. VOLT(Us) SIG. VOLT(Udc) Proportional valve sensor ERROR CN-308 ※Check resistance Dozer act N.O type pressure switch Normal : ∞Ω(open) CD-50 4-31...
Page 201 Part name Symbol Specifications Check LVDS POS LVDS NEG 7V 100mA Camera POWER 24V ADJUST SIGNAL CN-249 CN-249 CN-402 CN-403 CN-404 CN-405 INPUT-24V Equalizer OUTPUT-12V OUTPUT-12V CN-435 LAMBDA PUMP LAMBDA ADJUST LAMBDA HEATING LA M B D A H E A T I LAMBDA LAMBDA BATT+ sensor...
Page 202: Group 4 Connectors
GROUP 4 CONNECTORS 1. CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 I/conn (Frame harness-Pump PS harness) S816-010002 S816-110002 CN-2 I/conn (Engine harness-Frame 2 harness) 368047-1 368050-1 CN-3 I/conn (Frame harness-Engine harness) 1897009-2 1897013-2 I/conn (Frame harness-PVG controller CN-3A TYCO...
Page 203 Connector part No. Connector No. of Type Destination number Female Male CN-45 RING-TERM Starter motor B S820-108000 CN-48 Hour meter 2-520193-2 CN-51 DEUTSCH DRC26-40SA CN-52 DEUTSCH DRC26-40SB CN-53 DEUTSCH MCU (option) DRC26-40SA CN-56A Cluster 174663-2 CN-56B Cluster 174984-2 CN-60 YAZAKI Circuit breaker 7122-4125-50 CN-61...
Page 204 Connector part No. Connector No. of Type Destination number Female Male CN-157 Antena power S822-014002 CN-231 To fuse box S813-030201 CN-237 DEUTSCH Attach conflux solenoid DT06-2S-EP06 CN-242 DEUTSCH Attach EPPR 1 DT06-2S-EP06 CN-245 PTC power CN-245A Remote controller assy 368542-1 CN-245E Remote controller assy 174045-2...
Page 205 Connector part No. Connector No. of Type Destination number Female Male CN-420 DEUTSCH Swing parking solenoid-A2 DT06-2S-EP06 CN-421 DEUTSCH Swing parking solenoid-A3 DT06-2S-EP06 CN-423 DEUTSCH Tank header unit DT06-4S CN-425 SCR temperature sensor 282080-1 CN-426 DOC temperature sensor 282080-1 CN-427 MOLEX Reader-RMS 039012040...
Page 206 Connector part No. Connector No. of Type Destination number Female Male CS-26 DEUTSCH Breaker switch DT06-2S-EP06 CS-26A Breaker pedal switch S816-002002 S816-102002 CS-29 DEUTSCH Power max switch DT06-2S-EP06 CS-33 Emergency engine stop switch S816-006002 S816-106002 CS-52 Adjust & dozer switch SWF589790 CS-53 Wiper cut switch...
Page 207 Connector part No. Connector No. of Type Destination number Female Male CD-43 DEUTSCH Pump pressure sensor 2 DT06-3S-EP06 CD-44 DEUTSCH Pump pressure sensor 3 DT06-3S-EP06 CD-45 WIF sensor 282191-1 CD-50 Dozer pressure sensor MG640795 CD-69 DEUTSCH Attach pressure sensor DT06-3S-EP06 CD-70 DEUTSCH N1 pressure sensor...
Page 208 2. CONNECTION TABLE FOR CONNECTORS PA TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S811-005002 S811-105002 S811-007002 S811-107002 S811-009002 3S811-109002 S811-011002 S811-111002 4 - 39 4-39...
Page 209 No. of Receptacle connector (female) Plug connector (male) S811-013002 S811-113002 S811-017002 S811-117002 S811-021002 S811-121002 4 - 40 4-40...
Page 210 J TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S816-002001 S816-102001 S816-003001 S816-103001 S816-004001 S816-104001 S816-008001 S816-108001 4 - 41 4-41...
Page 211 SWP TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S814-001000 S814-101000 S814-002000 S814-102000 S814-003000 S814-103000 S814-004000 S814-104000 4 - 42 4-42...
Page 212 No. of Receptacle connector (female) Plug connector (male) S814-006000 S814-106000 S814-008000 S814-108000 S814-012000 S814-112000 S814-014000 S814-114000 4 - 43 4-43...
Page 213 CN TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S810-001202 S810-101202 S810-002202 S810-102202 S810-003202 S810-103202 S810-004202 S810-104202 4 - 44 4-44...
Page 214 No. of Receptacle connector (female) Plug connector (male) S810-006202 S810-106202 S810-008202 S810-108202 4 - 45 4-45...
Page 215 375 FASTEN TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S810-002402 S810-102402 AMP ECONOSEAL CONNECTOR No. of Receptacle connector (female) Plug connector (male) 344111-1 344108-1 AMP TIMER CONNECTOR No. of Receptacle connector (female) Plug connector (male) 85202-1 4 - 46 4-46...
Page 216 AMP 040 MULTILOCK CONNECTOR No. of Receptacle connector (female) Plug connector (male) 174045-2 AMP 070 MULTILOCK CONNECTOR No. of Receptacle connector (female) Plug connector (male) 173852 AMP FASTIN - FASTON CONNECTOR No. of Receptacle connector (female) Plug connector (male) 480003-9 925276-0 4 - 47 4-47...
Page 217 KET 090 CONNECTOR No. of Receptacle connector (female) Plug connector (male) MG610070 KET 090 WP CONNECTORS No. of Receptacle connector (female) Plug connector (male) MG640605 MG640795 4 - 48 4-48...
Page 218 KET SDL CONNECTOR No. of Receptacle connector (female) Plug connector (male) MG610406 4 - 49 4-49...
Page 219 DEUTSCH DT CONNECTORS DT 06 - 3S - ★★★★ Modifications (see below) Number of contacts (P : Pin, S : Socket) 06 : Receptacle, 04 : Plug Deutsch connectors Modification ※ E003 : Standard end cap - gray E004 : Color of connector to be black E005 : Combination - E004 &...
Page 220 No. of Receptacle connector (female) Plug connector (male) DT06-6S DT04-6P DT06-8S DT04-8P DT06-12S DT04-12P 4 - 51 4-51...
Page 221 MOLEX 2CKTS CONNECTOR No. of Receptacle connector (female) Plug connector (male) 35215-0200 35215-0200 ITT SWF CONNECTOR No. of Receptacle connector (female) Plug connector (male) SWF593757 MWP NMWP CONNECTOR No. of Receptacle connector (female) Plug connector (male) NMWP01F-B 4 - 52 4-52...
Page 222 ECONOSEAL J TYPE CONNECTORS No. of Receptacle connector (female) Plug connector (male) S816-001002 S816-101002 S816-002002 S816-102002 S816-003002 S816-103002 S816-004002 S816-104002 4 - 53 4-53...
Page 223 No. of Receptacle connector (female) Plug connector (male) S816-006002 S816-106002 S816-008002 S816-108002 S816-010002 S816-110002 S816-012002 S816-112002 4 - 54 4-54...
Page 224 No. of Receptacle connector (female) Plug connector (male) 368301-1 2-85262-1 METRI-PACK TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) 12040753 DEUTSCH HD30 CONNECTOR No. of Receptacle connector (female) Plug connector (male) HD36-24-23SN HD34-24-23PN 4 - 55 4-55...
Page 225 DEUTSCH MCU CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) DRC26-40SA/B DEUTSCH SERVICE TOOL CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) HD10-9-96P AMP FUEL WARMER CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) 2-967325-3 4-56...
Page 226 DEUTSCH ENGINE ECM CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) DRC26-50S-04 DEUTSCH INTERMEDIATE CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) DRB16-60SAE-L018 4-57...
Page 227: Section 5 Mechatronics System
SECTION 5 MECHATRONICS SYSTEM Group 1 Outline ---------------------------------------------------------------------------------------------------------------- 5-1 Group 2 Mode Selection System ------------------------------------------------------------------------------------ 5-3 Group 3 Automatic Deceleration System ----------------------------------------------------------------------- 5-6 Group 4 Power Boost System ----------------------------------------------------------------------------------------- 5-7 Group 5 Travel Speed Control System -------------------------------------------------------------------------- 5-8 Group 6 Automatic Warming Up System ----------------------------------------------------------------------- 5-9 Group 7 Engine Overheat Prevention System -------------------------------------------------------------- 5-10 Group 8 Variable Power Control System ----------------------------------------------------------------------- 5-11 Group 9 Attachment Flow Control System -------------------------------------------------------------------- 5-12...
Page 228: Group 1 Outline
SECTION 5 MECHATRONICS SYSTEM GROUP 1 OUTLINE The ADVANCED CAPO (Computer Aided Power Optimization) system controls engine and pump mutual power at an optimum and less fuel consuming state for the selected work by mode selection, auto-deceleration, power boost function, etc. It monitors machine conditions, for instance, engine speed, coolant temperature, hydraulic oil temperature, and hydraulic oil pressure, etc.
Page 229 SYSTEM DIAGRAM Work tool Attachment pilot Work Travel pressure pressure pressure SOLENOID VALVE Option (Dozer) Swing fine EPPR VALVE control Option Bucket Swing parking Breaker(opt) Arm 1 Arm regen Attachment Boom priority Travel speed Arm 2 Boom 2 pressure(opt) EPPR Attachment Swing Boom 1...
Page 230: Group 2 Mode Selection System
GROUP 2 MODE SELECTION SYSTEM 1. POWER MODE SELECTION SYSTEM Main control valve Engine Pilot pump Main pump Pump power shift EPPR Cluster Drive signal Power mode Accel dial pilot lamp Emergency CN-16B Power mode switch signal Accel dial signal CN-16A CN-16 CAN #2...
Page 231 2. WORK MODE SELECTION SYSTEM Work mode consists of the general operation (bucket) and the optional attachment (breaker, crusher). Attachment pilot pressure sensor Main control valve Work tool Option (Dozer) SOLENOID VALVE Option Bucket Breaker Arm 1 Arm regen Attachment Arm 2 Boom 2 conflux...
Page 232 3. USER MODE SELECTION SYSTEM Main control valve Engine Main pump Pilot pump Pump power shift EPPR Cluster Drive signal Accel dial User mode pilot lamp Emergency CN-16B User mode switch signal Accel dial signal CN-16A CN-16 CAN #2 Normal 130ZF5MS04 Engine speed, idle speed and pump power shift pressure can be adjusted and memorized in the U-mode.
Page 233: Group 3 Automatic Deceleration System
GROUP 3 AUTOMATIC DECELERATION SYSTEM Work Travel pressure pressure Main control valve Engine Pilot pump Main pump Cluster Pressure signal Auto idle Accel dial pilot lamp Emergency CN-16B Accel dial signal Auto idle switch signal CN-16A CN-16 CAN #2 Normal 130ZF5MS05 1.
Page 234: Group 4 Power Boost System
GROUP 4 POWER BOOST SYSTEM Main control valve Option (Dozer) Option Bucket Arm 1 Arm regen Arm 2 Boom 2 Boom 1 Swing Travel(RH) Travel(LH) Main relief valve pressure pressure Power boost solenoid valve Engine Pilot pump Main pump Power boost Pump power button shift EPPR...
Page 235: Group 5 Travel Speed Control System
GROUP 5 TRAVEL SPEED CONTROL SYSTEM Main control valve Option Travel motor (Dozer) Option Bucket Arm 1 Arm regen Regulator Boom 2 Arm 2 Boom 1 Swing Travel(RH) Travel(LH) Travel speed solenoid valve Engine Pilot pump Main pump Cluster Drive signal Travel speed pilot lamp Travel speed switch signal...
Page 236: Group 6 Automatic Warming Up System
GROUP 6 AUTOMATIC WARMING UP SYSTEM Main control valve Engine Pilot pump Main pump Pump power shift EPPR Hydraulic temp signal Cluster Hydraulic temp sensor Drive signal Accel dial Emergency CN-16B Warming up pilot lamp signal Accel dial signal CN-16A CN-16 CAN #2 Warming up...
Page 237: Group 7 Engine Overheat Prevention System
GROUP 7 ENGINE OVERHEAT PREVENTION SYSTEM Main control valve Engine Main pump Pilot pump Pump power shift EPPR Emergency warning lamp Cluster Hydraulic temp signal Hydraulic temp sensor Drive signal Accel dial Emergency CN-16B Overheat warning signal Accel dial signal CN-16A CN-16 CAN #2...
Page 238: Group 8 Variable Power Control System
GROUP 8 NEW VARIABLE POWER CONTROL SYSTEM Travel pressure Main control valve Engine Main pump Pilot pump Pump power shift EPPR Drive signal Switch signal RH control LH control Pressure signal lever lever Pressure signal Accel dial signal CN-16A CN-16 Normal CN-16B Emergency...
Page 239: Group 9 Attachment Flow Control System
GROUP 9 ATTACHMENT FLOW CONTROL SYSTEM Attachment pilot pressure sensor Main control valve Work tool Option (Dozer) SOLENOID VALVE Option Bucket Breaker Arm 1 Arm regen Attachment Arm 2 Boom 2 conflux Attachment Swing Boom 1 safety Travel(RH) Travel(LH) Engine Main pump Pilot pump Attachment...
Page 240: Group 10 Intelligent Power Control System
GROUP 10 INTELLIGENT POWER CONTROL SYSTEM Travel pressure Main control valve Option (Dozer) Option Bucket Arm 1 Arm regen Arm 2 Boom 2 Swing Boom 1 Travel(RH) Travel(LH) Attach flow EPPR 1 Engine Pilot pump Main pump Power boost Pump power button shift EPPR One touch...
Page 241 IPC MODE SELECTION IPC mode ON/OFF and the levels of flow rate limit can be selected at "Mode setup > IPC mode" Q(cc/rev) Balance mode Efficiency mode Pi(bar) 290F3CD311 130ZF5MS19 IPC mode Description Balance mode (default) IPC mode ON, limit level 1 Efficiency mode IPC mode ON, limit level 2 Speed mode...
Page 242: Group 11 Anti-Restart System
GROUP 11 ANTI-RESTART SYSTEM Engine Starter Start safety relay Drive signal 300L5MS12 1. ANTI-RESTART FUNCTION After a few seconds from the engine starts to run, MCU turns off the start safety relay to protect the starter from inadvertent restarting. 5-15...
Page 243: Group 12 Self-Diagnostic System
GROUP 12 SELF-DIAGNOSTIC SYSTEM OUTLINE When any abnormality occurs in the ADVANCED CAPO system caused by electric parts malfunction and by open or short circuit, the MCU diagnoses the problem and sends the error codes to the cluster and also stores them in the memory. MONITORING Active fault 290F3CD120...
Page 244 3. MACHINE ERROR CODES TABLE Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Hydraulic Oil Temp. Measurement Voltage > 3.8V ● 10 seconds continuous, Hydraulic Oil Temp. Measurement Voltage < 0.3V ● (Results / Symptoms) 1. Monitor – Hydraulic oil temperature display failure 2.
Page 245 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Main Pump 1 (P1) Press. Sensor Measurement ● Voltage > 5.2V 10 seconds continuous, 0.3V ≤ Main Pump 1 (P1) Press. Sensor ● Measurement Voltage < 0.8V 10 seconds continuous, Main Pump 1 (P1) Press. Sensor Measurement ●...
Page 246 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Negative 1 Press. Sensor ● Measurement Voltage > 5.2V 10 seconds continuous, 0.3V≤ Negative 1 Press. Sensor Measurement ● Voltage < 0.8V 10 seconds continuous, Negative 1 Press. Sensor ● Measurement Voltage < 0.3V (Results / Symptoms) 1.
Page 247 Application Diagnostic Criteria HCESPN FMI (when you had conditions mounting pressure sensor) 10 seconds continuous, Boom Down Pilot Press. Sensor Measurement ● Voltage > 5.2V (when you had conditions mounting pressure sensor) 10 seconds continuous, 0.3V≤ Boom Down Pilot Press. Sensor ●...
Page 248 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Swing Pilot Press. Sensor ● Measurement Voltage > 5.2V 10 seconds continuous, 0.3V≤ Swing Pilot Press. Sensor Measurement ● Voltage < 0.8V 10 seconds continuous, Swing Pilot Press. Sensor ● Measurement Voltage < 0.3V (Results / Symptoms) 1.
Page 249 Application Diagnostic Criteria HCESPN FMI (Detection) (When Pump EPPR Current is more than 10 mA) 10 seconds continuous, Pump EPPR drive current < 0 mA ● (Cancellation) (When Pump EPPR Current is more than 10 mA) 3 seconds continuous, Pump EPPR drive current ≥10 mA (Detection) 10 seconds continuous, Pump EPPR drive current >...
Page 250 Application Diagnostic Criteria HCESPN FMI (Detection) (When Travel EPPR Current is more than 10 mA) 10 seconds continuous, Travel EPPR drive current = 0 mA ● (Cancellation) (When Travel EPPR Current is more than 100 mA) 3 seconds continuous, Travel EPPR drive current ≥ 10 mA (Detection) 10 seconds continuous, Travel EPPR drive current >...
Page 251 Application Diagnostic Criteria HCESPN FMI (Detection) (When Working Cutoff Relay is Off) 10 seconds continuous, Working Cutoff Relay drive unit Measurement Voltage ≤ 3.0V ● (Cancellation) (When Working Cutoff Relay is Off) 3 seconds continuous, Working Cutoff Relay drive unit Measurement Voltage >...
Page 252 Application Diagnostic Criteria HCESPN FMI (Detection) (When Travel Speed Solenoid is Off) 10 seconds continuous, Travel Speed Solenoid drive unit Measurement Voltage ≤ 3.0V ● (Cancellation) (When Travel Speed Solenoid is Off) 3 seconds continuous, Travel Speed Solenoid drive unit Measurement Voltage >...
Page 253 Application Diagnostic Criteria HCESPN FMI Monitor – Selecting attachment(breaker / crusher) (Detection) (When Attachment Conflux Solenoid is Off) 10 seconds continuous, Attachment Conflux Solenoid drive unit Measurement Voltage ≤ 3.0V ● (Cancellation) (When Attachment Conflux Solenoid is Off) 3 seconds continuous, Attachment Conflux Solenoid drive unit Measurement Voltage >...
Page 254 Application Diagnostic Criteria HCESPN FMI Monitor – Selecting attachment(crusher) (Detection) (When Attachment Safety Solenoid is Off) 10 seconds continuous, Attachment Safety Solenoid drive unit Measurement Voltage ≤ 3.0V ● (Cancellation) (When Attachment Safety Solenoid is Off) 3 seconds continuous, Attachment Safety Solenoid drive unit Measurement Voltage >...
Page 255 Application Diagnostic Criteria HCESPN FMI (Model Parameter) mounting Reverse Cooling Fan Solenoid (Detection) (When Reverse Cooling Fan Solenoid is Off) 10 seconds continuous, Reverse Cooling Fan Solenoid drive unit Measurement Voltage ≤ 3.0V ● (Cancellation) (When Reverse Cooling Fan Solenoid is Off) 3 seconds continuous, Reverse Cooling Fan Solenoid drive unit Measurement Voltage >...
Page 256 Application Diagnostic Criteria HCESPN FMI (Detection) (When Attachment Flow EPPR 2 current is equal or more than 300 mA) 10 seconds continuous, Attachment Flow EPPR drive current < 100 mA ● (Cancellation) (When Attachment Flow EPPR 2 current is equal or more than 300 mA) 3 seconds continuous, Attachment Flow EPPR drive current ≥...
Page 257 Application Diagnostic Criteria HCESPN FMI (Mounting pressure sensor) 10 seconds continuous, Boom Cylinder Rod Press. Sensor Measurement ● Voltage > 5.2V (Mounting pressure sensor) 10 seconds continuous, 0.3V≤ Boom Cylinder Rod Press. Sensor ● Measurement Voltage < 0.8V (Mounting pressure sensor) 10 seconds continuous, Boom Cylinder Rod Press.
Page 258 Application Diagnostic Criteria HCESPN FMI Mounting pressure sensor (HCESPN 128 or 205) (Detection) (When Boom Down Pilot Pressure Cutoff Solenoid is Off) 10 seconds continuous, Boom Down Pilot Pressure Cutoff Solenoid drive unit Measurement Voltage ≤ 3.0V ● (Cancellation) (When Boom Down Pilot Pressure Cutoff Solenoid is Off) 3 seconds continuous, Boom Down Pilot Pressure Cutoff Solenoid drive unit Measurement Voltage >...
Page 259 Application Diagnostic Criteria HCESPN FMI Monitor – Selecting attachment(crusher) (Detection) (When ATT Relief Setting EPPR 2 Current is equal or more than 10 mA) 10 seconds continuous, ATT Relief Setting EPPR 2 drive current = 0 mA ● (Cancellation) (When ATT Relief Setting EPPR 2 Current is equal or more than 10 mA) 3 seconds continuous, ATT Relief Setting EPPR 2 drive current ≥...
Page 260 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Transmission Oil Press. Sensor Measurement ● Voltage > 5.2V 10 seconds continuous, 0.3V≤ Transmission Oil Press. Sensor ● Measurement Voltage < 0.8V 10 seconds continuous, Transmission Oil Press. Sensor Measurement ● Voltage < 0.3V (Results / Symptoms) 1.
Page 261 Application Diagnostic Criteria HCESPN FMI (Detection) (When Parking Relay is Off) 10 seconds continuous, Parking Relay drive unit Measurement Voltage ≤ 3.0V ● (Cancellation) (When Parking Relay is Off) 3 seconds continuous, Parking Relay drive unit Measurement Voltage > 3.0V (Detection) (When Parking Relay is On) 10 seconds continuous, Parking Relay drive current >...
Page 262 Application Diagnostic Criteria HCESPN FMI (Detection) (When Ram Lock Solenoid is Off) 10 seconds continuous, Ram Lock Solenoid drive unit Measurement Voltage ≤ 3.0V ● (Cancellation) (When Ram Lock Solenoid is Off) 3 seconds continuous, Ram Lock Solenoid drive unit Measurement Voltage >...
Page 263 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Travel Forward Press. Sensor Measurement Voltage > 5.2V 10 seconds continuous, 0.3V≤ Travel Forward Press. Sensor Measurement Voltage < 0.8V 10 seconds continuous, Travel Forward Press. Sensor Measurement Voltage < 0.3V (Results / Symptoms) 1.
Page 264 Application Diagnostic Criteria HCESPN FMI (Model Parameter) Mounting Acc. Dial ● 10 seconds continuous, Acc. Dial Measurement Voltage > 5.2V (Model Parameter) Mounting Acc. Dial ● 10 seconds continuous, Acc. Dial Measurement Voltage < 0.3V (Results / Symptoms) 1. Monitor – Acc. Dial Voltage display failure 2.
Page 265 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, ECM Communication Data Error ● (Results / Symptoms) 1. Control Function – ECM operation failure (Checking list) 1. CN-93 (#22) – CN-51 (#21) Checking Open/Short 2. CN-93 (#46) – CN-51 (#31) Checking Open/Short (When mounting the I/O Controller 1) ●...
Page 266 Application Diagnostic Criteria HCESPN FMI (When mounting the AAVM) ● 60 seconds continuous, AAVM communication Data Error (Results / Symptoms) 1. Control Function – AAVM operation failure (Checking list) 1. CN-401 (#86) – CN-51 (#22) Checking Open/Short 2. CN-401 (#87) – CN-51 (#32) Checking Open/Short 60 seconds continuous, RDU communication Data Error ●...
Page 267 4. ENGINE FAULT CODE J1939 Code Description Refer to Procedure Engine Exhaust Gas Recirculation Valve Position : 27-3 Valve Position - Test Voltage Above Normal Engine Exhaust Gas Recirculation Valve Position : 27-4 Valve Position - Test Voltage Below Normal Accelerator Pedal Position 2 : Voltage Above 29-3 Speed Control - Test...
Page 268 J1939 Code Description Refer to Procedure 108-3 Barometric Pressure : Voltage Above Normal Sensor Signal (Analog, Active) - Test 108-4 Barometric Pressure : Voltage Below Normal Sensor Signal (Analog, Active) - Test Engine Coolant Temperature : Voltage Above 110-3 Sensor Signal (Analog, Passive) - Test Normal Engine Coolant Temperature : Voltage Below 110-4...
Page 269 J1939 Code Description Refer to Procedure Engine Exhaust Gas Temperature : Voltage Below 173-4 Sensor Signal (Analog, Passive) - Test Normal 174-3 Engine Fuel Temperature 1 : Voltage Above Normal Sensor Signal (Analog, Passive) - Test 174-4 Engine Fuel Temperature 1 : Voltage Below Normal Sensor Signal (Analog, Passive) - Test Engine Speed : Abnormal Frequency, Pulse Width, 190-8 Speed/Timing - Test...
Page 270 J1939 Code Description Refer to Procedure 652-21 Engine Injector Cylinder #02 : Data Drifted Low Injector Data Incorrect - Test Engine Injector Cylinder #03 : Current Below 653-5 Injector Solenoid - Test Normal Engine Injector Cylinder #03 : Current Above 653-6 Injector Solenoid - Test Normal...
Page 271 J1939 Code Description Refer to Procedure The engine protection system has 1110-31 Engine Protection System has Shutdown Engine shutdown the engine. Troubleshoot all other diagnostic codes in order to clear this code. Engine Turbocharger 1 Boost Pressure : High - 1127-16 Intake Manifold Air Pressure Is High moderate severity (2)
Page 272 J1939 Code Description Refer to Procedure Engine Operator Primary Intermediate Speed Mode Selection - Test/Switch Circuits - Test 2880-2 Select : Erratic, Intermittent, or Incorrect (Throttle Switch) Engine Operator Primary Intermediate Speed Mode Selection - Test/Switch Circuits - Test 2880-3 Select : Voltage Above Normal (Throttle Switch) Engine Operator Primary Intermediate Speed...
Page 273 J1939 Code Description Refer to Procedure Particulate Trap Differential Pressure : Not Diesel Particulate Filter Has Differential 3251-7 Responding Properly Pressure Problem Particulate Trap Differential Pressure : Abnormal Diesel Particulate Filter Has Differential 3251-10 Rate of Change Pressure Problem Particulate Trap Differential Pressure : High - Diesel Particulate Filter Collects Excessive 3251-16 moderate severity (2)
Page 274 J1939 Code Description Refer to Procedure 5055-17 Engine Oil Viscosity : Low - least severe (1) Oil Contains Fuel 5055-18 Engine Oil Viscosity : Low - moderate severity (2) Oil Contains Fuel Engine Oil Pressure Low Lamp Data - Current 5099-5 Indicator Lamp - Test Below Normal...
Page 275 Operator Inducement Codes ※ If any of the diagnostic codes listed in table below are active, a 5246 or a 5826 diagnostic · code will also be active. When a 5246 or a 5826 diagnostic code is active, the engine will be derated. ·...
Page 276 5. AAVM FAULT CODE 5. AAVM FAULT CODE Fault Code Description AAVM Communication Error -AAVM AAVM Communication Error -Front Camera AAVM Communication Error -Rear Camera AAVM Communication Error -Left Camera AAVM Communication Error -Right Camera Manual Setting Fail No MCU CID MCU CID Format Error AAVM Hardware Error -AAVM AAVM Hardware Error -Front Camera...
Page 277: Group 13 Engine Control System
GROUP 13 ENGINE CONTROL SYSTEM 1. MCU and ECM (Engine Control Module) ECM (Engine Control Module) Bolt (M8) 130ZF5MS101 2. MCU ASSEMBLY To match the pump absorption torque with the engine torque, MCU varies EPPR valve output pressure, which control pump discharge amount whenever feedbacked engine speed drops under the reference rpm of each mode set.
Page 278: Group 14 Eppr Valve
GROUP 14 EPPR VALVE 1. PUMP EPPR VALVE COMPOSITION EPPR (Electro Proportional Pressure Reducing) valve consists of electro magnet and spool valve installed at main pump. Electro magnet valve Receive electric current from MCU and move the spool proportionally according to the specific amount of electric current value.
Page 279 OPERATING PRINCIPLE Structure 5-22(1) Sleeve O-ring Solenoid valve Spring O-ring Connector Spool Pilot oil supply line (pilot pressure) Return to tank Secondary pressure to flow regulator at main pump Neutral Pressure line is blocked and A oil returns to tank. Operating Secondary pressure enters into A.
Page 280 EPPR VALVE CHECK PROCEDURE Spec : 100~700 mA Check electric current value at EPPR valve Adapter(P/no.:21Q6-50410) Disconnect connector CN-75 from ① EPPR valve EPPR valve. Multimeter CN-75 Insert the adapter to CN-75 and install ② multimeter as figure. Start engine. ③...
Page 281 2. BOOM PRIORITY EPPR VALVE COMPOSITION The boom priority EPPR valve is built in a manifold and mainly consisting of valve body and coil. This EPPR valve installed under the solenoid valve. CONTROL The boom priority EPPR valve has to be controlled by a specific electronic amplifier card, which is supplying the coil with a current 580 mA at 30 and 24 V.
Page 282 EPPR VALVE CHECK PROCEDURE Spec : 400~600 mA (combined boom up and swing operation) Check electric current value at EPPR Safety solenoid valve valve Solenoid valve Disconnect connector CN-133 from ① EPPR valve. Insert the adapter to CN-133 and install ②...
Page 283: Group 15 Monitoring System
GROUP 15 MONITORING SYSTEM 1. STRUCTURE The cluster consists of LCD and switches as shown below. The LCD is to warn the operator in case of abnormal machine operation or conditions for the appropriate operation and inspection. Also, The LCD is to set and display for modes, monitoring and utilities with the switches. The switches or touch screen are to set the machine operation modes.
Page 284 Start key : ON Check monitor ① Buzzer sounding for 4 seconds with HYUNDAI logo on cluster. If the ESL mode is set to the enable, enter the password to start engine. ※ After initialization of cluster, the operating screen is displayed on the LCD.
Page 285 CLUSTER CONNECTOR CN-56A Name Signal Battery 24V 20~32Vdc Power IG (24V) 20~32Vdc CN-56B CN-56A CAN 1 (H) 0~5Vdc CAN 1 (L) 0~5Vdc CAN 2 (H) 0~5Vdc CAN 2 (L) 20~32Vdc N.C. Cluster N.C. Aux left 0~5Vdc Aux right 0~5Vdc Aux GND CN-56A CN-56B Name...
Page 286 GAUGE Operation screen When you first turn starting switch ON, the operation screen will appear. Default Option 130ZF3CD207 RPM / Speed gauge Tripmeter display Engine coolant temperature gauge Eco guage Hydraulic oil temperature gauge Accel dial gauge Fuel level gauge Operation screen type can be set by the screen type menu of the display.
Page 287 Hydraulic oil temperature gauge This gauge indicates the temperature of hydraulic oil. ① ·White range : 40-105˚C(104-221˚F) ·Red range : Above 105˚C(221˚F) If the indicator is in the red range or lamp pops up and the ② buzzer sounds reduce the load on the system. If the gauge stays in the red range, stop the machine and check the cause of the problem.
Page 288 WARNING LAMPS Engine check warning lamp Battery charging warning lamp Engine oil pressure warning lamp Air cleaner warning lamp Emergency warning lamp Overload warning lamp Engine stop warning lamp Engine coolant temperature warning lamp Fuel level warning lamp Hydraulic oil temperature warning lamp HEST warning lamp DPF regen inhibit warning lamp...
Page 289 Engine coolant temperature warning lamp Engine coolant temperature warning is indicated two steps. ① 103˚C over : The lamp pops up and the buzzer sounds. 107˚C over : The lamp pops up and the buzzer sounds. The pop-up lamps move to the original position and blinks ②...
Page 290 Battery charging warning lamp This warning lamp pops up and buzzer sounds when the ① battery charging voltage is low. Check the battery charging circuit when this lamp blinks. ② 290F3CD67 Air cleaner warning lamp This warning lamp pops up and buzzer sounds when the filter ①...
Page 291 (10) Engine check warning lamp The engine check warning lamp will activate as following condition. ① The engine oil pressure is low. The engine oil life has exceeded the maximum service limit. Also, the engine stop warning lamp and engine oil pressure ②...
Page 292 Method of the engine oil life reset ※ Once engine oil is changed, the oil life reset is required. To perform oil life reset, follow the procedure as below. (1) Turn the starting switch on without engine running. (2) Then press "Menu" → "Manage" → "Engine Oil Life Reset" (3) Press OK and Put "User Password".
Page 293 (11) DPF (Diesel Particulate Filter) warning lamp This warning lamp lights ON or BLINK when the regeneration is ① needed. When this lamp lights ON or BLINK, press the DPF switch to ② manual regeneration position (I) at least 2 seconds to initiate the manual DPF regeneration.
Page 294 DPF above 180% soot loading. Soot Engine power derates depen- Blink high dent on soot load. Regeneration is required. DPF above 250% soot loading. Soot Engine will be locked at low idle. Blink full Contact the Hyundai service center or a local dealer. 5-66...
Page 295 Manual DPF regeneration Manual DPF regeneration ※ (1) Manual DPF regeneration can be performed when the below conditions are met. Engine running > 10 seconds ① Coolant temperature > 65 ˚C ② Lock Engine at low idle ③ Soot load >130% (when DPF lamp is ON) ④...
Page 296 PILOT LAMPS Warming up pilot lamp Decel pilot lamp Preheat pilot lamp Power max pilot lamp Fuel warmer pilot lamp Maintenance pilot lamp Power/User mode pilot mode Auto idle pilot lamp Work tool mode pilot lamp Travel speed pilot lamp Smart key pilot lamp Entertainment pilot lamp 130ZF3CD274...
Page 297 Power max pilot lamp The lamp will be ON when pushing power max switch on the ① LH RCV lever. The power max function is operated maximum 8 seconds. ② Refer to the operator's manual page 3-38 for power max ※...
Page 298 Maintenance pilot lamp This lamp will be ON when the consuming parts are needed to ① change or replace. It means that the change or replacement interval of the consuming parts remains below 30 hours. Check the message in maintenance information of main menu. ②...
Page 299 SWITCHES Entertainment quick touch switch Main menu quick touch switch Work mode Travel speed pilot lamp pilot lamp Auto idle pilot lamp Power/User mode pilot lamp User mode switch Travel speed switch Auto idle/Buzzer stop switch Power mode switch Work mode switch Escape(previous or parent menu) Rear camera(option) Work light switch...
Page 300 User mode switch This switch is used to memorize the current machine operating ① status in the MCU and activate the memorized user mode. ·Memory : Push more than 2 seconds. : Push within 2 seconds. ·Action ·Cancel : Push this switch once more within 2 seconds. Refer to the page 5-76 for another set of user mode.
Page 301 Head light switch This switch is used to operate the head light. ① The pilot lamp is turned ON when operating the switch. ② 290F3CD94 Intermittent wiper switch This switch is used to wipe operates intermittently. ① The pilot lamp is turned ON when operating the switch. ②...
Page 302 (13) Beacon switch This switch turns ON the rotary light on the cab. ① The pilot lamp is turned ON when operating the switch. ② 290F3CD97 (14) Overload switch When this switch turned ON, buzzer makes sound and ① overload warning lamp comes ON in case that the machine is overload.
Page 303 MAIN MENU You can select or set the menu by touch screen. ※ On the operation screen, tap MENU to access the main menu screen. On the sub menu screen, you can tap the menu bar to access functions or applications. Operation screen ·...
Page 304 Mode setup Work tool ① 290F3CD108 290F3CD253 290F3CD254 Select on installed optional attachment · A : It can set the user's attachment. It is available in setting #1~#10. B : Max flow - Set the maximum flow for the attachment. Relief pressure - Set the relief pressure.
Page 305 Auto power boost ④ 210WF3CD118 290F3CD117 The power boost function can be activated or cancelled. · Enable - The digging power is automatically increased as working conditions by the MCU. It is operated max 8 seconds. Disable - Not operated. IPC mode ⑤...
Page 306 Automatic engine shutdown (option) ⑥ 210WF3CD11 210WF3CD12 130ZF3CD213 The automatic engine shutdown function can be set by this menu. · One time Always Disable Wait time setting : Max 40 minutes, min 2 minutes Initial mode ⑦ 290F3CD122 290F3CD119 Key on initial mode ·...
Page 307 Monitoring Active fault ① 290F3CD120 290F3CD121 290F3CD125 The active faults of the MCU or engine ECM can be checked by this menu. · Logged fault ② 290F3CD128 290F3CD123 290F3CD124 The logged faults of the MCU or engine ECM can be checked by this menu. ·...
Page 308 Management Fuel rate information ① 210WF3CD14 210WF3CD15 ·General record (A) Average fuel rate (left) (from "Reset" to now) Fuel consumption devided by engine run time (service meter time). A days fuel used (right) Fuel consumption from 24:00 (or "Reset" time) to now (MCU real time).
Page 309 Maintenance information ② 290F3CD131 290F3CD132 290F3CD133 Alarm lamp ( ) is ON when oil or filter needs to be changed or replaced. · Replacement : The elapsed time will be reset to zero (0). · Change interval : The change or replace interval can be changed in the unit of 50 hours. ·...
Page 310 Machine security ③ 290F3CD190 290F3CD135 290F3CD136 ESL mode setting · ESL : Engine Starting Limit ESL mode is desingned to be a theft deterrent or will pre- vent the unauthorized operation of the machine. If the ESL mode was selected Enable, the password will be required when the start switch is turned ON.
Page 311 Machine Information ④ 290F3CD144 290F3CD145 This can confirm the identification of the model information (ECU), MCU, monitor, switch · controller, RMCU, relay driver unit, FATC (air conditioner controller), AAVM (opt). Contact (A/S phone number) ⑤ 290F3CD146 290F3CD147 290F3CD148 Enter the new A/S phone number Service menu ⑥...
Page 312 Update (cluster & ETC devices) ⑧ 210WF3CD17 210WF3CD18 210WF3CD19 380F3CD06 380F3CD04 ETC devices and cluster can be updated through CAN 2 network. · Insert USB memory stick which includes program files, start download. · Engine oil life reset ⑨ Engine oil life rese 130ZF3CD100 130ZF3CD101 130ZF3CD102...
Page 313 Display Display item ① 290F3CD154 290F3CD155 130ZF3CD256 The center display type of the LCD can be selected by this menu. · The engine speed or each of the tripmeter (A,B,C) is displayed on the center display. · Clock ② 290F3CD157 290F3CD158 The first line's three spots "**/**/****"...
Page 314 Unit ④ 290F3CD161 290F3CD162 290F3CD193 Temperature : ˚C ↔ ˚F · Pressure : bar ↔ MPa ↔ kgf/cm · Volume : l ↔ gal · Flow : lpm ↔ gpm · Distance : km ↔ mile · Date format : yy/mm/dd ↔ mm/dd/yy ↔ dd-mm-yy ·...
Page 315 Utilities Entertainment ① 290F3CD195 290F3CD196 210WF3CD219 290F3CD197 210WF3CD220 290F3CD198 210WF3CD199 210WF3CD22 Video (A) : This menu operates the video play function. mp4, mkv, avi files and so on. Audio (B) : This menu operates the play music. mp3, mp4 files and so on. Smart terminal (C) : The menu features a smartphone and operates the miracast.
Page 316 Tripmeter ② 290F3CD168 290F3CD169 Maximum 3 kinds of tripmeters can be used at the same time. · Each tripmeter can be turned on by choosing "Start" while it also can be turned off by · choosing "Stop". If the tripmeter icon is activated in the operation screen, it can be controlled directly there. ·...
Page 317 AAVM (All Around View Monitoring, option) ④ The AAVM buttons of the cluster consist of ESC/CAM and AUTO IDLE/Buzzer stop. · Buzzer stop switch Escape switch 130ZF3CD244 Escape button It will enter into the AAVM mode from the beginning screen if the AAVM is installed. ·...
Page 318 AIR CONDITIONER AND HEATER Full auto air conditioner and heater system automatically keeps the optimum condition in accordance with operator's temperature configuration sensing ambient and cabin inside temperature. Location of air flow ducts · Switch panel Fresh air switch Mode switch Auto switch Power OFF switch Fan speed switch...
Page 319 POWER OFF SWITCH This switch makes the system and the LED OFF. Just before the power OFF, set values are stored. Default setting values Function Air conditioner In/outlet Temperature Mode Value Inlet Previous sw OFF Previous sw OFF 370073CD54 AUTO SWITCH Turn the starting switch to ON position, LCD lights ON.
Page 320 TEMPERATURE CONTROL SWITCH Setting temperature indication Type A : 17~32˚C, scale : 1˚C ① Type B : Lo, 18~31˚C, Hi, scale : 1˚C ② Max cool and max warm beeps 5 times. The max cool or the max warm position operates as following table. 370074CD57 Temperature Compressor...
Page 321 SELF DIAGNOSIS FUNCTION Procedure Starting switch ON Press the air recirculation button over 5 times within 2 seconds during pressing the AUTO switch All symbol of LCD blink 5 times Switch OFF Error check System OFF Press AUTO switch Cancelled diagnosis function(normal function) 3607A3CD69 Error check The corresponding error code flickers on the setup temperature display panel, the other symbol...
Page 322: Group 16 Fuel Warmer System
GROUP 16 FUEL WARMER SYSTEM 1. SPECIFICATION Operating voltage : 24±4 V Power : 350±50 W Filter head & Current : 15 A fuel warmer 2. OPERATION T h e c u r r e n t o f f u e l w a r m e r s y s t e m i s Prefilter automatically controlled without thermostat according to fuel temperature.
Page 323: Section 6 Troubleshooting
SECTION 6 TROUBLESHOOTING Group 1 Before Troubleshooting -------------------------------------------------------------------------------------- 6-1 Group 2 Hydraulic and Mechanical System ------------------------------------------------------------------- 6-4 Group 3 Electrical System ----------------------------------------------------------------------------------------------- 6-24 Group 4 Mechatronics System ---------------------------------------------------------------------------------------- 6-40...
Page 324: Group 1 Before Troubleshooting
SECTION 6 TROUBLESHOOTING GROUP 1 BEFORE TROUBLESHOOTING 1. INTRODUCTION When a trouble is occurred in the machine, this section will help service men repair the machine with easy. The trouble of machine is parted Hydraulic & Mechanical system, Electrical system and Mechatronics system.
Page 325 2. DIAGNOSING PROCEDURE To carry out troubleshooting efficiently, the following steps must be observed. STEP 1. Study the machine system Study and know how the machine is operating, how the system is composing, what kinds of function are installed in the machine and what are specifications of the system components by the machine service manual.
Page 326 STEP 4. Inspect the trouble actually on the machine In case that some trouble cannot be confirmed, obtain the details of the malfunction from the operator. Also, check if there are any in complete connections of the wire harnesses are or not. (210-7) 6-3(1) STEP 5.
Page 327: Group 2 Hydraulic And Mechanical System
GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM 1. INTRODUCTION MACHINE IN GENERAL If even a minor fault is left intact and operation is continued, a fatal failure may be caused, entailing a large sum of expenses and long hours of restoration. Therefore when even a small trouble occurs, do not rely on your intuition and experience, but look for the cause based on the troubleshooting principle and perform maintenance and adjustment to prevent major failure from occurring.
Page 328 2. DRIVE SYSTEM UNUSUAL NOISE COMES OUT OF PUMP CONNECTION Cause Remedy Coupling element Disassemble is broken. and repair. Remove dust plug under engine flywheel and Replace hub or check if rubber pieces or particles retighten are not present. setscrew. Coupling hub spline is worn or hub fastening...
Page 329 ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL Cause Remedy Replenish specified oil to the standard Is oil level in level. Abnormal noise hydraulic oil comes out of Hydraulic pump is Disassemble tank within hydraulic pump broken. and repair. standard level? Do not hydraulic Abnormal noise...
Page 330 3. HYDRAULIC SYSTEM HYDRAULIC OIL IS CLOUDY Cause Remedy Water is mixed. Put hydraulic oil still, separate water and Drop hydraulic oil dispose it or sample on hot plate and check if replace hydraulic foams come up. oil. Air is intruded. Check suction line and return line and eliminate...
Page 331 CAVITATION OCCURS WITH PUMP Cause Remedy Replenish specified oil to the standard level. Is hydraulic oil volume proper? Replace oil with one of proper Is not viscosity viscosity. of hydraulic oil too high? Clean suction strainer. Is not suction strainer clogged? Is not air intruding Check for air from pump...
Page 332 4. SWING SYSTEM BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE Cause Remedy Replenish Does safety specified oil to the ⓐ solenoid valve standard level. operation Safety solenoid Repair or replace. Is gear pump pilot normal? pressure within valve faulty or not standard level? Is oil in hydraulic operated.
Page 333 SWING SPEED IS LOW Cause Remedy Swing port relief Disassemble and Does swing spool valve is faulty. repair or replace. move? Swing control valve Disassemble Is MCV pilot spool is stuck. and repair. pressure same on LH and RH Clogged or oil Clean pilot piping sides? leak.
Page 334 SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION Cause Remedy Does symptom Swing port relief Disassemble change when LH valve is faulty. and repair. and RH port relief valves of swing motor are Shuttle valve is Disassemble exchanged? Does swing control faulty.
Page 335 THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE Cause Remedy ⓐ Is swing shuttle valve normal? Shuttle valve is Disassemble faulty. and replace. Is brake spring normal? Is return spring Brake spring is Disassemble of swing spool normal? faulty.
Page 336 5. TRAVEL SYSTEM TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE Cause Remedy ⓐ Does counterbalance spool move lightly by hand? Counter spool is Disassemble Is travel brake valve pressure stuck. and repair or within standard replace. Does the symptom level? change when relief valves in...
Page 337 SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES Cause Remedy Brake valve is Disassemble Do LH and RH defective. and repair or travel speeds replace. change when LH and RH travel Relief valve built Disassemble Does the symptom brake valves are change when in travel motor is and repair.
Page 338 MACHINE DOES NOT STOP ON A SLOPE Machine is pulled forward as sprocket rotates during digging operation. Cause Remedy Is parking brake None Friction plate is Disassemble friction plate worn? Check if parking faulty. and repair. brake pilot line is clogged.
Page 339 TRAVEL ACTION IS POWERLESS (travel only) Cause Remedy ⓐ Is travel motor's drain rate within standard level? Is travel brake Travel motor is Disassemble pressure within faulty. and repair. standard level? Is travel relief Travel brake valve Disassemble valve pressure within standard is defective.
Page 340 MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME Cause Remedy Normal. Is straight spool normal? Straight spool is Repair or Is pilot pressure faulty. replace. for travel straight spool within standard level? Remove dirt on...
Page 341 6. ATTACHMENT SYSTEM BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL Cause Remedy Port relief valve is Disassemble Does the symptom change faulty. and repair or when port relief replace. valve is replaced ⓐ with other valve? Is MCV pilot pressure within standard level? Inspect if pilot...
Page 342 BOOM, ARM OR BUCKET SPEED IS LOW Cause Remedy Normal. Are other ⓐ attachment speeds within Is combination ⓑ Is speed low only standard levels? of oil streams in composite normal at boom operation? Replace spring up and at arm Does spool of flow extrusion? summation check...
Page 343 BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS Cause Remedy Port relief valve is Disassemble Does the symptom faulty. and repair or change when port replace. Normal relief valve is ⓐ replaced with Is control valve normal value? return spring Is not hydraulic...
Page 344 BOOM, ARM OR BUCKET POWER IS WEAK Cause Remedy Check according to the procedure Is cylinder in Item "Speed is internal leakage within standard low". level? Is relief pressure in port relief Cylinder is faulty. Disassemble valve within and repair. standard level? Is relief pressure in main relief...
Page 345 BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED Cause Remedy Frictional noise occurs between the sliding faces of boom cylinder's oil seal and boom Is boom foot pin greased proper. sufficiently? ※ Frictional noise will disappear if they are kept used.
Page 346 ※ HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE Lower the bucket teeth to the ground with bucket cylinder fully retracted and arm cylinder rod retracted almost in full. 145ZF6TS01 Disconnect hose (A) from rod side of boom cylinder and drain oil from cylinders and hose.
Page 347: Group 3 Electrical System
GROUP 3 ELECTRICAL SYSTEM 1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.
Page 348 COMMUNICATION ERROR FLASHES ON THE CLUSTER (HCESPN 840, FMI 2) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective cluster...
Page 349 BATTERY CHARGING WARNING LAMP LIGHTS UP (Starting switch : ON) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective MCU...
Page 350 WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP (engine is started) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Check use HRDT...
Page 351 WHEN AIR CLEANER WARNING LAMP LIGHTS UP (engine is started) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Clogged air filter or...
Page 352 WHEN ENGINE OIL PRESSURE WARNING LAMP LIGHTS UP (engine is started) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective circuit,...
Page 353 WHEN HYDRAULIC OIL TEMPERATURE WARNING LAMP LIGHTS UP (engine is started) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy High temperature...
Page 354 8. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Check use HRDT...
Page 355 9. WHEN FUEL GAUGE DOES NOT OPERATE (HCESPN 301, FMI 3 or 4) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective MCU or...
Page 356 10. WHEN SAFETY SOLENOID DOES NOT OPERATE ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No. 26. ·After checking, insert the disconnected connectors again immediately unless otherwise specified. Cause Remedy Hydraulic system...
Page 357 11. WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE (HCESPN 167, FMI 4 or 6) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No. 24. ·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 358 12. WHEN ENGINE DOES NOT START ( lights up condition) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No. 2, 3, 11, 15, 19. ·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 359 13. WHEN STARTING SWITCH ON DOES NOT OPERATE ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted, master switch ON and check open circuit of circuit breaker (CN-60, CN-95). ·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 360 14. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No. 6, 11 and 21 is not blown out. CN-21 ·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 361 15. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.16. ·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 362 16. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.17. ·After checking, insert the disconnected connectors again immediately unless otherwise specified.
Page 363: Group 4 Mechatronics System
GROUP 4 MECHATRONICS SYSTEM 1. ALL ACTUATORS SPEED ARE SLOW Boom, Arm, Bucket, Swing and travel speed are slow, but engine speed is good. ※ Spec : P-mode 1850 ± 50 rpm S -mode 1750 ± 50 rpm E-mode 1650 ± 50 rpm ※...
Page 364 TEST PROCEDURE SPEC : 15~25Ω(20˚C) Test 1 : Check resistance at connector EPPR valve CN-75 CN-75. Starting switch OFF. ① Disconnect connector CN-75 from EPPR ② valve at main hydraulic pump. Multimeter Check resistance between 2 lines as ③ Valve casing figure.
Page 365 2. ENGINE STALL Before carrying out below procedure, check all the related connectors are properly inserted. ※ INSPECTION PROCEDURE Cause Remedy Not enough Check engine engine power fault Check pressure Contact cummins at EPPR valve Defective EPPR Replace SPEC:2~25 kgf/cm See TEST 5 valve Check electric...
Page 366 TEST PROCEDURE Spec : 100~700 mA Test 4 : Check electric current at EPPR Adapter(P/no.:21Q6-50410) valve. EPPR valve ① Disconnect connector CN-75 from EPPR Multimeter CN-75 valve. Insert the adapter to CN-75 and install ② multimeter as figure. ③ Start engine. Valve casing ④...
Page 367 3. MALFUNCTION OF CLUSTER OR MODE SELECTION SYSTEM Before carrying out below procedure, check all the related connectors are properly inserted. ※ INSPECTION PROCEDURE Cause Remedy No power supply to Check fuse No.8 the MCU See if all lamps off in the MCU case MCU failure Replace...
Page 368 4. AUTO DECEL SYSTEM DOES NOT WORK Fault code : HCESPN 105, FMI 0~4 (work pressure sensor) · HCESPN 108, FMI 0~4 (travel oil pressure sensor) Before carrying out below procedure, check all the related connectors are properly inserted. ※ INSPECTION PROCEDURE Cause Remedy...
Page 369 TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 7 : Check voltage at CN-52 (38) and ground. Prepare 1 piece of thin sharp pin, steel or ① copper. Insert prepared pin to rear side of ② CN-51 CN-52 connectors : One pin to (38) of CN-52.
Page 370 5. MALFUNCTION OF PUMP 1 PRESSURE SENSOR Fault code : HCESPN 120, FMI 0~4 · Before carrying out below procedure, check all the related connectors are properly inserted. ※ INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Short circuit or Replace or repair poor connection Check voltage between CN-52-...
Page 371 TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 9 : Check voltage at CN-52 (29) and ground. Prepare 1 piece of thin sharp pin, steel or ① copper. Insert prepared pin to rear side of ② connectors : One pin to (29) of CN-52. CN-51 CN-52 Starting switch ON.
Page 372 6. MALFUNCTION OF PUMP 2 PRESSURE SENSOR Fault code : HCESPN 121, FMI 0~4 · Before carrying out below procedure, check all the related connectors are properly inserted. ※ INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Short circuit or Replace or repair poor connection Check voltage between CN-52-...
Page 373 TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 10 : Check voltage at CN-52 (12) and ground. Prepare 1 piece of thin sharp pin, steel or ① copper. Insert prepared pin to rear side of ② connectors : One pin to (12) of CN-52. Starting switch ON.
Page 374 7. MALFUNCTION OF PUMP 3 PRESSURE SENSOR Before carrying out below procedure, check all the related connectors are properly inserted. ※ INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Short circuit or Replace or repair poor connection Check voltage between CN-52- between (32)-CN-1(7) CN-1(7)-GND...
Page 375 TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 11 : Check voltage at CN-52 (32) and ground. Prepare 1 piece of thin sharp pin, steel or ① copper. Insert prepared pin to rear side of ② connectors : One pin to (32) of CN-52. CN-51 CN-52 Starting switch ON.
Page 376 8. MALFUNCTION OF NEGATIVE 1 PRESSURE SENSOR Fault code : HCESPN 123, FMI 0~4 · Before carrying out below procedure, check all the related connectors are properly inserted. ※ INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Short circuit or Replace or repair poor connection Check voltage between CN-52-...
Page 377 TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 12 : Check voltage at CN-52 (33) and ground. Prepare 1 piece of thin sharp pin, steel or ① copper. Insert prepared pin to rear side of ② connectors : One pin to (33) of CN-52. Starting switch ON.
Page 378 9. MALFUNCTION OF NEGATIVE 2 PRESSURE SENSOR Fault code : HCESPN 124, FMI 0~4 · Before carrying out below procedure, check all the related connectors are properly inserted. ※ INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Short circuit or Replace or repair poor connection Check voltage between CN-52-...
Page 379 TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 13 : Check voltage at CN-52 (17) and ground. Prepare 1 piece of thin sharp pin, steel or ① copper. Insert prepared pin to rear side of ② connectors : One pin to (17) of CN-52. CN-51 CN-52 Starting switch ON.
Page 380 10. MALFUNCTION OF SWING PRESSURE SENSOR Fault code : HCESPN 135, FMI 0~4 · Before carrying out below procedure, check all the related connectors are properly inserted. ※ INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Check voltage between CN-52 Detective swing Replace or repair (36) - GND pressure sensor...
Page 381 TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 14 : Check voltage at CN-52 (36) and ground. Prepare 1 piece of thin sharp pin, steel or ① copper. Insert prepared pin to rear side of ② connectors : One pin to (36) of CN-52. Starting switch ON.
Page 382 11. MALFUNCTION OF ARM IN/OUT & BUCKET IN PRESSURE SENSOR Fault code : HCESPN 133, FMI 0~4 · Before carrying out below procedure, check all the related connectors are properly inserted. ※ INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Check voltage between CN-52 Detective arm in/ Replace or repair...
Page 383 TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 15 : Check voltage at CN-52 (14) and ground. Prepare 1 piece of thin sharp pin, steel or ① copper. Insert prepared pin to rear side of ② connectors : One pin to (14) of CN-52. CN-51 CN-52 Starting switch ON.
Page 384 12. MALFUNCTION OF BOOM UP PRESSURE SENSOR Fault code : HCESPN 127, FMI 0~4 · Before carrying out below procedure, check all the related connectors are properly inserted. ※ INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Check voltage between CN-52 Detective boom up Replace or repair (19) - GND...
Page 385 TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 16 : Check voltage at CN-52 (19) and ground. Prepare 1 piece of thin sharp pin, steel or ① copper. Insert prepared pin to rear side of ② connectors : One pin to (19) of CN-52. Starting switch ON.
Page 386 13. MALFUNCTION OF BOOM DOWN PRESSURE SENSOR Fault code : HCESPN 128, FMI 0~4 · Before carrying out below procedure, check all the related connectors are properly inserted. ※ INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Check voltage between CN-53 Detective boom up Replace or repair (23) - GND...
Page 387 TEST PROCEDURE SPEC : Actuator operating : 1~5 V Test 17 : Check voltage at CN-53 (23) and ground. Prepare 1 piece of thin sharp pin, steel or ① copper. Insert prepared pin to rear side of ② connectors : One pin to (23) of CN-53. Starting switch ON.
Page 388 14. MALFUNCTION OF POWER MAX Fault code : HCESPN 166, FMI 4 or 6 · Before carrying out below procedure, check all the related connectors are properly inserted. ※ INSPECTION PROCEDURE Cause Remedy Short circuit or poor Repair or replace connection between Check resistance CN-88(1)-CN-52 (2)
Page 389 TEST PROCEDURE SPEC : Starting switch ON : 24±1V Starting switch OFF : 0V Test 18: Check voltage between connector CN-88 (2) - GND. Disconnect connector CN-88 from power ① max solenoid valve. Power max switch Start switch ON. ② Check voltage as figure.
Page 390 15. MALFUNCTION OF BOOM PRIORITY EPPR VALVE Fault code : HCESPN 141, FMI 5 or 6 · Before carrying out below procedure, check all the related connectors are properly inserted. ※ INSPECTION PROCEDURE Cause Remedy Short circuit or poor Repair or replace connection between CN-52(35)-CN-133 (1) or CN-52(34)-...
Page 391 16. MALFUNCTION OF ARM REGENERATION SOLENOID Fault code : HCESPN 170, FMI 4 or 6 · Before carrying out below procedure, check all the related connectors are properly inserted. ※ INSPECTION PROCEDURE Cause Remedy Defective MCU Replace Check voltage between CN-52 Short circuit or Replace or repair (1)-GND...
Page 392 TEST PROCEDURE SPEC : Starting switch ON : 24±2 V Test 20 : Check voltage at CN-52 (1) and ground. Prepare 1 piece of thin sharp pin, steel or ① copper. Insert prepared pin to rear side of ② connectors : One pin to (1) of CN-52. Starting switch ON.
Page 393: Section 7 Maintenance Standard
SECTION 7 MAINTENANCE STANDARD Group 1 Operational Performance Test ------------------------------------------------------------------------- 7-1 Group 2 Major Components -------------------------------------------------------------------------------------------- 7-21 Group 3 Track and Work Equipment ------------------------------------------------------------------------------ 7-29...
Page 394: Group 1 Operational Performance Test
NEW MACHINE Whenever a new machine is delivered in parts and reassembled at a customer's site, it must be tested to confirm that the operational performance of the machine meets Hyundai spec. Working condition OPERATIONAL PERFORMANCE OF A WORKING MACHINE...
Page 395 2. TERMINOLOGY STANDARD Specifications applied to the brand-new machine, components and parts. 130ZF7MS02 SERVICE LIMIT The lowest acceptable performance level. When the perfor mance level of the machine falls below this level, the machine must be removed from work and repaired. Necessary parts and components must be replaced.
Page 396 3. OPERATION FOR PERFORMANCE TESTS Observe the following rules in order to carry out performance tests accurately and safely. The machine Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test. Test area Select a hard, flat surface.
Page 397 The measured speeds should meet the following specifications. Unit : rpm Model Engine speed Standard Remarks Start idle 1000±100 P mode 1850±50 S mode 1750±50 HX130CR HX130LCR E mode 1650±50 Auto decel 1100±100 One touch decel 1000±100 Condition : Set the multimodal dial at 10 (Max) position.
Page 398 Evaluation The average measured time should meet the following specifications. Unit : Seconds / 20 m Model Travel speed Standard Maximum allowable Remarks 1 Speed 22.0±2.0 27.9 HX130CR HX130LCR 2 Speed 13.2±1.0 17.0...
Page 399 ⑤ calculate the average values. Evaluation The revolution cycle time of each track should meet the following specifications. Unit : Seconds / 3 revolutions Model Standard Maximum allowable Travel speed 24.3±2.0 32.6 1 Speed HX130CR HX130LCR 2 Speed 14.2±1.0 19.8...
Page 400 (210-7) 7-7(2) Repeat steps ④ and ⑤ three times and ⑥ calculate the average values. Evaluation Mistrack should be within the following specifications. Unit : mm / 20 m Model Standard Maximum allowable Remarks HX130CR 200 below HX130LCR...
Page 401 Repeat steps ② and ③ three time and ④ calculate the average values. Evaluation The time required for 3 swings should meet the following specifications. Unit : Seconds / 3 revolutions Model Power mode switch Standard Maximum allowable HX130CR P mode 14.3±1.5 17.4 HX130LCR...
Page 402 Repeat steps ④ and ⑤ three times each ⑥ and calculate the average values. 130ZF7MS08 Evaluation The measured drift angle should be within the following specifications. Unit : Degree Model Power mode switch Standard Maximum allowable Remarks HX130CR P mode 90 below 157.5 HX130LCR...
Page 403 Record the dial gauge reading (h2). Calculate bearing play (H) from this data ③ (h1 and h2) as follows. H=h2-h1 Evaluation 145ZF7MS09 The measured drift should be within the following specifications. Unit : mm Model Standard Maximum allowable Remarks HX130CR 0.5 ~ 1.5 HX130LCR 7-10...
Page 404 HYDRAULIC CYLINDER CYCLE TIME Measure the cycle time of the boom, standard arm, and standard bucket cylinders. Preparation Boom cylinder To measure the cycle time of the boom ① cylinders: Raise With the arm rolled out and the empty bucket rolled out, lower the bucket to the ground, as shown.
Page 405 The average measured time should meet the following specifications. Unit : Seconds Maximum Model Function Standard Remarks allowable Boom raise 3.4±0.4 Boom lower 2.3±0.4 Regen ON 2.7±0.4 Arm in HX130CR Regen OFF 2.9±0.4 HX130LCR Arm out 2.9±0.3 Bucket in 3.7±0.4 Bucket out 2.4±0.3 7-12...
Page 406 The measured drift should be within the following specifications. Unit : mm / 5min Model Drift to be measured Standard Maximum allowable Remarks Boom cylinder 10 below HX130CR Arm cylinder 10 below HX130LCR Bucket cylinder 40 below 7-13...
Page 407 Unit : kgf Model Kind of lever Standard Maximum allowable Remarks Boom lever 1.5 or below Arm lever 1.5 or below HX130CR Bucket lever 1.5 or below HX130LCR Swing lever 1.5 or below Travel lever 2.1 or below 3.15 7-14...
Page 408 Evaluation The measured drift should be within the following specifications. Unit : mm Model Kind of lever Standard Maximum allowable Remarks Boom lever 85±10 Arm lever 85±10 HX130CR Bucket lever 85±10 HX130LCR Swing lever 85±10 Travel lever 139±10 7-15...
Page 409 Measure the primary pilot pressure by ② the monitoring menu of the cluster. Cluster 130ZF7MS12 Evaluation The average measured pressure should meet the following specifications: Unit : kgf / cm Model Engine speed Standard Allowable limits Remarks HX130CR P mode HX130LCR 7-16...
Page 410 Repeat step ② three times and calculate ③ the average values. Evaluation The average measured pressure should be within the following specifications. Unit : kgf / cm Model Travel speed mode Standard Maximum allowable Remarks 1 Speed HX130CR HX130LCR 2 Speed 40±5 7-17...
Page 411 Repeat step ② three times and calculate ③ the average values. Evaluation The average measured pressure should be within the following specifications. Unit : kgf / cm Model Description Standard Allowable limits Remarks Brake disengaged Over 9 HX130CR HX130LCR Brake applied 7-18...
Page 412 Monitoring ② (analog) pressure in the P mode (high idle). Cluster 130ZF7MS15 Evaluation The average measured pressure should meet the following specifications. Unit : kgf / cm Model Engine speed Standard Allowable limits Remarks HX130CR High idle 34±3 HX130LCR 7-19...
Page 413 The average measured pressure should be within the following specifications. Unit : kgf / cm Function to be tested Standard Port relief setting at 20 lpm Model Boom, Arm, Bucket 330 (360)±10 380±10 HX130CR Travel 330±10 HX130LCR Type 1 260±10 Swing Type 2 285±10 ) : Power boost 7-20...
Page 414: Group 2 Major Components
GROUP 2 MAJOR COMPONENT 1. MAIN PUMP 140Z97MP01 Recommended Standard Part name & inspection item replacement Counter measures dimension value Clearance between piston (1) & Replace piston or 0.032 0.056 cylinder bore (2) cylinder. (D-d) Play between piston (1) & shoe caulking 0-0.1 section (3) (δ)
Page 415 2. MAIN CONTROL VALVE Part name Inspection item Criteria & measure Casing ·Existence of scratch, rusting or corrosion. · I n case of damage in following section, replace part. - Sliding sections of casing fore and spool, especially land sections applied with holded pressure.
Page 416 3. SWING DEVICE WEARING PARTS Recommended Standard Inspection item replacement Counter measures dimension value Replace piston or Clearance between piston and cylinder block bore 0.041 0.060 cylinder block Thickness of valve plate 5.88 Replace Replace assembly Play between piston and shoe caulking section (δ) 0.025 of piston and shoe Replace assembly...
Page 417 4. TRAVEL MOTOR Problem Cause Remedy · · Does not Pressure is not Pump failure Check if action other than traveling is start developed available. If faulty, repair. · · Control valve malfunction Check if spool moves correctly. Repair if necessary.
Page 418 5. RCV LEVER Maintenance Criteria Remark check item Leakage The valve is to be replaced when the leakage becomes Conditions : more than 1000 cc/m at neutral handle position, or more Primary pressure : 40 kgf/cm than 2000 cc/m during operation. Oil viscosity : 23 cSt Spool This is to be replaced when the sliding surface has worn...
Page 419 6. RCV PEDAL Maintenance Criteria Remark check item Leakage The valve is to be replaced when the leakage effect Conditions : to the system. For example, the primary pressure Primary pressure : 40 kgf/cm drop. Oil viscosity : 23 cSt Spool This is to be replaced when the sliding surface has The leakage at the left condition is...
Page 420 7. TURNING JOINT Part name Maintenance standards Remedy Sliding surface with Plating worn or peeled due to seizure or contamination. Replace sealing sections. Sliding surface ·Worn abnormality or damaged more than 0.1 mm Replace between body and (0.0039 in) in depth due to seizure contamination. stem other than Body, ·Damaged more than 0.1 mm (0.0039 in) in depth.
Page 421 8. CYLINDER Part name Inspecting section Inspection item Remedy Piston rod ·Neck of rod pin ·Presence of crack ·Replace ·Weld on rod hub ·Presence of crack ·Replace · S tepped part to which piston ·Presence of crack ·Replace is attached. ·Presence of crack ·Recondition or replace ·Threads...
Page 422: Group 3 Track And Work Equipment
GROUP 3 TRACK AND WORK EQUIPMENT 1. TRACK TRACK ROLLER 21037MS01 Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange Ø190 Rebuild or Outside diameter of tread Ø150 Ø138 replace Width of tread 36.5 42.5 Width of flange 26.5...
Page 423 CARRIER ROLLER 21037MS02 Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange Ø175 Rebuild or Outside diameter of tread Ø151 Ø141 replace Width of tread 37.25 42.25 Width of flange 18.25 Standard size & Tolerance Standard Clearance clearance...
Page 424 IDLER 21037MS03 Unit : mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange Ø552 Outside diameter of tread Ø507 Ø497 Rebuild or replace Width of protrusion Total width Width of tread Standard size & Tolerance Standard Clearance clearance limit...
Page 425 TRACK 21037MS04 Unit : mm Check item Criteria Remedy Standard size Repair limit Turn or Link pitch replace 171.45 175.65 Outside diameter of bushing Ø53.75 Ø43.95 Rebuild or Height of grouser replace Height of link 94.5 86.5 Tightening torque Initial tightening torque : 42±4 kgf·m Retighten (Tightening angle method) Additional tightening angle : 32˚...
Page 426 TRACK FRAME AND RECOIL SPRING 21037MS05 Unit : mm Check item Criteria Remedy Standard size Tolerance Repair limit Track frame Vertical width of idler guide Rebuild or Idler support - 0.5 replace Track frame Horizontal width of idler guide Idler support Standard size Repair limit Free...
Page 427 2. WORK EQUIPMENT 130ZF7MS16 Unit : mm Bushing Remedy Measuring point Normal Recomm. Recomm. Mark & Limit Limit (Pin and Bushing) service value service Remark of use of use limit limit Boom Rear 68.5 70.5 Replace Boom Cylinder Head 68.5 70.5 〃...
Page 428: Section 8 Disassembly And Assembly
SECTION 8 DISASSEMBLY AND ASSEMBLY Group 1 Precaution ----------------------------------------------------------------------------------------------------------- 8-1 Group 2 Tightening Torque ----------------------------------------------------------------------------------------------- 8-4 Group 3 Pump Device ------------------------------------------------------------------------------------------------------ 8-7 Group 4 Main Control Valve --------------------------------------------------------------------------------------------- 8-32 Group 5 Swing Device ------------------------------------------------------------------------------------------------------ 8-46 Group 6 Travel Device ------------------------------------------------------------------------------------------------------- 8-99 Group 7 RCV Lever ----------------------------------------------------------------------------------------------------------- 8-131 Group 8 Turning Joint -------------------------------------------------------------------------------------------------------- 8-145 Group 9 Boom, Arm and Bucket Cylinder ---------------------------------------------------------------------- 8-150...
Page 429: Group 1 Precaution
SECTION 8 DISASSEMBLY AND ASSEMBLY GROUP 1 PRECAUTIONS 1. REMOVAL WORK Lower the work equipment completely to the ground. If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
Page 430 2. INSTALL WORK Tighten all bolts and nuts (sleeve nuts) to the specified torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pin or lock plate securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2-3 drops of adhesive.
Page 431 3. COMPLETING WORK If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level.
Page 432: Group 2 Tightening Torque
GROUP 2 TIGHTENING TORQUE 1. MAJOR COMPONENTS Torque Descriptions Bolt size kgf·m lbf·ft Engine mounting bolt (engine-bracket, FR) M12 × 1.75 12.8 ± 3.0 92.6± 21.7 Engine mounting bolt (engine-bracket, RR) M12 × 1.75 12.8 ± 3.0 92.6± 21.7 Engine mounting bolt (bracket-frame, FR) M16 ×...
Page 433 2. TORQUE CHART 2. TORQUE CHART Use following table for unspecified torque. 1) 1) BOLT AND NUT BOLT AND NUT (1) (1) Coarse thread Coarse thread 8.8T 10.9T 12.9T Bolt size kgf·m lbf·ft kgf·m lbf·ft kgf·m lbf·ft M 6 × 1.0 0.8 ~ 1.2 5.8 ~ 8.6 1.2 ~ 1.8...
Page 434 PIPE AND HOSE (FLARE TYPE) kgf·m lbf·ft Thread size (PF) Width across flat (mm) 28.9 1/4" 36.2 3/8" 68.7 1/2" 130.2 3/4" 151.9 1" 253.2 1-1/4" PIPE AND HOSE (ORFS TYPE) Thread size (UNF) Width across flat (mm) kgf·m lbf·ft 9/16-18 28.9 11/16-16...
Page 435: Group 3 Pump Device
GROUP 3 PUMP DEVICE 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
Page 436 INSTALL Carry out installation in the reverse order to removal. Remove the suction strainer and clean it. Replace return filter with new one. Remove breather and clean it. After adding oil to the hydraulic tank to the specified level. Bleed the air from the hydraulic pump. Remove the air vent plug (2EA).
Page 437 2. MAIN PUMP (1/3) STRUCTURE 533 789 733 732 532 214 548 531 702 792 534 901 808 954 724 717 723 402 151 981 983 130ZF2MP02 111 Drive shaft (F) 272 Pump casing (R) 711 O-ring 113 Drive shaft (R) 312 Valve block 717 O-ring 116 1st Gear...
Page 438 MAIN PUMP (2/3) 711 326 728 125 468 118 825 04 A1 pump side A2 pump side 130ZF2MP03 04 Gear pump 128 Bearing spacer 711 O-ring 115 Idler shaft 262 Cover 728 O-ring 117 Gear No. 2 326 Gear case 825 Retainer ring 118 Gear No.
Page 439 TOOLS AND TIGHTENING TORQUE Tools The tools necessary to disassemble/reassemble the pump are shown in the follow list. Tool name & size Part name Hexagon socket PT plug ROH / VP / UNF Hexagon socket Name head bolt (PT thread) plug (PF screw) head setscrew BP-1/16...
Page 440 Tightening torque Torque Wrench size Part name Bolt size kgf·m lbf·ft Hexagon socket head bolt 0.16 (material : SCM435) 0.20 21.7 0.24 42.0 0.31 10.0 72.3 0.39 16.0 0.47 24.0 0.55 34.0 0.55 44.0 0.67 PT Plug (material : S45C) PT1/16 0.16 ※ W ind a seal tape 1.5 to 2...
Page 441 DISASSEMBLY Select place suitable to disassembling. ※ Select clean place. ※ Spread rubber sheet, cloth or so on overhaul workbench top to prevent parts from being damaged. Remove dust, rust, etc, from pump surfaces with cleaning oil or so on. Remove drain port plug (468) and drain oil pump casing (271, 272).
Page 442 Remove flange socket (435) and remove gear pump (04). 140Z98MP14 Loosen hexagon socket head bolt (401) which tighten pump casing (271, 272) and valve block (312). 140Z98MP15 Place pump horizontally on workbench with its regulator fitting surface down, and separate pump casing (271,272) from valve block (312).
Page 443 (11) Remove hexagon socket head bolts (406) and then seal cover (F, 261). In the case removing it is difficult, and ※ hooking pull thin rod into notch, and the cover can be removed easily. Since oil seal is fitted on seal cover (F) ※...
Page 444 (15) Remove valve plate (313, 314) from valve block (312). These may be removed in Work 8. ※ 140Z98MP22 If necessary, remove stopper (L) (534), Qmin. plug (533), servo piston (532) and tilting pin (531) from pump casing (271, 272), and needle bearing (124) from valve block.
Page 445 ASSEMBLY F o r r e a s s e m b l i n g r e v e r s e t h e disassembling procedures, paying attention to the following items. ① Do not fail to repair the parts damaged during disassembling, and repair replacement parts in advance.
Page 446 Fit tilting bush (214) of swash plate (212) to tilting pin (531), and fit swash plate (212) with shoe plate (211) to swash plate support (251) correctly. Confirm with fingers of both hands that ※ swash plate can be removed smoothly. Apply grease to sliding sections of swash ※...
Page 447 Fit valve plate (313, 314) to valve block (312), spring pin (886) into pin hole. ※ Take care not to mistake suction / delivery direction of valve plate (312). 140Z98MP28 Place pump horizontally on workbench with its regulator fitting surface down, and attach pump casing (271, 272) to valve b l o c k ( 3 1 2 ) .
Page 448 (11) Attach the PTO unit (05) by fastening the flange socket (435) to the valve block (312). 140Z98MP32 (12) In case the pump is not provided with the PTO unit (05), attach the cover (262) with the hexagon socket head cap screw (414).
Page 449 3. REGULATOR STRUCTURE (1/2) 412 753 612 897 874 874 726 646 438 730 643 708 645 728 801 924 SECTION B-B 413 497 VIEW C (A1 pump) VIEW C (A2 pump) 079 753 755 466 755 656 496 KR76-9N01-V (A1 pump) KR76-9N02-V (A2 pump) 753 439 SECTION E-E...
Page 450 REGULATOR (3/3) 653 654 734 836 651 652 601 624 629 630 628 802 623 887 757 753 627 SECTION A-A 140Z92MP05 079 EPPR valve assembly 624 Spring seat (C) 708 O-ring 412 Hexagon socket screw 625 Outer spring 724 Square ring 413 Hexagon socket screw 626 Inner spring 725 O-ring...
Page 451 TOOLS AND TIGHTENING TORQUE Tools The tools necessary to disassemble/reassemble the pump are shown in the follow list. Tool name & size Part name Hexagon socket PT plug PO plug Hexagon socket Name head bolt (PT thread) (PF thread) head setscrew BP-1/16 Allen wrench BP-1/8...
Page 452 Tightening torque Torque Wrench size Part name Bolt size kgf·m lbf·ft Hexagon socket head bolt 0.16 (material : SCM435) 0.20 21.7 0.24 42.0 0.31 10.0 72.3 0.39 16.0 0.47 24.0 0.55 34.0 0.55 44.0 0.67 PT Plug (material : S45C) PT1/16 0.16 ※ W ind a seal tape 1 1/2 to 2...
Page 453 DISASSEMBLY Since the regulator consists of small precision finished parts, disassembly and assembly are rather complicated. For this reason, replacement of a regulator assembly is recommended, unless there is a special reason, but in case disassembly is necessary for an unavoidable reason, read through this manual to the end before starting disassembly.
Page 454 After removing cover (C, 629) subassembly, take out outer spring (625), inner spring (626) and spring seat (C, 624) from compensating section. Then draw out adjusting ring (Q, 645), pilot spring (646) and spring seat (644) from pilot section. Adjusting ring (Q,645) can easily be ※...
Page 455 (210-7) REG07 Remove lever 2 (613). Do not draw out pin (875). Work will be promoted by using pincers or ※ so on. (210-7) REG08 (10) Draw out pin (874) and remove feedback lever (611). Push out pin (874, 4 mm in dia.) from above with slender steel bar so that it may not interfere with lever 1 (612).
Page 456 (11) Remove lever 1 (612). Do not draw out pin (875). (12) Draw out pilot piston (643) and spool (652). (13) D r a w o u t p i s t o n c a s e ( 6 2 2 ) , c o m p e n s a t i n g p i s t o n ( 6 2 1 ) a n d compensating rod (623).
Page 457 ASSEMBLY For assembly, reverse disassembly procedures, but pay attention to the following items. Always repair parts that were scored at ① disassembly. Get replacement parts ready beforehand. ② Mixing of foreign matter will cause malfunction. Therefore, wash parts well with cleaning oil, let them dry with jet air and handle them in clean place.
Page 458 Fit feedback lever (611), matching its pin hole with pin hole in spool. Then insert pin (874). Insert pin in feedback lever a little to ease ※ Lever 1 side Lever 2 side operation. (fulcrum plug of Take care not to mistake direction of ※...
Page 459 (11) Fit set spring (655) to spool hole and put compensating piston (621) and piston case (622) into compensating hole. Fit pilot cover (641) and tighten it with hexagonal socket head screws (437, 438). (210-7) REG14 (12) Put spring seat (644), pilot spring (646) and adjusting ring (Q, 645) into pilot hole.
Page 460: Group 4 Main Control Valve
GROUP 4 MAIN CONTROL VALVE 1. REMOVAL AND INSTALL OF MOTOR REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
Page 461 2. STRUCTURE (1/4) REAR FRONT 125LCR8MC04 Housing-P1 26 Lock valve kit B 51 Pilot B1 cap Spool assy-travel (LH) 27 Regeneration block 53 Socket head bolt Spool assy-boom 1 33 Plug 56 Plain washer 10 Spool assy-arm 2 41 Orifice 58 O-ring 12 Spool assy-arm regen 42 Plug...
Page 462 STRUCTURE (2/4) REAR HOUSING-P1 FRONT 125LCR8MC05 16 Main relief valve 42 Plug 71 O-ring 17 Overload relief valve 43 Poppet 1 72 O-ring 28 Plug 44 Poppet 2 74 Back up ring 29 Plug 59 O-ring 75 Back up ring 31 Plug 61 O-ring 76 Back up ring...
Page 463 STRUCTURE (3/4) REAR FRONT 125LCR8MC06 Housing-P2 26 Lock valve kit B 54 Socket head bolt Spool assy-straight travel 29 Plug 55 Socket head bolt Spool assy-travel(RH) 30 Plug 56 Plain washer Spool assy-swing 40 Plug 57 Spring washer Spool assy-swing priority 46 Sleeve 59 O-ring Spool assy-boom 2...
Page 464 STRUCTURE (4/4) HOUSING-P2 REAR FRONT 130ZF8MC07 17 Overload relief valve 37 Plug 67 O-ring 18 Overload relief valve 43 Poppet 1 68 O-ring 21 Swing logic valve 44 Poppet 72 O-ring 23 ON/OFF valve-option 48 Orifice 73 O-ring 28 Plug 49 Coin type filter 77 Back up ring 29 Plug...
Page 465 3. DISASSEMBLY AND ASSEMBLY GENERAL PRECAUTIONS All hydraulic components are manufactured to a high precision. Consequently, before disassembling and assembling them, it is essential to select an especially clean place. In handling a control valve, pay full attention to prevent dust, sand, etc. from entering into it. When a control valve is to be remove from the machine, apply caps and masking seals to all ports.
Page 466 DISASSEMBLY Disassembly of spools without holding valve (travel right, travel left) Loosen hexagon socket head bolts with washer. ① (hexagon wrench : 5 mm) Remove the pilot cover. ② Pay attention not to lose the O-ring under the pilot cover. ※...
Page 467 Disassembly of spools with holding valve (boom 1, Arm 1 spool) Loosen hexagon socket head bolts with washer. ① (hexagon wrench : 5 mm) Remove the pilot cover with internal parts. ② Pay attention not to lose the O-ring and the poppet under the pilot cover. ※...
Page 468 Disassembly of the holding valve Remove the pilot cover with the holding valve as described on previous page. ① Do not disassembled internal parts of the pilot cover. ※ Loosen the poppet seat and remove the poppet, spring seat, spring and check. ②...
Page 469 Disassembly of the load check valve and the negative relief valve The load check valve ① Fix the body to suitable work bench. Pay attention not to damage the body. ※ Loosen the plug (hexagon wrench : 10 mm). Remove the spring and the load check valve with pincers or magnet. The negative relief valve ②...
Page 470 Disassembly of the main and overload relief valve Fix the body to suitable work bench. ① Remove the main relief valve. ② (spanner : 32 mm) Remove the overload relief valve. ③ (spanner : 32 mm) When disassembled, tag the relief valve for identification so that they can be reassembled ※...
Page 471 Inspection after disassembly Clean all disassembled parts with clean mineral oil fully, and dry them with compressed air. Then, place them on clean papers or cloths for inspection. Control valve ① Check whole surfaces of all parts for burrs, scratches, notches and other defects. Confirm that seal groove faces of body and block are smooth and free of dust, dent, rust etc.
Page 472 ASSEMBLY General precaution In this assembly section, explanation only is shown. ① For further understanding, please refer to the figures shown in the previous structure & disassembly section. Pay close attention to keeping all seals free from handling damage and inspect carefully for ②...
Page 473 Pilot covers Fit spool covers to the non-spring assembly end of the spool, and tighten the hexagonal socket ① head bolts to the specified torque. ·Hexagon wrench : 5 mm ·Tightening torque : 1.0~1.1 kgf·m (7.2~7.9 lbf·ft) Confirm that O-rings have been fitted. ※...
Page 474: Group 5 Swing Device
GROUP 5 SWING DEVICE (TYPE 1) 1. REMOVAL AND INSTALL OF MOTOR REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the pressure inside the hydraulic tank.
Page 475 2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR STRUCTURE VIEW X 17 18 21 20 29 30 3 2 11 10 1 16 19 18 38 25 26 24 23 41 31 40 23 24 26 25 38 130ZF2SM22 Casing 15 Parking piston 29 Plug Oil seal 16 Spring...
Page 476 DISASSEMBLY For easy assembly, put motor on worktable with the spline side of shaft (3) facing downwards. Lay rubber plate on worktable and take care not ※ to damage the components. Remove snap ring (4) using snap ring plier. Disassemble level gauge assembly (37) using pipe wrench.
Page 477 Unscrew socket bolt (38) (4EA) using 12 mm hexagon wrench. 125LCR8SM07 Remove valve plate (20) from valve casing. Take care not to drop the valve plate (20). ※ 125LCR8SM08 Remove O-ring (18) from valve casing. 125LCR8SM09 Remove plug (33) using 10 mm hexagon wrench and take out anti-rotating valve assembly (32).
Page 478 Remove plug (29) (1EA), plug (27) (2EA) using 4 mm, 6 mm hexagon wrench. 125LCR8SM11 (10) Remove plug (25) using 32 mm socket wrench and separate spring ; spring (24) and check valve (23). (same for the set on opposite side) 125LCR8SM12 (11) Remove spring (16) (24EA) from parking piston.
Page 479 (13) Lay casing down horizontally and remove cylinder block assembly from shaft. And remove all friction plate (13) and separator plate (14). 125LCR8SM17 (14) Separate piston assembly (12), ball guide (10), retainer plate (11) and cylinder spring (9). 125LCR8SM18 (15) Remove O-ring (19) from casing.
Page 480 (17) Disassemble shaft (3) and cylinderical roller bearing (5). Do not remove cylinderical roller bearing (5) ※ unless malfunction is detected, since it is mounted by shrink fit. 125LCR8SM21 (18) Turn casing (1) upside down and remove oil seal (2) using jig. 125LCR8SM22 8-52...
Page 481 ASSEMBLY Even though assembly is accomplished by ※ reversing disassembly steps, be careful of the following. Repair the damaged part when disassemblying ① and prepare parts for exchange in advance. All parts should be cleaned with cleaner, dried ② with compressed air. Sliding surface, O-ring, bearing and oil seal ③...
Page 482 Assemble shaft assembly in casing using urethane hammer. Take care not to damage oil seal. ※ 125LCR8SM25 Insert swash plate (7). Take care not to damage sliding surface. ※ 125LCR8SM26 After applying grease on O-ring (19), insert O-ring in casing (1). 125LCR8SM27 Assemble cylinder spring (9) (9EA) in cylinder block (8).
Page 483 Assemble ball guide (10) in cylinder block. Take care not to damage sliding surface of ※ cylinder block. 125LCR8SM29 Insert piston assembly (12) in retainer plate (11). Do not mix piston with other piston (9EA/1set). ※ Spread sufficient amount of hydraulic oil on ※...
Page 484 (11) Put friction plate (13) in casing. 125LCR8SM33 (12) Put separator plate (14) in casing. Put friction plate and separator plate alternately. ※ 125LCR8SM34 (13) Assemble O-ring (18) in parking piston (15). Apply grease on O-ring. ※ 125LCR8SM35 (14) Assemble parking piston (15) in casing using jig. Pay attention to the hole location of parking ※...
Page 485 (15) Put spring (16) (24EA) in each hole of parking piston. 125LCR8SM37 (16) Assemble plug (27) using 6 mm hexagon wrench. Tightening torque : 4.5±0.45 kgf · m ※ (32.5±3.3 lbf · ft) 125LCR8SM41 (17) Assemble plug (29) using 4 mm hexagon wrench.
Page 486 (19) Assemble plug (33) using 32 mm hexagon wrench. Tightening torque : 14.0±1.0 kgf · m ※ (101±7.2 lbf · ft) 125LCR8SM44 (20) Caulk check valve (23) using jig. (same for the set on opposite side) 125LCR8SM45 (21) Assemble spring (24), plug (25). (in that order) (same for the set on opposite side) Tightening torque : 25±2.5 kgf ·...
Page 487 (23) Assemble O-ring (18) & cylinderical roller bearing (6) in valve casing. Use jig (press fit or cold shrink fit). ※ 125LCR8SM48 (24) Apply grease on steel side of valve plate (20) to prevent plate from sliding. Assemble valve plate with the copper side facing upwards.
Page 488 (27) Assemble snap ring (4) in shaft by using snap ring plier. 125LCR8SM52 (28) Wrap teflon tape 2 or 3 times around the tap part of level gauge assembly (37). And assemble it using pipe wrench. 125LCR8SM53 8-60...
Page 489 3. REMOVAL AND INSTALL OF REDUCTION GEAR REMOVAL Remove the swing motor assembly. For details, see removal of swing motor assembly. Sling reduction gear assembly (1) and remove dowel pin (3) and mounting bolts (2). Remove the reduction gear assembly. ·Reduction gear device weight : 75 kg (165 lb) 13031GE18...
Page 490 4. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR STRUCTURE 2 25 26 27 8 7 15 11 12 14 13 21 15 20 18 19 32 23 9 6 31 24 1 10 16 17 24 22 125LCR2SM23 Ring gear 11 Planetary gear No. 2 21 Carrier pin No.
Page 491 DISASSEMBLY Remove the swing motor, and then place swing reduction gear on the bench. 125LCR8SM60 Disassemble sun gear No.1 (22). 125LCR8SM61 Disassemble carrier No.1 sub assembly. 125LCR8SM62 Carrier No.1 sub assy disassembly Put carrier No.1 sub assembly on the bench, then remove the snap ring (23).
Page 492 Disassemble thrust washer No.1 (upper) (32).(3 pcs) 125LCR8SM64 Disassemble planetary gear No.1 (18). (3 pcs) 125LCR8SM65 Disassemble thrust plate (24). 125LCR8SM66 Disassemble needle bearing No.1 (19). (3 pcs) 125LCR8SM67 8-64...
Page 493 Disassemble thrust washer No.1 (lower) (20). (3 pcs) 125LCR8SM68 (10) After placing spring pin (15) to center of carrier pin No.1 (21) with a jig, disassemble it. (3 pcs) Do not reuse spring pin, carrier and carrier ※ pin. 125LCR8SM69 (11) Disassemble sun gear No.2 (16).
Page 494 Carrier No.2 sub assy disassembly (13) After placing spring pin (15) to center of carrier pin No.2 (14) with a press machine, disassemble it.(3 pcs) Do not reuse spring pin. ※ 125LCR8SM72 (14) Disassemble planetary gear No.2.(3 pcs) 125LCR8SM73 (15) Disassemble thrust plate (24).
Page 495 (17) Disassemble needle bearing No.2 (12). (3 pcs) 125LCR8SM76 (18) Separate ring gear (1) from casing (8). 125LCR8SM77 (19) Loosen bolt (7) (4 pcs), and disassemble lock plate (6). 125LCR8SM78 (20) Disassemble ring nut (5) by using the jig. 125LCR8SM79 8-67...
Page 496 Drive shaft sub assy disassembly (21) Separate drive shaft sub assembly from casing (8). 125LCR8SM80 (22) Disassemble taper roller bearing (3) and oil seal (27) by using a press machine. 125LCR8SM81 (23) Disassemble sleeve (25) and O-ring (26). 125LCR8SM82 (24) Disassemble the outer ring of taper roller bearing (3) in casing (8) by using the jig.
Page 497 ASSEMBLY Even though assembly is accomplished by ※ reversing disassembly steps, be careful of the following. Repair the damaged part when disassemblying ① and prepare parts for exchange in advance. All parts should be cleaned with cleaner, dried ② with compressed air. Sliding surface, O-ring, bearing and oil seal ③...
Page 498 Caulking is performed on the assembled spring pin unit. Caulking To cover pins, implement the caulking in two ※ (two places) places that are located direction of 180 degrees around assembled spring pin. 1.0~2.0 125LCR8SM86 Assemble thrust washer No.1 (lower) (20). (3 pcs) 125LCR8SM87 Assemble needle bearing No.1 (19).(3 pcs)
Page 499 Assemble planetary gear No.1 (18) of which groove is faced downward.(3 pcs) 125LCR8SM90 Assemble thrust washer No.1 (upper) (32). (3 pcs) 125LCR8SM91 Assemble snap ring (23) (3 pcs), complete carrier No.1 sub assembly. Gear rotation state should be smooth. ※ 125LCR8SM92 Carrier No.2 sub assy assembly (10)
Page 500 (11) After spreading grease on thrust washer No.2 (13), assemble it on both upper side and lower side of planetary gear No.2. 125LCR8SM94 (12) Assemble thrust plate (24). 125LCR8SM95 (13) Assemble planetary gear No.2 in the carrier No.2 (10).(3 pcs) Thrust washer No.2 should notseparated.
Page 501 (15) Assemble spring pin (15).(3 pcs) 125LCR8SM98 (16) Caulking is performed on the assembled spring pin unit. Caulking To cover pins, implement the caulking in two ※ (two places) places that are located direction of 180 degrees around assembled spring pin. 1.0~2.0 125LCR8SM99 Drive shaft sub assy assembly...
Page 502 (19) Shrink fit taper roller bearing (3) on drive shaft, complete drive shaft sub assembly. 125LCR8SM102 Casing assembly (20) Press outer ring of the taper bearing in the casing (8) by using the jig. 125LCR8SM103 (21) Press in oil seal (27) by using the jig. Be careful of the direction of the assembly.
Page 503 (23) After fixing drive shaft so that it does not fall, and then turn it over, press taper bearing (4). 125LCR8SM106 (24) Assemble ring nut (5) by using the jig. Tightening torque : 3.5±0.4 kgf · m ※ (25.3±2.9 lbf · ft) 125LCR8SM107 (25) Place lock plate (6) on the ring nut.
Page 504 (27) Press parallel pin (31) by using press machine. 125LCR8SM110 (28) Spread the loctite #515 on the casing with Loctite #515 reference to the right detail view. Loctite should not flow into casing. ※ Detail view 125LCR8SM111 (29) Assemble ring gear (1) in accordance with a pin hole on casing.
Page 505 (31) Assemble sun gear No.2 (16). 125LCR8SM114 (32) Assemble carrier No.1 sub assembly. 125LCR8SM115 (33) Assemble sun gear No.1 (22) of which grinding surface is faced downward. 125LCR8SM116 (34) Fill with gear oil 3.5 liter. 125LCR8SM117 8-77...
Page 506 GROUP 5 SWING DEVICE (TYPE 2) 1. REMOVAL AND INSTALL OF MOTOR REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the pressure inside the hydraulic tank.
Page 507 2. DISASSEMBLY AND ASSEMBLY OF SWING MOTOR STRUCTURE DETAIL K 11 10 9 22 7 37 30 32,33 130ZF2SM02 2 3 4 8 13 12 15 14 17 Body 16 Brake piston 31 Anti-rotating valve Oil seal 17 O-ring 32 Time delay valve Roller bearing 18 O-ring 33 Wrench bolt...
Page 508 DISASSEMBLY Lift the motor out. Clean the motor in kerosene and dry with compressed air. To avoid dust inside the motor, mask all the ※ ports of the motor with tapes. 32038SM01 Loosen the drain plug to discharge oil in the body(1).
Page 509 Remove the relief valve (30) from rear cover (20). 32038SM05 Remove plug (25) from rear cover (20) and spring (28), check (29). Be careful not to damage the check seat ※ assembly. 32038SM06 Remove rear cover (20) from body (1). Then, remove the valve plate (23) from rear cover (20) with care.
Page 510 Remove brake piston (16) from body (1). 32038SM09 (10) Remove the cylinder (9) from the drive shaft (5) with the motor positioned horizontally. Remove ball guide (11), set plate (12), piston (13) and shoe plate (8). 32038SM10 (11) Remove friction plate (14) and separate plate (15) from body (1).
Page 511 (13) Remove the cone of roller bearing (3) by press. Do not reuse bearings. ※ Press Output shaft Roller bearing 32038SM15 (14) Remove bushing (6) and oil seal (2) from body (1). 25038SM05 (15) Remove the needle bearing (21) from the rear cover (20) by using slide hammer bearing puller.
Page 512 (16) When disassembling the relief valve, release the adjusting screw (5). Remove the piston (6), spring seat (8), spring (4) and plunger (3) with the body (1) downwards. 14007A2SM05 This completes disassembly. 8-84...
Page 513 ASSEMBLY Do the reassembly in the reverse procedure of the disassembly. Apply three bond of white color on outer surface of oil seal (2) and insert it to the body (1). 11078SM22 Install the roller bearing (3) to the drive shaft (5).
Page 514 Insert the shoe plate (8) with the body (1) position horizontally. 32038SM28 Insert the ball guide (11) into the cylinder (9). 32038SM29 Install the piston sub-assembly (13) to the set plate (12). 32038SM30 Reassemble the piston assembly (9) to the body (1).
Page 515 Assembly friction plate (14) and separate plate (15) to the body (1). 11078SM26 (10) Insert O-ring (17) inside the body (1). 32038SM33 (11) Reassemble brake piston (16) to the body (1). 32038SM34 (12) Reassemble brake spring (19) to the brake piston (16).
Page 516 (13) When assembling the needle bearing (21), insert the needle bearing (21) into rear cover (20) by hammering. 32038SM36 (14) Reassemble valve plate (23) to the rear cover (20) and reassemble O-ring (18). 32038SM37 (15) Connect the rear cover (20) with the body (1) and tighten the wrench bolt (24).
Page 517 (17) Insert O-rings to the relief valve (30) and reassemble them to rear cover (20). This completes assembly. 32038SM42 8-89...
Page 518 3. REMOVAL AND INSTALL OF REDUCTION GEAR REMOVAL Remove the swing motor assembly. For details, see removal of swing motor assembly. Sling reduction gear assembly (1) and remove dowel pin (3) and mounting bolts (2). Remove the reduction gear assembly. ·Reduction gear device weight : 60 kg (132 lb) 13031GE18...
Page 519 4. DISASSEMBLY AND ASSEMBLY OF REDUCTION GEAR STRUCTURE 29 5 1 10 27 12 13 Oil drain Grease port VIEW A 130ZF2SM03 Casing 12 No.2 pin 23 Stop ring Drive shaft 13 No.2 bushing 24 No. 1 sun gear Cover plate 14 No.2 sun gear 25 Stop ring Spacer...
Page 520 DISASSEMBLY Remove level gauge (38) from the swing motor casing. Pour the gear oil out of reduction gear into ※ the clean bowl to check out the friction decrease. 14W98SM05 Loosen the socket bolts (30) to separate swing motor from reduction gear. 130ZF8sm06 Remove sun gear 1 (24).
Page 521 Disassembling carrier 1 assembly (15). ① Remove stop ring (23). ② Remove planet gear 1(17) from the carrier 1 (16). ③ Using M8 solid drill, crush spring pin (22) so that the pin 1 (19) can be removed by hammering. Remove thrust washer (21).
Page 522 Disassembling carrier 2 assembly (8). ① Using M8 solid drill, crush spring pin (22) so that the pin 2 (12) can be removed. ※ Do not reuse spring pin (22). ② Remove pin 2 (12), planet gear 2 (10) and thrust washer (21) from the carrier 2 (9).
Page 523 (12) Remove roller bearing (6) and oil seal (7) from the drive shaft (2). Do not reuse oil seal (7) once removed. ※ 14W98SM16 (13) Using the bearing disassembly tool, remove roller bearing (5). 14W98SM17 (14) Remove plugs (31, 32) from the casing (1).
Page 524 ASSEMBLY Assemble roller bearing (5) inside the casing (1). 14W98SM17 Assemble the drive shaft (2) into the casing (1) and then install oil seal (7) and roller bearing (6). 14W98SM19 Install stop ring (25) on top of drive shaft (2). 130ZF8sm14 Apply loctite to the tapped holes of casing (1).
Page 525 Assembling carrier 2 assembly (8). ① Install the planet gear 2 (10) and thrust washer inside the carrier 2 (9). ② Assemble the pin 2 (12) to the carrier 2 (9) and then press the spring pin (22) by hammering. ③...
Page 526 (10) Assemble carrier 1 assembly (12) into the ring gear (27). 130ZF8sm20 (11) Hammer 4 knock pins (28) around the ring gear (27). (12) Assemble sun gear 1 (24) to the drive shaft of the swing reduction gear. 130ZF8sm26 (13) Apply loctite to the tapped holes of the ring gear (27) and then mount swing motor onto the ring gear (27).
Page 527: Group 6 Travel Device
GROUP 6 TRAVEL DEVICE 1. REMOVAL AND INSTALL REMOVAL Swing the work equipment 90˚and lower it completely to the ground. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
Page 528 2. TRAVEL MOTOR 49 40 43 42 41 44 64 69 68 67 66 65 62 17 18 21 20 19 22 23 53 55,56 28 24 2 29 88 3 63 7 10 11 71 70 59 77 14 15 13 16 26 27 6 8 130ZF2TM21 Casing...
Page 529 DISASSEMBLY Choose a clean place, remove contaminants (dust, etc) and cleans motor before placing it on worktable. Lay the rubber plate on worktable and take care ※ not to damage the component. 125LCR8TM02 Remove the connector (45) using 21 mm socket wrench.
Page 530 Remove spring seat (42) and spool (40). 125LCR8TM06 Disassemble relief valve assembly (38) using 26 mm socket wrench. (2 sets) 125LCR8TM07 Disassemble cover (32) using 41 mm socket wrench. 125LCR8TM08 Disassemble spring seat (37) and spring (33). (2 sets) 125LCR8TM09 8-102...
Page 531 Separate main spool assembly (31) from rear cover. 125LCR8TM10 (10) Unscrew socket bolt (47) (1EA), (48) (3EA), (49) (6EA) from rear cover. 125LCR8TM11 (11) Remove parallel pin (29). 125LCR8TM12 (12) From rear cover, disassemble valve plate (24) and O-ring (27). Take care not to damage assembly surface of ※...
Page 532 (13) Disassemble restrictor (55, 56) (2EA). Mark the number on restrictor and its hole to ※ avoid confusing (55) and (56). 125LCR8TM14 (14) Remove plug (52). 125LCR8TM15 (15) Remove restrictor (34) and spring (35). (2 sets) Do not confuse restrictor (34) and check valve ※...
Page 533 (17) Remove check valve (50) and spring (51). (2 sets) Do not confuse restrictor (34) and check valve ※ (50). Do not confuse spring (35) and spring (51). ※ Do not lose spring. ※ Do not mix spring with other springs. ※...
Page 534 (21) From parking piston separate O-ring (20) and back-up ring (21). 125LCR8TM22 (22) Lay casing down horizontally and remove cylinder block assembly, friction plate (17) (3EA) and separator plate (18) (4EA). 125LCR8TM23 (23) Separate retainer plate (15) and piston assembly (16).
Page 535 (25) Disassemble swash plate (11) and pivot (10). Take care not to damage sliding surface. ※ 125LCR8TM26 (26) Disassemble shaft (6) and ball bearing (7). Do not remove ball bearing unless malfunction is ※ detected, since it is mounted by shrink fit. 125LCR8TM27 (27) Disassemble 1, 2 speed piston (4) and steel ball...
Page 536 (29) Turn casing (1) upside down and remove oil seal (3) using jig. 125LCR8TM30 8-108...
Page 537 ASSEMBLY Even though assembly is accomplished by ※ reversing disassembly steps, be careful of the following. Repair the damaged part when disassemblying ① and prepare parts for exchange in advance. All parts should be cleaned with cleaner, dried ② with compressed air. Sliding surface, O-ring, bearing and oil seal ③...
Page 538 After applying grease on pivot (10), insert steel ball in casing. 125LCR8TM33 After assembling piston seal (5) and steel ball (9) in 1, 2 speed piston (4), insert piston in hole of casing. Check whether piston sticks in hole. ※ Use piston seal jig.
Page 539 Assemble spring (13) (9ea) and ball guide (14) in cylinder block (12) in that order. 125LCR8TM37 Insert piston assembly (16) in retainer plate (15) and assemble them in cylinder block. Spread hydraulic oil on piston assembly. ※ Take care not to damage each component. ※...
Page 540 (11) Insert back-up ring & O-ring in parking piston. 125LCR8TM41 (12) Align the pin hole of parking piston (19) with oil hole of casing, assemble them using jig. Spread grease on O-ring and back-up ring. ※ Take care not to damage components. ※...
Page 541 (15) Assemble check valve (50) and spring (51) in order. Do not confuse check valve (50) and restrictor ※ (34). Do not confuse spring (51) and spring (35) ※ 125LCR8TM45 (16) Clamp plug (52) using 5 mm hexagon wrench. Tightening torque : 3.0±0.3 kgf · m ※...
Page 542 (19) Clamp plug (54). Tightening torque : 4.5±0.5 kgf · m ※ (32.5±3.6 lbf · ft) 125LCR8TM49 (20) Assemble restrictor (55) and (56) in rear cover. Check whether the restrictor is placed in exact ※ hole. Do not confuse (55) and (56). ※...
Page 543 (23) After spreading grease sufficiently to the bottom side of valve plate (24), assemble valve plate in rear cover by matching its holes with pins. Take care not to damage sliding surface. ※ Pay attention to the assembly direction. ※ 125LCR8TM53 (24) Assemble O-ring (27) in rear cover.
Page 544 (27) Settle cover (32). Tightening torque : 15±1.5 kgf · m ※ (108±10.8 lbf · ft) 125LCR8TM57 (28) Insert relief valve (38) in rear cover. Tightening torque : 15±1.8 kgf · m ※ (108±13.0 lbf · ft) 125LCR8TM58 (29) After clamping connector (45) to rear cover, assemble spool (40).
Page 545 (31) After assembling spring (44) in order, clamp plug (41). Tightening torque : 5.5±0.5 kgf · m ※ (39.8±3.6 lbf · ft) 125LCR8TM61 8-117...
Page 546 TRAVEL REDUCTION GEAR DISASSEMBLY While travel reduction gear is tilted to one side disassemble PF3/8 plug (82), remove gear oil and place motor sideto the bench. 125LCR8TM70 Disassemble cover (80) by unscrewing the M10 bolts (81) (12 pcs). 125LCR8TM71 Disassemble sun gear No.1 (78). 125LCR8TM72 Disassemble carrier No.1 assembly.
Page 547 Carrier No. 1 sub assy disassembly Disassemble M8 bolt (76) from the carrier assembly. (3 pcs) 125LCR8TM74 Disassemble thrust plate No.1 (75) from the carrier assembly. 125LCR8TM75 Disassemble planetary gear No.1 (72).(3 pcs) 125LCR8TM76 Disassemble needle bearing (73).(3 pcs) Do not disassemble inner race in the absence of ※...
Page 548 Disassemble Sun gear No.2 (70). 125LCR8TM78 Disassemble M10 bolt (64).(4 pcs) 125LCR8TM79 Disassemble thrust washer No.2 (65).(4 pcs) 125LCR8TM80 Disassemble planetary gear No.2 (66).(4 pcs) 125LCR8TM81 8-120...
Page 549 Disassemble needle bearing No.2 (67).(4 pcs) 125LCR8TM82 Disassemble thrust plate No.2 (69).(4 pcs) Do not disassemble inner race in the absence of ※ abnormalities. 125LCR8TM83 Disassemble M10 bolt (89), plain washer (88) and M8 screw (77). 125LCR8TM84 Disassemble lock plate (63). 125LCR8TM85 8-121...
Page 550 Disassemble nut ring (62) by using the jig. 125LCR8TM86 Disassemble ring gear assembly (59) from motor assembly. 125LCR8TM87 Disassemble folating seal assembly (61) from ring gear assembly and motor assembly. 125LCR8TM88 Disassemble bearing (60) (2ea) from ring gear assembly. Do not disassemble bearing in the absence of ※...
Page 551 TRAVEL REDUCTION GEAR ASSEMBLY Even though assembly is accomplished by ※ reversing disassembly steps, be careful of the following. Repair the damaged part when disassemblying ① and prepare parts for exchange in advance. All parts should be cleaned with cleaner, dried ②...
Page 552 Assemble planetary gear No.1 (72) of which groove is faced downward. (3 places) 125LCR8TM92 Assemble thrust plate No.1 (75). 125LCR8TM93 After spreading loctite #242, assemble the M8 bolt (76).(3 pcs) Tightening torque : 2.7 ± 0.3 kgf · m ※ After the assembly, instantly check the noise and ※...
Page 553 After turning ring gear over, assemble bearing the same way. Be care of nick and safety when turn ring gear ※ over. 125LCR8TM96 Assemble folating seal assembly (61) by usingthe jig. After assembling, wipe steel-lined section with ※ alcohol. Flatness deviation has to be less than 1 mm. ※...
Page 554 After assembling nut ring (62) by using the jig, disassemble the clamping. Tightening torque : 60 kgf · m (434 lbf · ft) ※ 125LCR8TM100 Place lock plate (63) on the nut ring groove. Select best position from one of 4 casing hole to ※...
Page 555 Shrink fit the inner race No.2 (68).(4 pcs) 125LCR8TM104 Assemble thrust plate No.2 (69).(4 pcs) 125LCR8TM105 Assemble needle bearing No.2 (67).(4 pcs) 125LCR8TM106 Assemble planetary gear No.2 (66).(4 pcs) Grooves of planetary gear will be facingup. ※ 125LCR8TM107 8-127...
Page 556 Assemble thrust washer No.2 (65).(4 pcs) 125LCR8TM108 After spreading loctite #242, assemble the M10 bolt (64).(4 pcs) Tightening torque : 5.5 ± 0.6 kgf · m ※ (39.8 ± 4.3 lbf · ft) 125LCR8TM109 Assemble sun gear No.2 (70). 125LCR8TM110 Assemble carrier No.1 assembly.
Page 557 Assemble sun gear No.1 (72). 125LCR8TM112 Spread the loctite #515 on the cover (80) with reference to the right detail view. Detail view 125LCR8TM114 Place cover (80) to fit the bolt holes. 125LCR8TM115 After spreading loctite #242, assemble the M10 bolt (81).(12 pcs) Tightening torque : 6.3 ±...
Page 558 Inject the 2.3 ± 0.3 liter gear oil to PF3/8 tap section. 125LCR8TM117 After assembling the O-ring (83) to the plug (82), assemble it to the cover. (3 pcs) Tightening torque : 5.5 ± 0.5 kgf · m ※ (39.8 ± 3.6 lbf · ft) 125LCR8TM118 8-130...
Page 559: Group 7 Rcv Lever
GROUP 7 RCV LEVER 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
Page 560 2. DISASSEMBLY AND ASSEMBLY STRUCTURE 300L2RL06 Case Plug 15 Joint assembly 22 Nut Bushing Push rod 16 Swash plate 23 Boot Spool 10 O-ring 17 Adjusting nut 24 Last guard filter Shim 11 Rod seal 18 Bushing 25 O-ring Spring 12 Plate 19 Plug 26 O-ring...
Page 561 TOOLS AND TIGHTENING TORQUE Tools Tool name Remark Allen wrench Spanne (+) Driver Length 150 (-) Driver Width 4~5 Torque wrench Capable of tightening with the specified torques Tightening torque Torque Part name Item Size kgf·m lbf·ft Joint 25.3 Swash plate 5.0±0.35 36.2±2.5 Adjusting nut...
Page 562 DISASSEMBLY Procedures are based on the type M1. ※ Clean pilot valve with kerosene. Put blind plugs into all ports ※ Fix pilot valve in a vise with copper (or lead) sheets. Remove end of boot (23) from case (1) and take it out upwards.
Page 563 Loosen adjusting nut (17) and swash plate (16) with spanners on them respectively, and remove them. 36078RL01 36078RL02 Turn joint anticlockwise to loosen it, utilizing jig (Special tool). When return spring (7) is strong in force, ※ plate (12), plug (8) and push rod (9) will come up on loosening joint.
Page 564 Remove plate (12). 36078RL05 When return spring (7) is weak in force, plug (8) stays in casing because of sliding resistance of O-ring. Take it out with minus screwdriver. ※ Take it out, utilizing external periphery groove of plug and paying attention not to damage it by partial loading.
Page 565 (12) Take push rod (9) out of plug (8). 36078RL11 (13) Remove O-ring (10) and seal (11) from plug (8). Use small minus screwdriver or so on to remove this seal. 36078RL12 36078RL13 8-137...
Page 566 (14) Remove lock nut (22) and then boot (23). 36078RL14 2507ARL10 8-138...
Page 567 (15) Cleaning of parts Put all parts in rough cleaning vessel ① filled with kerosene and clean them (rough cleaning). If dirty part is cleaned with kerosene just ※ after putting it in vessel, it may be damaged. Leave it in kerosene for a while to loosen dust and dirty oil.
Page 568 ASSEMBLY Put shim (4), springs (5) and spring seat (6) onto spool (3) in this order. 36078RL16 Assemble spring (7) into casing (1). Assemble reducing valve subassembly into casing. Assemble them to their original positions. ※ 36078RL18 Assemble O-ring (10) onto plug (8). 36078RL19 Assemble seal (11) to plug (8).
Page 569 Assemble push rod (9) to plug (8). Apply working oil on push-rod surface. ※ 36078RL21 Assemble plug subassembly to casing. When return spring is weak in force, ※ subassembly stops due to resistance of O-ring. 36078RL22 When return spring is strong in force, assemble 4 sets at the same time, utilizing plate (12), and tighten joint (15) temporarily.
Page 570 (10) Assemble swash plate (16) to joint (15). Screw it to position that it contacts with 4 ※ push rods evenly. Do not screw it over. ※ 36078RL25 (11) Assemble adjusting nut (17), apply spanner to width across flat of plate (16) to fix it, and tighten adjusting nut to the specified torque.
Page 571 (13) Fit boot (23) and lock nut (22), and handle subassembly is assembled completely. 2507ARL10 36078RL27 (14) Pull out cord and tube through adjusting nut hole provided in direction 60。to 120。from casing hole. 1408DA66 (15) Assemble bushing (18) to plate and pass cord and tube through it.
Page 572 (16) Determine handle direction, tighten lock nut (22) to specified torque to fix handle. 300E8RL05 (17) Apply grease to rotating section of joint and contacting faces of disk and push rod. 300E8RL06 (18) Assemble lower end of bellows to casing. (19) Inject volatile rust-preventives through all ports and then put blind plugs in ports.
Page 573: Group 8 Turning Joint
GROUP 8 TURNING JOINT 1. REMOVAL AND INSTALL REMOVAL Lower the work equipment to the ground and stop the engine. Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the 13031GE18 pressure inside the hydraulic tank.
Page 574 2. DISASSEMBLY AND ASSEMBLY STRUCTURE ※ Descriptions are based on the without dozer blade. 14098TJ03 Shim 11 Wear ring Shaft Slipper seal 12 Retainer ring Cover O-ring 13 Plug Spacer O-ring 14 Hexagon bolt Shim 10 O-ring 15 Spring washer 8-146...
Page 575 DISASSEMBLY ※ Before the disassembly, clean the turning joint. Remove bolts (14), washer (15) and cover (3). 21078DA10 Remove shim (6) and O-ring (10). Remove retainer ring (12), spacer (4) and shim (5). 21078DA11 Place hub (1) on a V-block and by using a Secure with hand wood buffer at the shaft end, hit out shaft Wooden block...
Page 576 ASSEMBLY Clean all parts. ※ As a general rule, replace oil seals and ※ O-ring. Coat the sliding surfaces of all parts with ※ engine oil or grease before installing. Fix seven slipper seal (7) and O-ring (9), two wear ring (11) to hub (1). Fit O-ring (8) to shaft (2).
Page 577 Install cover (3) to body (1) and tighten bolts (14). ·Torque : 10~12.5 kgf·m (72.3~90.4 lbf·ft) 21078DA10 8-149...
Page 578: Group 9 Boom, Arm, Bucket And Dozer Cylinders
GROUP 9 BOOM, ARM, BUCKET AND DOZER CYLINDERS 1. REMOVAL AND INSTALL BUCKET CYLINDER Removal Expand the arm and bucket fully, lower ※ the work equipment to the ground and stop the engine. Operate the control levers and pedals ※ several times to release the remaining pressure in the hydraulic piping.
Page 579 Sling bucket cylinder assembly (8) and ④ remove bolt (6) then pull out pin (5). Remove bucket cylinder assembly (8). ⑤ ·Weight : 78 kg (172 lb) 130ZF8DA83 Install Carry out installation in the reverse order ① to removal. When aligning the mounting position of the pin, do not insert your fingers in the pin hole.
Page 580 ARM CYLINDER Removal Expand the arm and bucket fully, lower the ※ work equipment to the ground and stop the engine. Operate the control levers and pedals ※ several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the ※...
Page 581 Sling arm cylinder assembly (8) and ⑥ remove bolt (7) then pull out pin (6). Remove arm cylinder assembly (8). ⑦ ·Weight : 118 kg (260 lb) 130ZF8CY21 Install Carry out installation in the reverse order ① to removal. When aligning the mounting position of the pin, do not insert your fingers in the pin hole.
Page 582 BOOM CYLINDER Removal Expand the arm and bucket fully, lower ※ the work equipment to the ground and stop the engine. Operate the control levers and pedals ※ several times to release the remaining pressure in the hydraulic piping. Loosen the breather slowly to release the ※...
Page 583 ⑤ Disconnect boom cylinder hoses (7) and put plugs on cylinder pipe. 130ZF8CY25 ⑥ Remove bolt (9) and pull out pin (8). ⑦ Remove boom cylinder assembly (6). ·Weight : 96 kg (212 lb) 130ZF8CY26 Install ① Carry out installation in the reverse order to removal.
Page 584 2. DISASSEMBLY AND ASSEMBLY STRUCTURE Bucket cylinder 22,21 12,11 10,9 8 6,7 14,13 3 16 17 Internal detail 37,38,39 40,2 4, 40 35,36 25,25,27,28 32,31 33,34 29,30 25,25,27,28 130ZF8CY01 Tube assembly 15 O-ring 29 O-ring Pin bushing 16 Cushion ring 30 Pipe assembly Rod assembly 17 Piston...
Page 585 Arm cylinder 12,11 10,9 20 19 18 21,22 27 7 13,14 16 17 Internal detail 41,42,43 39,40 37,38 4,44 2,44 33,34 28, 29, 30, 31, 32 35,36 130ZF8CY02 Tube assembly 16 Cushion ring 31 O-ring Pin bushing 17 Piston 32 Plug Rod assembly 18 Piston seal 33 Pipe band assembly...
Page 586 Boom cylinder 12,11 10,9 16 17 20 19 18 21,22 23 24 14,13 Internal detail 37,36 26,27,28,29 33,32 4,42 35,34 2,42 30,31 41,40,39,38 130ZF8CY03 Tube assembly 16 Cushion ring 31 O-ring Pin bushing 17 Piston 32 Spring washer Rod assembly 18 Piston seal 33 Hexagon socket bolt Pin bushing...
Page 587 Dozer cylinder ① Type 1 8,9 19 3 5,6 7 4 10, 11 13,14 12 15 16 17,18 23 27 25 20,21 26 24 130ZF8CY04 1 Tube assembly 10 O-ring 19 Hexagon socket head bolt 2 Rod assembly 11 Back up ring 20 Pin bushing 3 Gland 12 Piston...
Page 588 ② Type 2 12,11 23 5 10,9 8 6,7 14,13 20,21 19 17 18 24 25 2,30 4, 30 29,28 130ZF8CY05 Tube assembly 12 Retaining ring 23 Hexagon socket bolt Pin bushing 13 O-ring 24 Check valve Rod assembly 14 Back up ring 25 Hexagon socket bolt Pin bushing 15 O-ring...
Page 589 TOOLS AND TIGHTENING TORQUE Tools Tool name Remark Allen wrench Spanner (-) Driver Small and large sizes Torque wrench Capable of tightening with the specified torques Tightening torque Torque Part name Item Size kgf·m lbf·ft Bucket cylinder 17.9±1.8 129±13.0 Boom cylinder 19±1.0 137±7.2 Socket head bolt...
Page 590 DISASSEMBLY Remove cylinder head and piston rod ※ Procedures are based on the boom cylinder. ① Hold the clevis section of the tube in a vise. ※ Use mouth pieces so as not to damage the machined surface of the cylinder tube.
Page 591 Note that the plated surface of rod assembly (1) is to be lifted. For this reason, do not use a wire sling and others that may damage it, but use a strong cloth belt or a rope. ⑤ Place the removed rod assembly on a wooden V-block that is set level.
Page 592 Disassemble the piston assembly Remove wear ring (19). ① Remove dust ring (20) and piston seal ② (18). Exercise care in this operation not to ※ damage the grooves. 125LCR8DA33 Disassemble cylinder head assembly 12 11 10 9 8 14 13 Remove back up ring (14) and O-ring ①...
Page 593 ASSEMBLY Assemble cylinder head assembly ※ Check for scratches or rough surfaces if found smooth with an oil stone. ① Coat the inner face of rod cover (5) with hydraulic oil. 21078DA37 ② Coat dust wiper (11) with grease and fit Press here dust wiper (11) to the bottom of the hole (Straight down)
Page 594 Fit back up ring (14) to rod cover (5). ⑤ Put the backup ring in the warm water of ※ 30~50˚C . Fit O-ring (13) and O-ring (15) to rod ⑥ cover (5). 130ZF8DA37 Assemble piston assembly Check for scratches or rough surfaces. ※...
Page 595 Install piston and cylinder head Cylinder head assembly Fix the rod assembly to the work bench. ① Apply hydraulic oil to the outer surface of ② Rod assembly rod assembly (3), the inner surface of piston and cylinder head. Insert cylinder head assembly to rod ③...
Page 596 Bucket cylinder ⑦ Tighten the set screw (21). ·Tightening torque 1.5 kgf·m (10.8 lbf ·ft) 130ZF8DA45 Overall assemble Fix with a bar ① Place a V-block on a rigid work bench. Mount the tube assembly (1) on it and Lift fix the assembly by passing a bar through the clevis pin hole to lock the Straight...
Page 597: Group 10 Undercarriage
GROUP 10 UNDERCARRIAGE 1. TRACK LINK REMOVAL Move track link until master pin is over Master pin front idler in the position put wooden block as shown. Loosen tension of the track link. If track tension is not relieved when the ※...
Page 598 2. CARRIER ROLLER Frame REMOVAL Grease Loosen tension of the track link. valve 8-162(1) Jack up the track link height enough to permit carrier roller removal. Jack Carrier roller 8-162(2) Loosen the lock nut (1). Carrier roller Open bracket(2) with a screwdriver, push out from inside, and remove carrier roller assembly.
Page 599 3. TRACK ROLLER Frame REMOVAL Grease Loosen tension of the track link. valve 8-163(1) Using the work equipment, push up track frame on side which is to be removed. After jack up the machine, set a block ※ under the unit. 90~110 140Z98UC05 Remove the mounting bolt (1) and draw...
Page 600 4. IDLER AND RECOIL SPRING REMOVAL Remove the track link. For detail, see removal of track link. 130ZF8UC10 Sling the recoil spring (1) and pull out idler and recoil spring assembly from track frame, using a pry. ·Weight : 215 kg (474 lb) 130ZF8UC11 Remove the bolts (2), washers (3) and separate ilder from recoil spring.
Page 601 DISASSEMBLY AND ASSEMBLY OF IDLER Structure 21078DA43 Shell Bushing Spring pin Shaft Bracket Plug Seal assembly O-ring 8-173...
Page 602 Disassembly Press ① Remove plug and drain oil. ② Draw out the spring pin (7), using a press. 8-166(1) ③ Pull out the shaft (2) with a press. Press ④ Remove seal (3) from idler (1) and bracket (5). ⑤ Remove O-ring (6) from shaft.
Page 603 Assembly Before assembly, clean the parts. ※ Press Coat the sliding surfaces of all parts with ※ oil. Cool up bushing (4) fully by some dry ice ① and press it into shell (1). Do not press it at the normal temperature, or not knock in with a hammer even after the cooling.
Page 604 ⑥ Install bracket (5) attached with seal (3). 8-168(1) ⑦ Knock in the spring pin (7) with a hammer. 8-168(2) ⑧ Lay bracket (5) on its side. Supply engine oil to the specified level, and tighten plug. 8-168(3) 8-176...
Page 605 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING Structure 7, 8 130ZF8UC30 Body Lock plate 11 Dust seal Tie bar Bolt 12 Rod assembly Spring Spring washer 13 Grease valve Bracket Rod packing 14 Spring pin Lock nut 10 Back up ring 8-177...
Page 606 Disassembly Press ① Apply pressure on spring (3) with a press. The spring is under a large installed load. ※ This is dangerous, so be sure to set properly. 7, 8 ·Spring set load : 8497 kg (18733 lb) Remove bolt (7), spring washer (8) and ②...
Page 607 Assembly Install dust seal (11), back up ring (10) and rod seal (9) to body (1). When installing dust seal (11) and rod ※ seal (9), take full care so as not to damage the lip. 130ZF8UC33 ② Pour grease into body (1), then push in rod (12) by hand.
Page 608 Lighten the press load and confirm the ⑥ Press set length of spring (3). After the setting of spring (3), install lock ⑦ plate (6), spring washer (8) and bolt (7). 7, 8 130ZF8UC36 8-180...
Page 609: Group 11 Work Equipment
GROUP 11 WORK EQUIPMENT 1. STRUCTURE SECTION A SECTION B SECTION C SECTION A SECTION B SECTION C 130ZF8DA44 8-181...
Page 610 2. REMOVAL AND INSTALL BUCKET ASSEMBLY Removal Lower the work equipment completely to ① ground with back of bucket facing down. 130ZF8BK01 Remove nut (1), bolt (2) and draw out the ② pin (B). 130ZF8BK02 Remove nut (3), bolt (4) and draw out the ③...
Page 611 ARM ASSEMBLY Removal Loosen the breather slowly to release ※ the pressure inside the hydraulic tank. Escaping fluid under pressure can penetrated the skin causing serious injury. Remove bucket assembly. ① For details, see removal of bucket 130ZF8AM01 assembly. Disconnect bucket cylinder hose (1). ②...
Page 612 BOOM ASSEMBLY Removal Remove arm and bucket assembly. ① For details, see removal of arm and bucket assembly. ② Remove boom cylinder assembly from boom. For details, see removal of boom cylinder assembly. 130ZF8BM01 Disconnect head lamp wiring. ③ Disconnect bucket cylinder hose (2) ④...

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