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SWE210NB
1、safety precautions
This chapter provides safety guidelines during maintenance and service for personnel’s safe
operation.
2、chapter overview
This chapter provides dimensions, technical specifications, and working range information of
complete machine and master parts.
This chapter illuminates structure and function of individual parts, and provides reference
about trouble shooting, maintenance and service.
This chapter provides instruction for inspection before or after service, and all adjustment
required in maintenance and service.
This chapter provides all procedure that should be followed during disassembly and assembly,
and all safety precautions required in operation.
6、others
This chapter provides hydraulic system & electrical drawing, and air conditioning system
drawing (if equipped with air conditioning).
(Note: design and specification are subject to change without notice and obligation)
I
CONTENTS
1. Safety precaution........................................................................................................................................ 1
1.1 Gerneral attention ................................................................................................................................. 1
1.2 Prepareation.......................................................................................................................................... 1
1.3 Attention in working hours ................................................................................................................... 2
2. Summary .................................................................................................................................................... 3
2.1 Dimensional drawing............................................................................................................................ 3
2.1.1 Drawing ............................................................................................................................................. 3
2.1.2 Dimention datas .......................................................................................................................... 3
2.1.3 Working range figure .................................................................................................................. 4
2.1.4 Working range datas ................................................................................................................... 4
2.2 Technical specification ......................................................................................................................... 5
2.3 Weight datas ......................................................................................................................................... 6
2.4 Engine oil, fuel and coolant.................................................................................................................. 7
3. Structure function and maintenance standard............................................................................................. 8
3.1 For mechanical device.......................................................................................................................... 8
3.1.1. Engine parts...................................................................................................................................... 8
3.1.2 Cool system ................................................................................................................................ 9
3.1.3 Power drive system................................................................................................................... 10
3.1.4 End drive (traveling motor reductor) ........................................................................................ 11
3.1.5 Swing bearing ........................................................................................................................... 11
3.1.6 Track frame and tension spring................................................................................................. 12
3.1.7 Guiding wheel........................................................................................................................... 13
3.1.8 Carrier roller ............................................................................................................................. 14
3.1.9 Thrust wheel ............................................................................................................................. 15
3.1.10 Track plate .............................................................................................................................. 16
3.1.11 working device........................................................................................................................ 17
3.2 Function and maintenance standard for hydraulic equipments .......................................................... 18
3.2.1 Hydraulic arrangement plan ..................................................................................................... 18
3.2.2 hydraulic oil tank ...................................................................................................................... 20
3.2.3 Hydraulic pump ........................................................................................................................ 21
3.2.4 Swing motor ............................................................................................................................. 34
3.2.5 Pilot control valve..................................................................................................................... 42
3.2.6 Electromagnetic valve .............................................................................................................. 47
3.2.7 Pilot filter.................................................................................................................................. 48
3.2.8 Travel motor ............................................................................................................................. 48
3.2.9 Multiple way valve ................................................................................................................... 56
3.2.10 Rupture valve.......................................................................................................................... 73
3.3 For electric equipments ...................................................................................................................... 78
3.3.1 Power supply circuit ................................................................................................................. 78
3.3.2 Starting circuit(key switch:START) ................................................................................. 79
3.3.3 Pilot closing circuit(key switch:ON) ................................................................................ 80
3.3.4 Engine closing circuit(key switch:OFF)........................................................................... 81
3.3.5 Wiper and scrubber circuit........................................................................................................ 82
3.3.6 Controller.................................................................................................................................. 83
3.3.7 Engine control........................................................................................................................... 86
3.3.8 ECM system ............................................................................................................................. 87
3.3.9 Multifunction moniter system................................................................................................... 92
4. Test and adjustment and Failure Diagnosis .............................................................................................. 95
4.1 Test and adjustment of mechanical structure device........................................................................... 95
4.1.1 Standard table of engine spare parts ......................................................................................... 95
4.1.2 Standard table of complete machine ......................................................................................... 96
4.2 Test and adjustment of hydraulic device........................................................................................... 105
4.2.1 Test and adjustment of system working pressure.................................................................... 105
4.2.2 Test and adjustment of pilot oil supply pressure..................................................................... 109
II
4.2.3 Inspection for main return oil pressure of the system..............................................................111
4.2.4 Inspection for output pressure of the pilot solenoid valve ...................................................... 113
4.2.5 Measuring for output pressure of pilot control valve.............................................................. 115
4.2.6 Measuring for hydraulic drift of working devices .................................................................. 117
4.2.7 Release the residual pressure in hydraulic oil circuits ............................................................ 118
4.2.8 Check for leakage volume ...................................................................................................... 118
4.2.9 Adjusting of main pump ......................................................................................................... 121
4.2.10 Devices exhaust .................................................................................................................... 125
4.3 Fault diagnose................................................................................................................................... 126
4.3.1 Inspection before fault diagnose ............................................................................................. 126
4.3.2 Fault sorts and check methods ................................................................................................ 127
5. Disassembly and assembly ..................................................................................................................... 133
5.1 How to read this manual................................................................................................................... 133
5.2 Instruction during operation ............................................................................................................. 134
5.3 Working device ASSY assemly and disassembly ............................................................................. 137
5.4 Counterweight ASSY assembly and disassembly ............................................................................ 139
5.5 Cab ASSY assembly and disassembly.............................................................................................. 140
5.6 Engine disassemble and assembly.................................................................................................... 142
5.7 Radiator ASSY disassembly and assembly ...................................................................................... 144
5.8 Hydraulic pump ASSY disassembly and assembly .......................................................................... 147
5.9 Hydraulic pump body disassembly and assembly ............................................................................ 150
5.10 Main pump adjustor disassembly and assembly............................................................................. 158
5.11 Rotary motor ASSY disassembly and assembly ............................................................................. 166
5.12 Rotary motor noumenon disassembly and assembly...................................................................... 168
5.12 Handle pilot valve disassembly and assembly................................................................................ 178
5.13 Multiple way valve ASSY disassemble and assemble.................................................................... 185
5.14 Travel motor ASSY disassembly and assembly ............................................................................. 188
5.15 Central rotary joint ASSY disassembly and assembly.................................................................... 190
5.16 Hydraulic tank ASSY. disassembly and assembly.......................................................................... 191
5.17. Carrier roller ASSY disassembly and assembly ............................................................................ 194
5.18. Thrust wheel ASSY disassembly and assembly ............................................................................ 195
5.19. Guiding wheel ASSY. disassembly and assembly ......................................................................... 196
5.20. Tension device disassembly and assembly .................................................................................... 199
5.21 Sproket wheel disassembly and assembly ...................................................................................... 202
5.22. Track shoe ASSY disassembly and assembly................................................................................ 203
5.23. Rotary bearing ASSY disassembly and assembly ......................................................................... 207
5.24. Rotary table ASSY disassembly and assembly.............................................................................. 208
5.25. Air-conditioning ASSY disassembly and assembly....................................................................... 210
6. Figures and others .................................................................................................................................. 213
6.1 Hydraulic system schematic diagram ............................................................................................... 213
6.2 Electrical system drawing................................................................................................................. 214
III
1. Safety precaution
1
4. Clean the steps by which you get on and off the machine and the pedals. When you get on or
off the machine, use handrails, steps or gangboards. Do not just jump in or off the machine. If
handrails, steps or gangboards are not available for use, racks should be used in sake of safety.
1.3 Attention in working hours
1. When disassembling the cover of oil filling opening, oil drain plug or hydraulic
measurement plug, release them gradually to prevent the oil from ejecting.
a) When disconnect or disassemble pipes for oil, water or gas supply, release the pressure
in pipeline first.
2. When the engine flames out and the water and oil in the pipeline are hot, be careful to
avoid being scalded.
3. Disconnect battery cable prior to operation. Make sure to disconnect negative terminal first.
4. When lifting heavy loads of parts, use winch or crane to check steel rope, chain and
hook for damage.Be certain to use over rated power crane.Assembling the crane at correct
place.Operating a winch or crane slowly to prevent lifting parts colliding with other objects and
do not work on the parts which is lifted by winch or crane.
5. When removing caps under internal pressure or spring pressure, maintain two bolts on
the other side. With pressure relieved, loosen bolts to remove.
6. Pay attention not to crash or damage cable during parts removal. Failure to do so can cause
electric spark.
7. During pipeline disassembly, prevent any leakage of fuel or oil from pipeline. In case of
any leakage on the floor, wipe it immediately, because fuel or oil on the floor can result in
personnel slip or fire.
8. Do not clean parts with gasoline in normal situation. However a small amount of gasoline is
allowed in an exceptional case.
9. Make sure to position all parts properly, and replace defective parts with new ones.
10. During hose or cable installation, do not let them make contact with other parts.
11. Make sure all high-pressure hose is free of distortion during hose installation. Damaged
pipeline is of highly dangerous. Therefore, pay undivided attention to it during high-pressure
hose installation. In addition, check connecting piece for proper installation.
12. Always operate with specified tightening torque during assembly or disassembly. When
assembling protective parts (e.g. protective guard) or installing other parts with sharp vibration
and high-speed rotation. Make sure they are properly installed.
13. When aligning two holes, do not insert fingers or hands into them so as to prevent finger
from being caught in.
14. Make sure all tools for measuring purpose are properly installed before attempting hydraulic
pressure measurement or other measuring procedures.
15. During track disassembly or assembly, please note that track may disengage out of place
abruptly; make sure the area on both end of the track is clear of persons.
2
2. Summary
2.1 Dimensional drawing
2.1.1 Drawing
Platform to ground
C mm 1060
distance
Chassis to ground
I mm 470
distance
3
2.1.3 Working range figure
4
2.2 Technical specification
Model SWE210NB
Operation weight kg 21
5
2.3 Weight datas
The table can de referred during maintenance or transportion.
Unit:kg
Model SWE210NB
Uppercarriage 8084
Undercarriage 8011
Boom 2470
Arm 1195
Bucket 828
Cab 294
6
2.4 Engine oil, fuel and coolant
Ambient temperature
-22 -4 14 32 50 68 86 104 Speci Refill
1220F fied capac
capac ity
-30 -20 -10 0 10 20 30 40 it
500C
SAE 30
SAE 10W
Engine
oi SAE 15W-40
SAE 5W-30
Swing reductor
API-GL-4 85W-90
API-GL-5 80W-90
Travel reductor
GB252 premium 0#
Swing
mechanism
grease chamber Grease NLGI No.2
Oil cup
7
3. Structure function and maintenance standard
3.1 For mechanical device
3.1.1. Engine parts
8
3.1.2 Cool system
9
3.1.3 Power drive system
SWE210NB
Engine 750201000121
Electromagnetic
730305000085
valve group
Swing motor 730250000241
10
3.1.4 End drive (traveling motor reductor)
11
3.1.6 Track frame and tension spring
1.Track frame
6.Driving wheel
7.Traveling mortor
8.Tension spring
9.Guiding wheel
12
3.1.7 Guiding wheel
Unit:mm
satandard
NO. Checking item measures
Standard dimension Repayment limit
2 Flange width 84 -
13
3.1.8 Carrier roller
Unit:mm
Standard
NO. Checking item Measures
Standard dimention Repair limit
Flange outer
1 φ145 -
diameter
Track bearing
2 surface outer φ120 φ106
diameter
Repair or
3 Total width 170 - replace
Track bearing
4 43 -
surface width
5 Flange width 14 -
14
3.1.9 Thrust wheel
Unit:mm
Standard
NO. Checking item Measures
Standard dimention Repair limit
Flange outer
1 φ188 -
diameter
Track bearing
2 surface outer φ156 φ144
diameter
Repair or
3 Total width 230 - replace
Track bearing
4 174 -
surface width
Inner side
5 85 -
width
15
3.1.10 Track plate
Unit:mm
Standard
NO. Checking item Measures
Standard dimention Repair limit
1 Hight 25 15
Repair or
Thickness replace
2 35 -
16
3.1.11 working device
1.Bucket 5.Arm
2.Connecting rod 6.Arm cylinder
3.Rocker arm 7.Boom
4.Bucket oil cylinder 8.Boom cylind
17
3.2 Function and maintenance standard for hydraulic equipments
3.2.1 Hydraulic arrangement plan
18
19:Arm cylinder 20:Right boom cylinder 21:Left boom cylinder
22:Bucket cylinder 23:Shutoff valve- right side 24:Shut off valve- left side
19
3.2.2 hydraulic oil tank
1:Pressure signal
2:Drain plug
3:Air filter
5:Tank body
20
Technical parameters
oil tank oil return filter core oil suction filter core
oil tank
190L flow 750L/min flow 1000L/min
capacity
oil tank filtering
155L rated pressure 1.6MPa 100μ
capacity accuracy
filtering
10μ
accuracy
By-pass valve
opening 0.3MPa
pressure
The pump includes two variable cam-type plunger pumps、pilot oil source、one
electromagnetic proportional valve and two main pump adjusters.
21
1:Front main pump
2:Back main pump
3:Pilot oil source
4:Electromagnetic proportional valve
5:Adjuster
A1:Output port-front pump pressure oil
A2:Output port-back pump pressure oil
B1:Port-main pump suction oil
Dr:Drain oil port
Pi1:Feedback port-front pump negative flow
Pi2:Feedback port-back pump negative flow
Psv:Input port-electromagnetic proportional valve
a1:Pressure test port-front pump vent
a2:Pressure test port-back pump vent
a3:Pressure test port-pilot oil source vent
A3:Pressure oil output port-pilot oil source
B3:Pump suction port-pilot oil source
23
111:Drive axle
123:Roller bearing
124:Needle bearing
141:Oil tank body
151:Plunger
152:Slipper
153:Pressure plate
156:Spherical cylinder
157:Oil tank spring
24
158:Shim
211:Piston shoe
212:Sloping cam plate
214.Tilting cylinder liner
251:Sloping cam plate support table
312:Valve block
313:Valve plate
531:Tilting pin
532:Servo-oil tan
25
Maintenance standard (front pump and back pump)
When the wear extents of every parts of pump exceed the following standard, change or
adjust it again. While apparent damage happens it must be replaced.
standard dimension /
recommend replacing value
Name and inspection Item Disposal
pump type
K3V112 K3V140
gap value in piston and oil tank replace piston or
0.039~0.067 0.043~0.070
(D-d) oil tank
gap part looseness of piston and replace piston and
0~0.3 0~0.3
piston shoe(δ) coupling parts
replace piston and
thickness of piston shoe( t ) 4.7~4.9 5.0~5.4
coupling parts
replace oil tank
free height of oil tank spring(L) 40.3~41.1 47.1~47.9
spring
replace pressure
assembly height of pressure plate 11.0~12.0 12.5~13.5
plate and spherical
and spherical liner(H-h) liner
26
Function (adjuster)
Use adjuster to realize the adjusting and controlling output power and flow of main pump
automatically.
Structure (adjuster)
Main pump adjuster(see JPG0006):Front and back pump adjusters are also consist of
plunger units 1,plunger units,servo-valve core unit 3, connecting rod(612、613), feedback
rod(611),shell and end cover. They are the parts that make up the flow and power adjusting units
of main pump.Pin shaft(548 ) connects feedback rod(611)with servo-piston on main pump.The
whole adjuster is connected to the body of main pump by four hexagon socket screws(438).
Working procedure (adjuster)
The adjuster of main pump could adjust the flow and power automatically and prevent
engine from overloading operations.
1. Flow control
The obliquity (output flow) could be controlled randomly by changing leading pressure Pi.
The working way of adjuster: Control negative flow (negative sense control) as leading pressure
Pi increasing and output flow Q decreasing. This unit could give leading pressure instruction in
line with the necessary operation flow.Piston pump only output essential flow. Therefore power
will not be exhausted in vain.
z Motion illustration
See as the following figure (JPG0004). The output flow of piston pump could be controlled
randomly as the changing of leading pressure Pi.
27
z Motion of flow reduction
As leading pressure Pi increased, leading piston (643) moves right. As the pressure of guide
spring(646)and oil pressure resting at the equilibrium position, the pin(875)fixed on connecting
rod 2(613)is embedded in the groove part [A part]of leading piston.Therefore, as the moving of
leading piston, connecting rod 2 pivots on point B[fixed by pivot plug(614),pin(875)]. Because
of the pin (897)fixed on feedback connectiong rod (611)lies in the big hole part [C part]of
connecting rod 2, pin (897)would move right as connecting rod 2 rotating. The (D) part of
feedback connecting rod tables the pin (548) fixed on tilted pin (531)(tilted pin shakes tilted
plate ). So when pin(897)moves,feedback connecting rod pivots on point D. Short pipe would
move right because feedback connection rod connects pin (874) with short pipe (652).As moving
procedure, output pressure P1 is led to the port of servo-piston through pipe C1. While output
pressure P1 is led to the small port of servo-piston and makes it move right to reduce obliquity as
area difference. When servo-piston moves right, point D will also move right. Offsetting
spring(654)on short pipe produces a pull force that will make short pipe move left and that
makes pin(897)pressed to the big hole part[C patr] of connecting rod 2. As the moving of point
D, feedback connecting rod pivot on point C and short pipe moves left. These moving make
sleeve aperture (651) and short pipe aperture (652) close slowly, and servo-piston would stop as
it closed completely.
z Motion of increasing flow
When leading pressure Pi decreased, the pressure of guide spring (646) makes leading
piston (643) move left. Connecting rod 2(613)pivots on point B. Pin (897) is pushed to the big
hole[C part] of connecting rod 2 by offsetting spring (654) through short pipe (652), pin (874)
and feedback connecting rod (611). As the moving of connecting rod 2, feedback connecting rod
2 pivots on point D and short pipe moves left.
As short pipe moving, pipe C would open to oil tank, the pressure on big port of
servo-piston would reduce. Output pressure P1 on small port would act on servo-piston and
make it move left and flow increased. Point D also moves left as servo-piston moving. Feedback
connecting rod pivots on point C. Short pipe moves right. This moving repeated until the
aperture of sleeve and short pipe closed and would stop at the closed place.
28
2. Power control
The increasing of output pressure P1 and P2 of piston pumps makes the obliquity (output
flow) reduces automatically and controls output torque under fixed value (input power remains if
rev remains). Operate according to the summation of load pressure on two piston pumps of the
double piston pumps in series and take full power way. Therefore, under the power control status,
make the obliquitis (output flow) the same by controlling the adjusters of every piston pumps. In
spite of how variable the two piston pumps loads are, this mechanism could prevent the
overloading operations of engine automatically.
The motiong of power control is the same as flow control. The following are simple
illustration. (Refer to flow control about the details of every units motion).
z Motion instruction
Increase load pressure (see fig JPG0005) and decrease obliquity of piston pump to prevent
engine overloading. As the adjuster adopts the synchronous power control way, so control the
obliquities of the two piston pumps (extrusion capacity) to make them the equivalent. See as the
following formula.
30
601.Pump shell 626.Internal spring 651.Sleeve
611.Feedback rod 627.Telescopic link (C) 652.Slide valve
612.Connecting rod (1) 628.Regulating screw (C) 653.Spring
613.Connecting rod (2) 629.Cover (C) 654.Offsetting spring
614.Bearing pin 630.Locknut 655.Regulating spring
615.Regulating pole 631.Sleeve PF
621.Compensation piston 641.Guide housing
622.Piston cover 643.Guide piston
623.Compensation rod 644.Spring (Q)
624.Spring (C) 645.Spring (Q)
625.External spring 646.Guide spring
31
Function (pilot oil source)
Provide stable pressure oil for pilot control of multiple way valve, unlocking of swing
motor, high and low speed control of traveling and electronic proportional valve of main pump,
ect. The maximum pressure in pilot oil circuit is set by the relief valve in pilot oil source.
Structure (pilot oil source)
Pilot oil source (see figure JPG0007) :consists of two meshed gears(354、353),two drive
shafts (354、353) standing on shell, relief valve module and shell (351). Spline end of power
input shaft (353) connects with spline hole on main shaft end (113) of back pump. Bolt (435)
connects shel l (351) of pilot oil source to supporting plateform (251) of sloping cam plate on
main pump.
353.Gear
354.Gear
351.Shell
435.Hexagon socket screw
32
Function (electromagnetic proportional decompression)
It can set the output power of main pump momently. When coil of electronic proportional
valve gets a current value from host machine controller, the output port of proportional
decompression valve would export a corresponding pressure value. The force acts directly on
plunger rod (621) of adjuster to counteract parts of the spring force and reaches the output power
of main pump which has been set.
Structure (electromagnetic proportional decompression)
Electromagnetic proportional valve(see figure JPG0008):It is a screw thread plug-in valve
and is installed in valve plate (313) of main pump. It consists of valve pocket (312), valve core
(311), offsetting spring (324) and electromagnetic coil (801).
311.Valve core
312.Valve pocket
324.Offsetting spring
801.Proportional electromagnetic coil
33
3.2.4 Swing motor
Summary
M5X180CHB-12A-1PA/265-149
It consists of valve units, motor and swing reductor.
34
Structure (motor noumenon)
Motor noumenon consists of sloping cam plate, rotor, plunger, port plate,shell, output shaft
and swing stop brake (consists of spring, brake piston, sheet steel, friction disk and swing stop
brake switch ), ect.
35
2. brake releasing
1) When swing or working device joy stick operating, swing stop brake release valve rod in
signal pilot pressure control valve moves and pilot hydraulic oil flows into oil port SH through
pilot pump.
2) Valve rod is pushed right by pilot pressure which flows into oil port SH. Pilot pressure in oil
port PG comes into brake piston room through valve rod and the upper and the under cavities in
brake piston room are broken, brake piston moves up and motor releases brake.
3. brake works
1) When swing and joy stick of working devices release, swing stop brake release valve rod in
signal pilot pressure control valve returns to free position, pilot pressure flows into oil port
SH would be decreased.
2) Valve rod returns back. Pilot pressure from oil port PG is blocked up and time-delay valve
opened.
3) Hydraulic oil in brake piston room returns to swing motor shell through time-delay valve.
4) Spring force 1 acts on sheet steel and friction disk. Sheet steeel and friction disk mesh with
rotor outer diameter and shell inner diameter by brake piston. So rotor outer diameter is
supported by friction force. When engine stops working, there is no pilot pressure into oil
port SH and makes brake to work automatically.
4. brake delay
1) When the order of releasing brake for hole SH disappears, valve rod moves left under the act
of spring and cuts off hole PG and PR.
2) Oil in hole PR flow into hole D through orifice in time-delay valve. Brake has certain stroke
volume (V:cm3). Assume the flow through orifice is Q, then the delay time from releasing
status of brake piston to contact friction disk and sheet steel is : t=V/S.
36
Maintenance and service standard (motor noumenon)
1. Replace standard for friction parts
When friction extent of every friction parts over the standards in the following figure, it
should be replaced or adjusted again. While there are evident damages in appearance, it should
not refer to the following standards and should be replaced in advance.
replacement
standard
item recommended remedy
dimension(mm)
value(mm)
fit
replace plunger or
clearance-plunger 0.027 0.052
rotor
& rotor(D-d)
hinge
replace plunger and
clearance-plunger 0 0.3
slipper units
&slipper sphere(δ)
replace plunger and
slipper thickness(t) 5.5 5.3
slipper units
37
2. Refacing standard for swing engagement face
As the degrees of roughness of every parts’ swing engagement faces over the following
standards, it should be refaced or replaced.
38
Function (valve units)
Compensator valve:Prevent motor sucking air or cavitation erosion due to oil unable to
supply in time during the process of braking.
Overflow valve:When swing operation starts or stops, oil pressure in swing oil way
increased. Relief valve could prevent oil way pressure from going up above the setting pressure.
Anti-reverse-rotation valve:When swing stops, it reduces revolution shaking owing to
inertia of revolving body, recoil strength and rigidity of mechanical system and compressibility
of hydraulic oil, ect. And it could prevent the load things in bucket from coming out and reduce
cycle time efficiently. (Good locating performance and fast moving for the next operation).
2. Overflow valve
Low-pressure overflow operation(shock absorption function):
1) Pressure of oil port HP (swing oil way) enter oil cavity C through thr orifice of lift valve.
2) Pressure oil in oil cavity C enter oil cavity A and B separately through oil way A and B.
3) Pressure area in oil cavity B is bigger than that in oil cavity A, so piston moves left.
4) Piston moves continuously and pressure difference presents in lift valve. When pressure
39
difference over spring force, lift valve leaves its position and makes pressure oil enter into oil
port LP.
5) When piston moves total excursion, pressure difference of lift valve disappears and makes
lift valve back to its position.
High-pressure overflow operation(prevent over loading):
1) After piston moves total excursion, spring is compressed to increase the pressure in oil way
to the setting pressure.
2) If the pressure in oil port HP increased above the setting pressure of spring, lift valve leaves
its positon and makes pressure oil flow into oil port LP through oil port HP.
3) When pressure in oil port HP decreased to the setting pressure, lift valve returns to its
position because of the spring force.
3. Anti-reverse-rotation valve
See figure JPG0159 , figure 1 shows the connection between neutral condition of
anti-reverse-rotation valve and hydraulic circuit. Assume that there was brake pressure at the
side of port A and is in brake state. When port A is pressed, the pressure flows into room n
through way 1, port above the shaft of valve base 313 and way m of plunger 311. When pressure
P exceeds the setting value of pring 321, plunger 311 leads spring 321 moving left. Valve base
313 is pushed by plunger 311 and leads spring 322(week elasticity) moving left. [as figure 2].
When inertia load stops moving, brake pressure decreases. When P <PS, plunger 311 moves
right and returns under the act of spring 321. Valve base 313 also moves right under the act of
spring 322. But there is antihunt action produced by orifice g in room P, therefore, comparing
with plunger return, the return time of valve base lags. Part t on valve base becomes open status,
through the procedure of 1一t—r—k,it forms the way which consists connect port A with port
B,ie, two sides of the port of hydraulic motor. Work as the above principle, when the pressure in
port A and port B are as the same, using close pressure of port A to prevent reversal of hydraulic
motor.
40
Function (swing reduction device)
Planetary gear train in reductor could reduce the output speed of motor noumenona and
increase torque.
41
231: Primary planet carrier 204: Second central gear
211: Primary central gear 230: Second planet carrier
210: Primary planet pinion 201: Gear shaft
202: Gear ring 102: Shell
203: Second planet pinion
42
2. Travel control pilot valve PVD8P5021A
1 forward-right travel
travel backward-right
2
two-gang travel
pedal valve 3 forward-left travel
4 backward-left travel
43
3. Auxiliary pedal valve RCV8C1109
44
Structure (right handle pilot control valve)
45
Working procedure (right handle pilot control valve)
The theory and working procedure of pilot control valve are similar. Only working
procedure of right handle control valve are described here.
46
Total excursion(output graph:E~F)
1. When joystick is in total excusion, push rod (212) moves down till the push rod (212) of pilot
valve comes into contact with shell (111).
2. Therefore, the oil pressure of output oil port and oil port P are the same.
47
Technical parameters
rated pressure 3.5MPa accumulator air pressure 1.5MPa
EF-097B
48
1: Valve unit PS:Two-speed control port
2:Motor noumenon Tin: hydraulic oil filling opening
3:Travel speed brake FILL: gear oil refill opening
p1: main oil port LEVEL: detecting port of gear oil
P2: main oil port DRAIR: gear oil drain
Pm1: pressure testing port (P1) of main oil
Pm2: pressure testing port (P2) of main oil pressure
49
1-1:Shell of motor 14:Screw
3: Angular contact ball bearing 15:Second central pinion
4: Reduction case 17:Primary planet carrier
6: Bracket 20:Needle bearing
11:Needle bearing 25:Gear shaft
12:Second planet pinion 27:Gear case end cover
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(1-21), sloping cam plate (1-5), rotor (1-4-1), plunger (1-4-2), shaft (1-3) and brake plunger
(1-15) etc. Shaft (1-3) connects with rotor (1-4-1),plunger (1-4-2) inserts in rotor. Port plate
(1—21) clings to rotor but would not rotate with it. Slipper and rotor are pressed on sloping cam
plate under the act of spring (1-4-7).
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Function (valve unit)
z Balance valve:When machine travels downgrades, it would get out of control as its weight
make the machine itself move faster than motor. This is very dangerous. However, balance
valve can prevent it.
z Buffer overflow valve:When machine stop short, start-up or travel reverse, it could release
the instant high pressure produced by motor so as to prevent the damage of motor and
pipeline.
z Two-speed control valve:Switch motor discharge to control high and low speed of motor.
Working procedure
1. Working procedure of motor
When operate travel joystick, pressure oil from control valve are converted to oil port (P2).
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Pressure oil push away the check valve (1-2-2-2) in balance valve core (1-2-2-1) and flow into
oil cavity (M2) through motor,flow into the plunger cavity in rotor (1-4-1) through port plate
(1-21) so as to give rotary applied torque. Meanwhile, return oil from plunger cavity flow out
through oil cavity (M1). But motor oil output cavity (M1) is shut off by check valve (1-2-2-2)
and balance valve core (1-2-2-1). So the pressure of oil feeding side increased. Then the pressure
oil flow from orifice (G1) into balance valve oil cavity (S1).Balance valve core push right when
the pressure in oil cavity (S1) is higher than the converse pressure of balance valve core.
Therefore, oil cavity(M1)connects with oil port(P1),that is, motor oil return side opened and
motor begins to run.
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3. Stop and release brake
Stop and release brake is a kind of wet multi-disc brake. Brake is negative pressure style
and it would declutch only as hydraulic oil released by brake flows into the piston chamber of
brake. Stop and release brake decluches automatically. Friction disk (1-14) and sheet steel (1-13)
bond with rotor (1-4-1) and shell (1-1) separately.
1) Travel start
Suppose feed oil from (P2) and when operate travel joystick, pressure oil from pump flow
into oil port (P2) to make balance valve core (1-2-2-1) move right. Oil cavity (E) connects with
high pressure oil in (P2) and flow into brake piston cavity (F) through oil canal (L). Pressure oil
absorbs spring force of spring (1-18) and push brake piston (1-15) to the left. Then sheet steel
(1-13) separates from friction disk (1-14) and release braking.
2) Travel stop
Suppose feed oil from P2 and when travel joystick is placed at middle position, motor stop
oil feeding and pressure of P1 disappears. Meanwhile, balance valve core (1-2-2-1) return to
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middle position under the act of spring force. The oil canal from oil port (P2) to oil cavity (E) is
cut off. Brake piston (1-15) moves right under the act of brake spring (1-18) until sheet steel
(1-13) contacts with friction disk (1-14) and so produce brake torque. Then oil in oil cavity (F)
flows back to oil tank from motor shell through orifice in brake piston. Oil return orifice in brake
piston (1-15) is for producing brake lag effect and stop and release brake would brake after
motor stop by hydraulic brake.
Suppose feed oil from(P2)and return oil from (P1),when machine travel on falling gradient,
travel speed may over motor speed as the weight of the machine. And motor would be in
load-free running. Then the pressure of motor inlet oil port would decrease, and also do the
pressure in oil cavity (S1). Balance valve core (1-2-2-1) would move left under the act of spring
when the pressure in oil cavity (S1) decreases under the switch pressure of balance valve core,
which produces throttle effect to motor oil return canal and forms oil return backpressure to
avoid losing control of machine. The higher of machine’s falling speed, the higher of the back
pressure to control travel speed by supplied flow of pump so as to ensure smooth travel.
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5. Working procedure of buffer overflow valve
Suppose feed oil from (P2) and return oil from (P1),when joystick back to middle position,
the pressure of motor oil inlet port (P2) decreases, and so the pressure of cavity S1. Balance
valve core (1-2-2-1) returns to the left side under the act of spring force and oil canal of motor oil
return side (M1) is closed. Under this circumstance, motor still run under the effect of inertia
force. Pressure of oil return side (M1) increase and would act on valve core (1-2-7-2) through
port (P) of buffer relief valve. Valve core (1-2-7-2) would open immediately when the pressure
is above the setting pressure of spring (1-2-7-5). Then high pressure oil is released from port (T)
to motor low pressure side (M2). Meanwhile, oil in M1 flow into spring cavity through damping
hole (X) and flow out from hole (Y) to act on the left end side of plunger (1-2-7-9) so as to make
plunger move right.When plunger moves to the left end, pressure of spring cavity increase.
When the force acts on the left end side of valvel core is above the right side force, valve core
(1-2-7—2) would be shut off. As there is a period for plunger (1-2-7-5) to move from left end to
right end, pressure increased instantly is avoided and also as hydraulic buffer. And the valve can
act as the same when motor just start.
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1:Check valve (arm valve kit 1) 22:Blocking relief valve (big cavity of arm)
2: By-pass shutoff valve 23:Negtive flow valve (P1)
3: Check valve (boom valve kit 1) 24: Oil return throttle valve (arm valve kit)
4: Flow control (rotary valvel kit) 25: Arm valve kit 1
5: Check valve (auxiliary valve kit) 26:Jockey valve (arm)
6: Check valve (left travel valve kit) 27:Boom valve kit 2
7: Check valve 28:Blocking relief valve (big cavity of boom)
8: Negtive flow valve (p2) 29:Flow control valve (rotary valve kit)
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9: Arm valve kit 2 30:Rotary valve kit
10:Locking relief valve (small cavity of arm) 31:Shutoff valve (auxiliary valve kit)
11:Boom valve kit 1 32:Auxiliary valve kit
12:Jockey valve (boom) 33:Left travel valve kit
13:Bucket valve kit 34:Check valve
14:Blocking relief valve (small cavity of bucket) 35:Blocking relief valve (small cavity of
15:Flow control valve (bucket valve kit) boom)
16:Right travel valve kit 36:Blocking relief valve (big cavity of
17:Straight travel pilot valve bucket)
18:Straight travel valve kit 37:Shutoff valve (auxiliary valve kit)
19:Check valve 38:Check valve (arm valve kit 2)
20:Main relief valve 39:Check valve (boom valve kit 2)
21:Flow control valve (arm valve kit) 40:Check valve (right travel valve kit)
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PA:Signal port of travel pressure pa3:From left handle control valve (rotary)
PC3:From oil port Pi1 pb3:From left handle control valve (rotary)
Pbu:To hydraulic oil tank pa4:To oil port Pi1
pcc:To oil port DR5 Pb4:To oil return block
PH:From solenoid valve (high and low Pa5:From left handle control valve (arm
pressure) epicycloid)
Pi1: From oil port Pa4 Pb5:From left handle control valve (arm
Pi2: Flow control valve pilot port (bucket digging)
valve kit) pa7:From right handle control valve (bucket
PS1:To main pump (negtive flow feedback of epicycloid)
back pump) pb7:From right handle control valve (bucket
PS2:To main pump (negtive flow feedback of digging)
front pump) pb8:From right handle control valve (boom
DR6:To oil port DR4 down)
DR4:To oil return block Pa8:From right handle control valve (boom
DR5:To oil return block up)
DR3:To hydraulic oil tank Pb9:To shuttle valve of oil port Pi2
T1:To radiator (main oil return) A1:To left side travel motor
T2:To hydraulic oil tank (main oil return) B1: To left side travel motor
P1:From main pump (back pump) A2: To auxiliary
P2:From main pump (front pump) B2:To auxiliary
prs1: To swing motor (deblocking signal) A3:To rotary motor
pa1:From travel control valve (left side B3:To rotary motor
travel) A5:To arm oil cavity (small cavity)
pb1:From travel control valve (left side B5:To arm oil cavity (big cavity)
travel) A6:To right side travel motor
pa6:From travel contrl valve (right side travel B6:To right side travel motor
pb6:From travel control valve (right side A7:To bucket oil tank (small cavity)
travel) B7:To bucket oil tank (big cavity)
pa2:From auxiliary control valve A8:To boom oi tank (big cavity)
pb2:From auxiliary control valve B8:To boom oi tank (small cavity)
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Function
Multiple way valvel is mainly used for distributing oil pressure and flow in oil circuit and
controlling flow direction, etc.
Structure
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Function
z Main oil circuit:arm valve kit 1(25) and arm valve kit 2 (9) act together to control arm oil
tank together and make a confluence of (P1) and (P2). Arm valve kit 1 (25) has the function of
oil returning and regeneration as arm oil tank extends. Boom valve kit 1(11) and boom valve kit
2 (27) take control together of boom oil tank to make a confluence of (P1) and (P2) as boom
lifting. Boom valve kit 1 (11) has the function of oil returning and regeneration as boom oil tank
goes down. Bucket valve kit (13) also has the function of oil returning and regeneration as
bucket oil tank extends.
z Pilot oil circuit:Each oil circuit connects with control valve directly takes control of the
stroke of main valve cores. Interior pilot oil circuit gets control of jockey valve and travel
straight valve, and exports the signal of rotary deblocking and travel pressure. Pilot oil circuit
connects with pressure increasing solenoid valve is for controlling the boosting of system.
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z Jockey valve : when joystick is in middle position, boom and arm would descend
automatically because of internal drainage of main valve core.
z Oil returning and regeneration:when boom descends , arm retracts and bucket digs, the
corresponding control valve kits have the function of oil returning and regeneration, which is for
increasing oil tank speed, preventing break-off of oil tank and tightening machine controllability.
z Travel straight valve:when travel motor runs together with other performers, travel motor
and other performers are fed oil separately to avoid travel action being interfered by other
actions.
z Main relief valve:when performer(except ratary motor)runs, main relief valve would
prevent overloading of system pressure and retain the pressure in the range of set value.
z Blocking relief valve:the oil circuits of boom , arm and bucket are fit with overload relief
valve. When performer moved by exterior load, blocking relief valve controls the oil circuit’s
pressure of performer to avoid abnormal increasing. And when the pressure decreases,
overloading relief valve complement hydraulic oil to prevent producing gas cavity.
z By-pass shutoff valve:get control of oil supply volumn by opening and closing the oil return
circuit of middle position.
z Flow control valve:It is assembled on arm, bucket and oil return circuit. And it would take
precedence over other performers to restrict the flow of oil circuit when in compound operation.
Match the actions of every performer by controlling oil inlet circuits of every valve kis.
Working procedure
1. Travel straight
1) When execute travel and other compound operations, machine travel straightly through
travel straight valve. The following is the figure of oil circuit when travel and bucket running at
the same time. When operate joystick to make bucket do epicyclic motion and left and right
motors travel together, the pilot signal oil of bucket from(Pa7) and the pilot signal oil(Pb1、Pb6)
from left and right travel act together to reverse travel straight valve core.
2) When travel straight valve core is moved, the pressure oil of pump (P1) supplies to left and
right travel motor at the meantime and the pressure oil from pump (P2) supplies to bucket, which
makes separate oil supply for travel and bucket to avoid getting the different speed between the
left and right travel motors because of the changing of bucket load. When other actions
compound travel action, these functions come into effect through travel straight valve.
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2. Main relief valve
1. The pressure in oil port HP (main oil circuit) is applied to pilot lift valve through orifice A of
main lift valve and orifice B of valve base.
2. When the pressure in oil port HP rises above the setting pressure of spring B,pilot lift valve
moves from its base to make pressure oil flow to oil port LP(oil return) through the oil canal and
clearance around sleeve.
3. Meanwhile, the pressure difference between oil port HP and spring cavity would rises because
of orifice A.
4. If the pressure difference rises above the setting pressure of spring A, main lift valve would
move from its place to make the pressure oil in oil port HP flow to oil port LP.
5. So, pressure in main oil circuit decreases.
6. When main oil circuit pressure decreases under the stated pressure, main lift valve would be
retracted by spring A.
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3. Blocking relief valve
Relief operation:
1. The pressure in oil port HP (oil circuit of performer) applies to pilot lift valve through orifice
on piston.
2. When the pressure in oil port HP rises above the setting pressure of spring B,pilot lift valve
moves from its base to make pressure oil flow to oil port LP (hydraulic oil tank) through the
channel A and clearance around sleeve.
3. Meanwhile, the pressure difference between oil port HP and spring cavity would rises because
of orifice.
4. If the pressure difference rises above the setting pressure of spring A, main lift valve would
move from its place to make the pressure oil in oil port HP flow to oil port LP.
5. So, pressure in main oil circuit decreases.
6. When main oil circuit pressure decreases under the stated pressure, main lift valve would be
retracted by spring A.
Compensation operation:
1. When the pressure in oil port HP (oil circuit of performer) decreses under the the pressure in
oil port LP (hydraulic oil tank),sleeve would move right.
2. Then, hydraulic oil flows from oil port LP to oil port HP to avoid producing cavity.
3. When the pressure in oil port HP rises above the stated pressure, sleeve would be shut off by
spring C.
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4. Flow control valve
The functions of every flow control valves are shown as the following
flow control
compound operation
valve
arm boom lifting and arm
bucket bucket and boom lifting or digging with arm
rotary boom lifting and rotary
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5. Jockey valve
Retain operation
1. When joystick is on free position(valve kit place of free position),switch valve in jockey
valve would not move.
2. So, the pressure on the bottom of boom oil tank (the rod side of arm oil tank) transmitted to
the check valve (the side of spring) in jockey valve through switch valve.
3. So, check valve closes to stop oil returning to oil tank and decreases the shift of oil tank.
Relief operation
1. When arm retracts or boom descends, pilot pressure oil from pilot valve pushes the plunger of
jockey valve to move switch valve.
2. Then, the oil in spring chamber of check valve flows back to hydraulic oil tank through switch
valve.
3. So, check valve opens to let return oil flow from the bottom of boom oil tank (rod side of arm
oil tank) to main valve kit.
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6. Oil returning and regeneration
Regeneration functions of every valve kits are similar. Let’s take regenerative valve of
bucket as example:
1) When bucket digging, the return oil of the small cavity flow into part (a) of bucket kits and
act on check valve.
2) If the pressure in the big cavity of oil tank is lower than that in small cavity, check valve will
open.
3) Then, the return oil in small cavity will flow into the big cavith together with the outlet oil of
the pump to increase the speed of oil tank.
4) If the total excursion of oil tank moves or digging load increases, the oil circuit pressure in
the big cavity will increase above the pressure in the small cavity to shut off check valve and
stop the regeneration operation.
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3.2.10 Rupture valve
1. Summary
The purpose of equipment of maintainng valve on working device is to prevent oil cylinder
to be out of control when main pipeline connected to load device occurs rupture.
2 Installation position
Rupture valve is installed in protected oil circuit located between load device and
corresponding main control valve kit, and it is connected to load device by flange. Rupture
valves are equipped in two places of the whole machine, the one locates in boom cylinder large
cavity port, and another locates in arm cylinder small cavity port.
Function
When pilot hand lever (5) has no action, main control valve kit (2) locates in middle
position, and port Vst has no pressure, rupture valve is on no leakage and close state, and
cylinder cavity connected with it will be choked, the cylinder position is on maintaining state.
When oil in main oil circuit enters port St, oil can enter cylinder cavity freely through
by-pass check valve to move the cylinder. When cylinder need inverse action, oil in cylinder
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need to retrun to oil tank through rupture valve Z port; the control pressure from pilot hand lever
(5) enters Vst port and acts on adjusting slide valve in rupture valve,and conquer pressure spring
and open the valve, and then load device begins smooth falling action. When pilot pressure rises
again, the throttle of whole slide vale is fully opened and attains highest falling speed. During the
falling process, if pipeline rupture occurs, rupture valve will adjust the highest falling speed to
setting value to prevent from exceeding the regulated highest falling speed. When control lever
turns back to middle position, load device will be prevented from further falling because slide
valve is in balance due to load pressure. So adjusting slide valve will not be closed when oil
retuen pressure acts on it.
Secondary overflow valve is connected to port Z, when pressure of cylinder cavity
connected to the port attains to setting value, Secondary overflow valve will open the passway to
Vs port, and adjusting slide valve is opened, and pressure is unloaded from port Z to port St.
AL ports of rupture valve located on both sides of boom cylinder are connected hy rubber
hose, which can eliminate pressure difference of two cylinders.
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1. Main pump
2. Main control valve kit
3. Working device relief valve
4. Pilot control lever
Before disassembly and assembly of rupture valve, please fall working device to the ground,
and flame out the engine, and release residual pressure of the system.
★ Label the detached hoses for fear mistakes in assembly. In the same time, seal evey pipe port,
and save the seal parts properly.
Disassembly
A. Arm rupture valve
②. Detach main oil circuit hose (3) and pipe clamp (4)
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B. Boom rupture valve
Detach oil leakage pipe (1), pilot pipe (2), balance pipe (3), steel pipe fixed screw (4),
rupture valve fixed screw (5) in turn.
Assemly
1) Assemble according to inverse sequence of disassembly.
★. Pay attention to connecting port label in rupture valve
★. Hose can not be contacted with rupture valve, or else hose will be damaged due to
overheated.
★. Flange mounting surface can not be damaged when assembly
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5. Adjutment of rupture valve
Rupture valve do not need adjustment in normal state, when it need adjustment, do it
according to following content.
Rupture valve will be heated to oil temperature in operation.
1) Adjust rupture valve open point
a). Loosen lock screw (1).
b). Rupture opening pressure:
Increase: tighten screw (2) clockwise.
Decrease: loosen screw (2) counter clockwise.
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3.3 For electric equipments
Electric system contains following section:
3.3.1 Power supply circuit
3.3.2 Starting circuit
3.3.3 Pilot closing circuit
3.3.4 Engine stop circuit
3.3.5 Wiper and scrubber circuit
3.3.6 Controller
3.3.7 Engine control
3.3.8 ECM system
3.3.9 Multifunction monitor system
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3.3.2 Starting circuit(key switch:START)
1) When the key switch is turned to START position, terminal 30 in switch is connected to
terminal 15 and 17.
2) When current from terminal 15 delivers a input signal to GPS and controller, GPS will
output a current signal to activate accumulator relay, accumulator current will be sent to starter
terminal B and start relay terminal B through accumulator relay.
3) Current from the teminal 17 delivers GPS an input signal, and GPS output a current signal to
ECM and start relay terminal S.
4) So start relay response, current flow from start relay terminal C to starter terminal C.
5) Magnetic coil in starter become live to make tips response, and starter runs.
6) When EMC get the electric signal from GPS, it will output an electric signal to make the
main relay to response. Current from fuse F1 flow to B terminal of start cut relay coil and coil of
fuel pump relay through main relay tips, and fuel pump relay
responses to make the fuel pump work.
7) After the engine runs, EMC make C terminal of start relay
get grounding, start cut relay responses, which make start relay
terminal G to be broken from ground connection, at this time,
even if the key switch is turned to start position, start can not
have any actions. This is the anti-restart function in starting
circuit.
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3.3.3 Pilot closing circuit(key switch:ON)
1) When pliot closing stick is put to free position, current of fuse F10 flow to GPS, after it
received the signal, it output a current signal to turn on pilot cut-off electromagnetic valve, and
pressure oil from pilot pump will be provided to pilot valve.
2) When pilot closing stick(as figure 1 show) is
turned to free position, terminal b of pilot switch has
no current, and GPS can not receive current signal
from terminal 17, so it can not output current to
terminal S of start relay, and start relay will not
response. So although the key switch is turned to
START position, starter will not rotate. This fuction
can avoid unexcepted hydraulic action when starting.
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3.3.4 Engine closing circuit(key switch:OFF)
1) When key switch is turned from ON position to OFF position, signal current will stop from
flowing from terminal 15 to GPS.
2) Output signal current of GPS stop to flow to ECM
3) ECM stops spraying of oil ejector, the engine will stop.
4) When engine stops, ECM will close main relay
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3.3.5 Wiper and scrubber circuit
1) Wiper OFF step
Wiper has no action in this step. Tips 1 and 2 are connected, and 4
and 5 are connected of the two pairs of tips in switch. Because tios 4
are suspended, so circuit is on off-state.
2) Wiper interval step
Wiper will act in 5-seconds interval, Tips 1 and 2 are connected, and 5
and 6 are connected of the two pairs of tips in switch. Current flow
direction is 6-5-2-1,and then from tip 1 to interval signal output
terminal 4 of wiper controller.
3) Wiper continuous action step
Wiper act continuously in this step, tips 2 and 3 are connected, and 5
and 6 are connected of the two pairs of tips in switch. Current flow
direction is 6-5-2-3,and then from tip 3 to continuous signal
output terminal 14 of wiper controller, and then wiper motor act
continuously under wiper controller controlling.
4) Scrubber operation
Scrubber switch is auto-reseting wane type switch, scrubber circuit is
cut-off when switch is not pressed; when it is pressed, and tips 2 and 3 are connected, current
flows into scrub input signal terminal 1 of scrubber controller.
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3.3.6 Controller
The controller is equipped on every control device in this machine, to display situation of
whole machine on monitor in cab, the controllers are connected by CAN.
CONTROLLER: Main controller
ECM: Engine control module
GPS: globle locating system
MONITOR: monitor
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CAN (controller local net)
Controller, monitor, GPS, controller and ECM are connected by concentration line, and
transfer signal and datas to each other. CAN concentration line includes two lines: CAN high
line and CAN low line. Every controller judge level of CAN concentration line by pressure
difference between CAN high line and CAN low line. Every controller arranges the level of
concentration line, and sends signal and datas to other controller.
CONTROLLER: main controller
It is used to control the operation of whole machine. Signals of control knobs from engine,
all kinds of sensors and switches will be sent to main controller and be processed in logic circuit.
Main controller sends signal corresponding to target engine rotational speed to ECM (engine
control module) by CAN communication, to control engine.
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Ports definition of main controller:
signal
stitch Input/output stitch signal description Input/output
description
controller
1 power Input 31 CANH1.2 communication
supply
controller
controller power
2 power Input 34 output
supply
supply
Analogue
3 Input 38 Electric signal Input
GND
4 throttle dial Input 39 Pressure switch S1 Input
oil level Travel
5 Input 40 Input
sensor pressyreswitch
power
11 supply Input 41 Pressure switch S2 Input
GND.
12 CANL1.1 communication 42 Air filter alarming Input
touch stress
13 CANH1.1 communication 43 Input
application
power
14 supply Input 44 auto idle speed Input
GND.
current travel high/low
16 Input 45 Input
output speed switch
18 RS232-R1 communication 46 spare
19 signal GND communication 47 power GND Input
controller
proportional
20 battery Input 48 Output
solenoid valve
power
Pump 1
proportional
22 pressure output 49 Output
solenoid valve PV1
sensor
Pump 2
proportional
23 pressure Input 50 Output
solenoid valve PV2
sensor
Pump 3
secondary overflow
24 pressure Input 51 Output
valve(reinforcement)
sensor
controller
travel high/low
27 power Input 52 Output
speed control valve
supply
Pressure
28 Input 53 travel alarm system Output
switch S3
30 CANL1.2 communication 54 buzzer Output
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ECM: engine control module
1) fuel ejecting control
ECM inspect engine working situation and control fuel ejecting according to sensors and
signals from main controller.
2) Engine starting control
ECM control connecting time of current of preheating plug and improve the starting of
engine.
3) EGR(exhaust gas recycle)control
ECM ensures the gas quantity according to engine rotational speed, fuel flow, collant
temperature, atmospheric pressure and input air temperature. ECM turns on the EGR valve and
makes exhaust gas to be recycled. Quantity of exhaust gas is equivalent to air input quantity in
air-in manifold. Some EGR exhaust gas is mixed with input air to lower burning temperature and
to lower the producing of NOx in EGR exhaust gas.
4) Fuel eljecting modifying
EMC adjusts fuel ejecting according to atm pressure sensor signal.
5) Engine stop control
When you press emergency cut-off switch, ECM will stop fuel ejecting of oil ejector and
close engine.
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4) Close engine
When key switch is turned to OFF position, ECM can not receiveindication signals sent
from GPS, and then ECM stop the oil ejection and stop the engine. When you encounter
emergency, or you can not stop the engine even if you turned the key switch to OFF position,
you can press emergency cut-off button, and engine stop terminal V47 will receive current signal
from GPS, and then ECM will stop the engine.
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Oil ejection control
ECM inspects engine running situation and controls oil ejection mass, ejecting pressure, and
ejecting timing and rate according to signals of sensors and main controller.
Two-sport control
z oil ejecting mass control
z oil ejecting timing control
z oil ejecting rate control
z oil suction control valve control
z oil ejecting pressure
Oil ejecting mass control
Fuction: Control optimum oil ejecting mass
1) ECM inspects engine rev. according to signals from crank rev. sensor and crank shaft angle
sensor.
2) MC calculates target engine rev. according to engine control knob and signals of sensors and
switches, and it sends signals to ECM by CAN communication.
3) ECM controls oil ejecting mass according to engine rev. and signals from main controller
trough open/close two-sport valve in oil ejector.
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Oil ejecting pressure control
Function: control fuel ejecting pressure according to fuel pressure in common rail.
1) ECM calculates fuel ejecting massaccording to engine rev. and signals from main controller
through CAN communication.
2) Common rail pressure sensor sends signals to ECM according to pressure in common rail.
3) ECM calculates optimum fuel pressure according to engine rev., oil ejecting mass and
signals from common rail pressure. ECM drives oil suction control valve in high pressure oil
feed pump and provides optimum fuel mass to common rail.
4) Fuel is provided to oil ejector from common rail according to fuel pressure, which controls
fuel ejecting pressure.
Fuel ejecting
1) Nozzle in oil ejector is always pressurized.
2) When magnetic coil is switched on in two-sport valve, high pressure fuel in control cavity
returns back to fuel tank though orifice 1
3) Then hydraulic pitson moves upward, nozzle is open, and ejecting starts.
4) When magnetic coil in two-sport valve is cut-off, the valve will be closed, and oil circuit to
fuel tank is also closed, pressure oil from common rail flows to control cavity through orifice 2.
5) So when high pressure oil flows to control cavity, hydraulic pitson moves downwards due to
pressure difference, and ejecting stops.
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Engine start control
Function: control current connect time of preheat plug and improve engine starting according to
coolant temperature.
1) Sensor sends signals to ECM according to coolant temperature.
2) ECM connects GND circuit of preheat plug relay according to signals and control current
connect time of preheat plug.
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EGR (exshaust gas recycle) control
Function: make some air to recycle in air-in manifold and mix with inlet air. So burning
temperature falls and controls NOx.
z EGR air control
1) ECM ensures EGR air according to engine rev., fuel flow, coolant temperature, and atm
pressure and air-in temperature.
2) ECM drives EGR motor, open EGR valve and send the EGR air into air-in manifold
according to engine condition, to make EGR air and inlet air mixed together.
3) ECM ensures EGR valve open extent by EGR motor position.
z EGR cooling system
Some exhaust air is cooled by EGR cooler; the cooled exhaust air is mixed together with air-in,
which lowers burning temperature and descends producing of NOx. In EGR exhaust air.
z Check valve
It prevents fresh air to enter into EGR, and prevent EGR exhaust gas flow in inverse direction.
Thus, EGR air current flows in one direction and air increases.
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Engine stop control
1) When engine stop switch is at stop position, ECM can not receive ON situation instructive
signals sent from GPS.
2) ECM stops ejecting of oil ejector and stops engine.
3) Close ECM after ECM main relay is closed.
92
A. coolant temperature alarm monitor
Coolant temperature alarm monitor (1) displays ( ) when it’s functioning properly. If the
coolant temperature is high, and exceeds alarm limit, the alarm monitor symbol will become
( ) and a alarm symbol ( ) will flash in the same time. On this occasion, if the engine is still
running at high revs, the controller will regulate work speed according to current coolant
temperature. The revs will slow down; work equipment speed will decrease until coolant
temperature returns to normal state.
B. engine oil pressure alarm monitor
Engine oil pressure alarm monitor displays as , if engine lubricating oil pressure is normal. In
case of low lubricating oil pressure and reaching limits, the alarm symbol will change to , an
alarm symbol will flash simultaneously. In this case, stop the engine, check engine
lubricating system. With the failure identified and restored, the engine is allowed to start again.
Note: when starting switch is set to ON position, engine oil pressure alarm monitor displays
red. With engine started, the red disappears. This is a normal sign.
will emerge. After getting this alarm information, operator needs to check fuel tank as soon
as possible and refill.
D. air filter clogging alarm monitor
Air filter clogging alarm monitor (1) displays as if it works normally. In case of clogging,
the alarm symbol will change to , an alarm symbol will flash as well. When getting this
information, the operator needs to check, clean up or replace the air filter.
E、charging alarm monitor
Charging alarm monitor (5) displays as if the battery voltage is normal. In case of
abnormality (engine fails to charge), alarm monitor will change to and an alarm
symbol will flash as well. The moment getting this information, stop the engine, check
charging circuit and engine function.
Note: when starting switch is set to ON position, charging alarm monitor will display in
red, after starting the engine, the red light disappears. It’s normal.
93
Abnormal Check
Symbol Display Item
Display
coolant coolant level and cooling duct
temperature
engine oil shut off engine and check engine oil
pressure level
check oil tank ASAP, and refill fuel
fuel level
in time
check, clear up or replace air filter
air filter clogging
ASAP
check charging circuit and engine
charging alarm
working state
94
4. Test and adjustment and Failure Diagnosis
4.1 Test and adjustment of mechanical structure device
4.1.1 Standard table of engine spare parts
engine AI-4HK1X
standard value
service limit
item measure work condition unit of new
value
machine
95
4.1.2 Standard table of complete machine
96
suitable machine model SWE210NB
cla standard allowable
item measure working condition unit
ss value value
joy rotary control engine misses
75 75±10
sti valve ·at the handle center of joystick
ck travel control ·measure the max. value to the stroke
180 180±20
str valve terminal
ok joystick (except joystick is in the middle
max.10 max.15
e clearance position)
joy boom joystick 7
·hydraulic oil temperature : within
sti arm joystick 7
working range
ck bucket
·engine running in high idle speed 7
op joystick
·at the handle center of joystick N
era rotary joystick 7
·at the top of pedal
tin Trav joystic 15
·measure the max. value to the stroke
g el k
terminal
for joyst 105
pedal
ce ick
·hydraulic oil temperature : within
working range
unloading ·engine running in high idle speed
3 3±0.5
pressure ·work mode:H
·hydraulic pump output pressure with all
the joysticks in the middle position
boom ·hydraulic oil temperature : within
hy arm working range
dra bucket ·engine running in high idle speed
uli rotary ·work mode:H 32±0.5
c 32(34)
·hydraulic pump output pressure when (34±0.5)
pre
all measure oil circuits releasing
ssu travel
·value in bracket:hydraulic oil pressure MPa
re
of touch type switch in ON mode
·hydraulic oil temperature : within
working range
pressure of
·engine running in high idle speed 3.5±0.5
control oil 3.5
·output pressure of pressure-relief valve
circuit supply
with all the joysticks at the middle
position
97
suitable machine model SWE210NB
cla standard allowabl
item measure working condition unit
ss value e value
rotary brake
·hydraulic oil temperature : within degree 72.4 100
angle
working range
·engine running in high idle speed
·work mode:H
·rotary stops after running one circle
required time
·hydraulic oil temperature : within second 24.6±2.5 max.30
for rotary
working range
·engine running in high idle speed
·initial rotary after one circle,required
time for measuring rotary 5 circles
98
suitable machine model SWE210NB
cla standard allowabl
item measure working condition unit
ss value e value
rotary mm 0 0
hydraulic drift
99
suitable machine model SWE210NB
H
13.1 13.1±1
tra
vel
100
suitable machine model SWE210NB
cla standard allowabl
item measure working condition unit
ss value e value
travel
Mm 0 0
hydraulic drift ·hydraulic oil temperature : within
working range
tra ·engine misses
vel ·sproket faces the up grade position and
park the machine on 12º slope
·5 minutes sliding space
·hydraulic oil temperature: in working
range
travel motor ·engine runs at high idle speed
L/min
leakage ·travel when rag wheel is locked
·oil leakage after trvelling 1 minute in
overflow state
101
suitable machine model SWE210NB
standa
cla allowabl
item measure working condition unit rd
ss e value
value
complet
e
working
device(t
200 ≤
ooth
point
fall
extent)
boom oil
hy cylinder
dra (retracti ·hydraulic oil temperature:within working 20 ≤
uli ve range
mm
c extent) ·flat ground
dri arm oil ·in measuring state as the above fig
ft cylinder ·engine misses
wo
(extende ·the joystick is in the middle position 20 ≤
rki
d ·measure falling amount every 5 minutes
ng
degree) and make a conclusion refer to the result in
de
bucket 15 minutes
vic
e oil
cyinder
20 ≤
(retracti
ve
degree)
102
suitable machine model SWE210NB
standa
clas allowabl
item measure working condition unit rd
s e value
value
bucket
·hydraulic oil temperature : within unlo
working range 2.3 2.3±0.5
ad
·engine running in high idle speed
·work mode:H
·required time from unload stroke
end to digging stroke
103
suitable machine model SWE210NB
cl
standard allowabl
as item measure working condition unit
value e value
s
co
m
po
un
d travel deviation
op amount for
er working device
ati and travel ·hydraulic oil temperature:within working Mm 300 ≤
on synchro range
pe operation ·engine running in high idle speed
rf ·work mode:H
or • travel speed:low
m • flat ground
an • travel deviation amount(X)for measuring
ce of traveling 20m after traveling 10m
hy
dr
au
lic
pu
m hydraulic pump
p flow
pe
rf
or
m
an
ce
104
4.2 Test and adjustment of hydraulic device
4.2.1 Test and adjustment of system working pressure
Instruments
VKA3/06SA
S3 730101000358 pressure testing joint 1
3C
End direct
connectionG
S3 730101000080 joint 1
E008LROM
DA3C
★The working pressure (output pressure of hydraulic pump) of every actuator is displayed on
the monitor of the cab.
★Before measuring, the hydraulic oil temperature should be increased to 50~55º Celsius.
Measurement
1. Combination of pumps, hydraulic components and valves
Please refer to the contents of main pump and multiple way valve and hydraulic schematic
diagram in chapter 3.2 for hydraulic device functions and maintenance standards so as to
understand the structure and test point of main pump and multiple way valve and system flow
distribution.
The flow distribution to every actuators by front and back main pumps when act separately:
Lower the working device to the ground and stop the engine, release pressure in pipes by
operating joystick and pressure in oil tank by loosening the cover of pouring orifice.
1) Dismantle the pressure sensor(1) which connects with oio port a1(or a2),then connects joint
S3, and connects piezometric joint to the other end of S3. Connect manometer S1 with
piezometric hose S2 to S3.
2) Start engine and keep it running until the increasing of hydraulic oil pressure meets the
working range.
106
★ If press the touch compression switch on handle, oil pressure will transform to high overflow
pressure. If release the pressure, it will transform to low overflow pressure.
2) Measure hydraulic oil pressure when engine runs in high idle speed and rotary oil circuit
overflows.
★Display hydraulic oil pressure when the safety valve of rotary motor overflows.
★The overflow pressure of rotary motor islower than the main overflow pressure.
6. Measuring for overflow pressure of travel oil circuits
1) Latch travel. Put pin (1) between the sprocket wheel and track bracket to insure latch travel.
Adjusting
1. Adjusting for overflow pressure (one-level pressure setting value)
★ If the one-level overflow pressure of working device or travel is abnormal, or the two-level
overflow setting pressure is adjusted, the one-level overflow pressure should also be adjusted.
107
1) Break hose.
2) Unscrew latch nut (7) and adjust pressure through turning keeper (8).
★ If the screw turns to the right, pressure will increase.
★ If the screw turns to the left, pressure will decrease.
3) Check the pressure after adjusting. Perform measuring work according to the above steps.
★ Please connect the pilot hose when measure pressure.
108
1) Unscrew latch nut (1) and adjust pressure according to turning adjust screw (2).
★If the screw turns to the right, pressure will increase.
★If the screw turns to the left, pressure will decrease.
2) Check the pressure after adjusting. Perform measuring work according to the above steps.
★Use latch nut for locking after adjusting.
Instruments
specificatio
mark No. name qty.
n
shock
resistance
S1 740402000034 0-6MPa 1
pressure
table
pressure
S2 730505000005 testing SMA3-5000 1
hose
pressure
VKA3/06S
S3 730101000358 testing 1
A3C
joint
End direct
connection
S4 730101000080 joint 1
GE008LRO
MDA3C
★Before measuring, the hydraulic oil temperature should be increased to 50~55º Celsius.
109
Measuring
Lower the working device to the ground and stop the engine, release pressure in pipes by
operating joystick and pressure in oil tank by loosening the cover of pouring orifice.
1) Dismantle the oil plug (1) of piezometric point (a3).
2) Connect piezometric joint S3 to piezometric point (a3). Connect piezometric hose (S2) with
manometer (S1) to (S3).
3) Start engine and keep it running until the increasing of hydraulic oil pressure meets the
working range.
4) The measured oil pressure is pilot overflow pressure when engine runs in high idle speed
and all the joysticks are in middle position.
Adjusting
★If the measured pilot overflow pressure cannot match the setting pressure, please adjust the
pressure of pilot overflow (1) according to the following steps:
110
1) Unscrew nut (312) and adjust screw (311).
★If the screw turns to the right, pressure will increase.
★If the screw turns to the left, pressure will decrease.
2) Check the pressure after adjusting. Perform measuring work according to the above steps.
★Use latch nut for locking after adjusting.
Instruments
VKA3/06SA3
S3 730101000358 pressure testing joint 1
C
End direct
connection
S4 730101000080 Transition joint 1
GEO08LROM
DA3C
★Before measuring, the hydraulic oil temperature should be increased to 50~55º Celsius.
111
Measuring
Lower the working device to the ground and stop the engine, release pressure in pipes by
operating joystick and pressure in oil tank by loosening the cover of pouring orifice.
1) Dismantle the oil plug (1) of piezometric point (TR).
2) Connect piezometric joint S3 to piezometric point (a3). Connect piezometric hose (S2) with
manometer (S1) to (S3).
3) Start engine and keep it running until the increasing of hydraulic oil pressure meets the
working range.
4) Read the max. value of being displayed by manometer when working device is running.
★If the volume of system return oil is max., the pressure of return oil will be the max.
★The return oil volume will be the max. if there are no other actions except operating the
control valve to lower the boom, make the arm and bucket do epicyclic motion.
5) Dismantle all the measuring tools after completing measure work and make sure the
machine’s normal condition.
112
4.2.4 Inspection for output pressure of the pilot solenoid valve
Instruments
★Measure the output pressure of solenoid valve after insuring the initial pressure of control oil
circuit is normal.
★Before measuring, the hydraulic oil temperature should be increased to 50~55º Celsius.
Measuring
Lower the working device to the ground and stop the engine, release pressure in pipes by
operating joystick and pressure in oil tank by loosening the cover of pouring orifice.
★outgoing direction for output oil port of solenoid valve:
1. Break the hoses of solenoid valve to measure out its output pressure.
2. Connect transition joint on the output oil port joint. Connect oil port(1) with (S4),
113
(2)and(3)with(S5),and fit with piezometiric joint (S3). Connect piezometric hose (S2) with
manometer (S1) to (S3).
3. Start engine and keep it running until the increasing of hydraulic oil pressure meets the
working range.
4. Run the machine with model H, then operate the pilot control valve or cut off the solenoid
valve for measuring pressure.
★If every outlet pressure data shows as the following fig, it is regarded as normal.
solenoid output
valve pressure
OFF
0
(erasement)
★Please refer to the “function state fig”for every solenoid valve about how to open or close
them.
Pilot latch solenoid valve
state function
security lock OFF
lock
unlock ON
lever
state function
pilot latch solenoid
valve ON
ON
press the pressure
button
reset the pressure
OFF
button
114
Two-speed solenoid valve
state function
pilot latch solenoid
valve ON
ON
close the
two-speed switch
break the
OFF
two-speed switch
Instruments
★Measure the output pressure of solenoid valve after insuring the initial pressure of control oil
circuit is normal.
★Before measuring, the hydraulic oil temperature should be increased to 50~55º Celsius.
Measuring
1. Break the pilot hoses on multiple way valve according to the following table to measure its
pressure.
mark measuring oil circuit mark measuring oil circuit
boom
1 left travel(forward) 6
(descend)
arm(epicyclic
2 platform rotary(to the right) 7
motion)
platform rotary(to the
3 arm(digging) 8
left)
4 right travel(forward) 9 left travel(backward)
5 bucket(digging) 10 boom(lift)
115
2. Connect transition joint (S4) on the pilot oil port, and thread piezometric joint (S3). Connect
piezometric hose (S2) with manometer (S1) to (S3).
3. Start engine and keep it running until the increasing of hydraulic oil pressure meets the
working range.
4. Run the machine with model H, and then measure the output pressure for joystick when it is
in free state or full-stroke state.
★If outlet pressure shows as the following fig, it is regarded as normal.
joystick output pressure
free state 0
full-stroke 2.6MPa
116
5. Dismantle all the measuring tools and make sure that the machine is in normal state.
2) Operate pilot valve to make the main valve core of the boom move to its lift position or
make the main valve core of the bucket move to its epicyclic motion position.
• Increasing of the fall speed indicates there are leakage fault in oil tank.
• No change indicates there are faults in control valve.
★The start switch of the engine is in ON position,press security handle and operate joystick.
★If the pressure in accumulator descend; keep the engine running about 10 seconds for
recharging.
117
2) Operate arm joystick to move the arm to the side of digging.
• Increasing of the fall speed indicates there are leakage fault in oil tank.
• No change indicates there are faults in control valve.
★ The start switch of the engine is in ON position,press security handle and operate joystick.
★ If the pressure in accumulator descend, keep the engine running about 10 seconds for
recharging.
When break the pipes of hydraulic system, the residual pressure should be released according
to the following methods.
1. Stop the engine and unscrew the pouring orifice gradually to release the pressure in oil tank.
2. Operate the joystick for several times.
★Operate joystick when engine start switch is in ON position.
★Pressure stored in accumulator wll be released when joystick is operated for 2-3 times.
3. Start the engine, runs it at low idle speed for 10 second to store pressure in accumulator, and
then stop engine.
4. Repeat step 2 and step 3 for several times.
118
3) Start the engine and apply overflow pressure on the big cavity of oil cylinder when the
engine runs in high idle speed.
4) Remain this state for 30 seconds and then measure the leakage volume of one minute.
5) After measuring, insure the machine return to the normal state.
Release the residual pressure in pipes. Refer to the last part “Release the residual pressure in
hydraulic oil circuits”.
2) Break the hose (1) in the small cavity of oil cylinder.
Be careful not to break the hoses at the bottom of the oil cylinder.
3) Start the engine and apply overflow pressure on the big cavith of oil tank when the engine
runs in high idle speed.
4) Remain this state for 30 seconds and then measure the leakage volume of one minute.
5) After measuring, insure the machine return to the normal state.
3. Measuring for the leakage volume of bucket oil cylinder
1) Start the engine and keep it running until hydraulic temperature rises to the working range
and extend the pistion rod of bucket cylinder to the end of the stroke.
Release the residual pressure in pipes. Refer to the last part “Release the residual pressure in
hydraulic oil circuits”.
2) Break the hose (1) in the small cavity of oil cylinder.
119
3) Start the engine and apply overflow pressure on the big cavith of oil tank when the engine
runs in high idle speed.
4) Remain this state for 30 seconds and then measure the leakage volume of one minute.
5) After measuring, insure the machine return to the normal state.
4. Measuring for the leakage volume of rotary motor
1) Break hose (1) which connects with oil tank,and plug its oil port.
2) Put working device on flat ground and make the bucket against ground.
3) Start the engine. Measure leakage volume when engine runs in high idle speed and apply
rotary overflow pressure.
★Travel motor remains still.
★Keep the state of step 3)for 30 seconds,measure the leakage volume of one minute.
★After the first measuring, turn the up rotary platform of 180 º, and measure again with the
same method.
3) Break hose (1) of drain oil port of travel motor, fit with choke plug on the end of the hose.
4) Start the engine. Measure leakage volume when engine runs in high idle speed and apply
rotary overflow pressure.
When doing this measuring, a faulty operation of the joystick will cause a serious accident, so
insure every signal and make correct confirmation.
★Remain step 4) for 30 seconds,measure the leakage volume for one minute.
★ Run the motor slightly to change the position of oil distributing plate and rotor. And then
repeat the above steps to measure several times.
5) After measuring, insure the machine returns to the normal state.
It is forbidden to do the following recovery operation to the pumps in normal station, unless
the power and displacement of the main pump are different from the setting data caused by
dismantlement or service to the main pump.
★Adjust the screw on adjustor can adjust the max. flow, min.flow, power and flow control
character.(Refer to fig. 1 and fig.2 for adjust volume)
1. Adjusting of the max. flow
Release hexagon nut (1),tighten(or release) fix screw (2)for adjusting. There are no changes
of the other control characters except for the max. flow.
121
2. Adjusting of the min. flow
Release hexagon nut(1),tighten (or release) fix screw (2) for adjusting.No changes of the
other control characters. Notice that if tightened too much, it may need increasing power in
overflow state.
122
3. Adjusting of input power
★ Adjustor uses the sync full power control way. When adjust the setting volume of the power,
make the same change for the adjust screws of front and back pumps. The changed value of the
pressure is the value when the pressure of the two pumps increased simultaneously.
1) Adjusting of external spring
Release hex nut(1),tighten(or release adjust screw(4)for adjusting. When tighten the adjust
screw, see as (JPG0328). Control the line gragh move to the right and increase the inlet power.
After turning adjust screw(4)for N times,the setting value of internal spring will change as well.
So turn adjusting screw (3) inversely.
123
4. Adjusting of charaters of the flow control
Release hex nut(2),tighten(or release adjust screw(1)for adjusting. When tighten the fix
screw, see as (JPG0035). Control the line graph move to the right when tightening.
124
adjust input power
adjusting for internal spring adjusting for external spring
compensate
adjuster rev adjust adjust and variabl
variable
model (r/min) the variable in the contro e in
in
screw-in input screw-in l start input A
discharge
depth torque(N.M) depth pressu torque
(ℓ/min)
(turning) (turning) re (N.M)
(MPa)
KR3G-2
2100 +1/4 10 42 +1/4 1.6 43 1.8
NO9
126
4.3.2 Fault sorts and check methods
No. fault sorts fault processing method
diagnosis(probable
cause)
1. Measure the voltage of the
accumulator by multimeter. The normal
insufficiency of the voltage should be over 24V;
accumulator’s 2. Observe the electric check hole
electricity (maintenance-free battery is green under
the normal state, it will turn black if the
electric is insufficient).
Keep the start switch of the engine in
fault in the start switch OFF state,OFF position is over 1M
of the engine ohm. Keep it in start state, which is
under 1 ohm.
Put the start switch light on start
position, if the input end (S, E)of the
fault in security relay relay is normal, then use multimeter to
check if the output (B, C)of the security
engine can
1 relay is closed, or it may be destroyed.
not start
fault in the relay of Turn the start switch to ON position, if
extinction motor the input end (1, 2)of the relay is normal,
then use multimeter to check if the
output contact(3, 5)of the security relay
is closed, or it may be destroyed.
fault in extinction Turn the start switch to ON position,
motor check if the extinction motor B, P1
terminal voltage(24V)and P2 terminal
voltage(0V)is normal , or it may be
destroyed.
fault in the start Turn the start switch to ON position,
motorof the engine check if the B 、 C terminal
voltage(24V)of the start motor is
normal, or the start motor is break or
damaged.
Keep the engine running when fault
rev displays
diagnose.Use multimeter to measure the
abnormal or fault in rotary
2 voltage of the two ends of the
diplays transducer
transducer. The normal voltage should
nothing
be over 5V, or it may be destroyed.
127
No. fault sorts fault processing method
diagnosis(probable
cause)
Turn the start switch to OFF position,
rev displays
use multimeter to measure the resistance
abnormal or break in rotary
2 of the two wires, which shoud be under 1
diplays transducer harness
ohm,or the rotary transducer wire group
nothing
may be break.
Break the connector of start switch and
turn it to OFF position. Use multimeter
to measure if the resistance of the
terminal BR and B are normal (above
start switch fault 1M ohm). If they are normal, it shows
there is short circuit and check the start
circuit please. If the resistance is under1
ohm, it shows the start switch is
short-circuited.
Keep the start switch at ON position.Use
engine multimeter to measure the voltage of
3 cannot terminal A on extinction motor, the
extinct extinction motor fault normal voltage is 24V, or the extinction
motor may be break.
Keep the start switch at ON position.Use
multimeter to measure the voltage of the
output end (3) on extinction relay, the
normal value is 4V. Keep the start switch
extinction relay fault at OFF position, use multimeter to
measure the voltage of the output end
(3), the norma value is 0V, or the relay
may be damaged.
wire group break
automatic idle switch Check the automatic idle switch. Its
fault resistance should above 1M if it is at
OFF position, and under 1M if it is at
ON position.
wire group break Use multimeter to measure the resistance
of the two wires, its normal value should
automatic below 1 ohm.
4 idle function rev doesn’t reach the If the engine rev is above 1500 /m,the
do not work setting value automatic idle will work.
the pressure value of If the pressure of the main pump is under
the main pump is 4M Pa,the automatic idle will work.
excessive
Start the machine, if the cooling
temperature is under 25 degrees
the machine is in
centigrade,the machine will come into
warming-up process
warming-up state automatically and the
automatic idle function will not work.
128
No. fault sorts fault processing method
diagnosis(probable
cause)
When the machine is running, the engine
will retard automatically if the cooling
the cooling temperature
automatic temperature of the engine is above
of the engine is low
retard of the 100°C.If it is under 100°C, the automatic
5
engine do retard will not work.
not work If the engine rev is under 1800/m, the
engine rev is low automatic retard of the engine will not
work in the machine’s running state.
If the engine rev is above 1200/m,its
automatic engine rev is high automatic warming-up function will not
warming-u work.
6 p of the cooling water When start the machine, the automatic
engine do temperature of the warming-up of the engine will not work
not work engine is high if the cooling water temperature is above
25°C.
touch step-up switch Use multimeter to check the touch
fault press-up button on handle.
wire group fault Use multimeter to check if the wire
groups are break or not.
touch
If the engine rev is under 1600/m,the
step-up of engine rev is low
7 touch press-up function will not work.
the engine
do not work working mode of the Only the engine is on mode S or H, the
engine is not correct touch press-up function will work.
pressure increasing Use multimeter to check the pressure
solenoid valve is increasing solenoid valve
damaged
cooling water Check the cooling temperature of the
temperature of the engine is higher than the normal value
engine is higher
engine cooling Check if the resistance of the cooling
the alarm temperature sensor of water temperature sensor changes along
light for the engine fault with the temperature change. The higher
cooling of the temperature, the less of the
8 temperature resistance.
of the wire group of Use multimeter to check if the wire
monitor temperature sensor group of temperature sensor connect
turns red connect ground ground.
Others (i.e. inlet scoop Check if it is tight sealed around the
of the engine false air, engine inlet scoop. If it false air, the
etc.) cooling effect will be bad and the cooling
temperature rises.
129
No. fault sorts fault processing method
diagnosis(probable
cause)
fuel level is low The actural fuel level is a little low
Use multimeter to check if the resistance
range of the fuel sensor is 10 ohm~180
ohm,the range value will not change
fuel alarm fuel level sensor fault
9 light turns with the fuel level change. If the
red resistance is too high or too low, the
sensor may be damaged.
wire break of fuel level Use multimeter to check if the end wire
sensor fault group of the fuel level sensor is open
circuit.
machine won’t start The charging alarm light turns red when
the machine doesn’t work.
the generator doesn’t After the engine start, measure if there is
charging work output voltage at the output end of the
10 alarm light generator. If the generator belt is slip or
turns red break, or the generator fault.
charge loop group fault Measure if there is open circuit or ground
connection fault in the wire group of
charging return circuit.
air filter clogging clogging in the air filter
In normal condition the air filter is open
air filter air filter clogging all the time. If the air filter is clogging,
11 clogging sensor fault the sensor will be closed constantly, or
alarm light the sensor may be damaged.
is red sensor wire group Measure if the wire group of the sensor
connect ground connects ground.
The engine oil alarm light will turn red in
machine won’t start
this state.
alarm light Measure the engine oil level is a little
engine oil pressure is
for engine lower after a few minutes of the engine
low
12 oil stop.
pressure engine oil pressure Engine oil sensor fault
turns red sensor fault
sensor wire group Measure if the sensor wire group
connect ground connects grouond.
throttle knob fault Turn the throttle knob and measure if its
resistance value changes in the range of
5K ohm. If therer is no change or the
rev doesn’t value is too high, the throttle knob is
change by damaged.
13 adjusting wire group break Measure if the throttle knob and the wire
the throttle group of throttle motor have been broken
knob or connected ground.
feedback signal wire of The resistance value of the throttle
the throttle open circuit feedback potentiometer changes in the
range of 10K ohm.
130
No. fault sorts fault diagnosis(probable processing method
cause)
throttle motor fault Supply the throttle motor with
DC12V power. The motor may be
damaged if it doesn’t work.
machine is under the When the machine is in the state of
automatic idle state automatic idle, the rev will have no
rev doesn’t change
change by adjusting the throttle
13 by adjusting the
knob.
throttle knob
The machine is in low idle state
when it has just started for a few
machine is start just
seconds, and the rev will have no
now
change by adjusting throttle knob at
this time.
Measure the ratio electromagnet in
halt mode, its normal resistance is
ratio electromagnet
about 17.5 ohm, otherwise the
fault
the working device ratio electromagnet may be
14
speed is too low destroyed.
wire group of ratio Measure the wire group of the ratio
electromagnet break electromagnet if it is broken or
connected ground.
Measure if the CAN bus is broken
or connected ground. Measure
monitor displays bus CAN break or short when to connect the negative of the
15
abnormal(displayed circuit accumulator after breaking it for
data is 255) several seconds. Observe if the data
showed on the monitor recover.
proportional valve
Use multimeter to measure if there
of the main valve proportional valve open
are open circuit or ground
16 indicator light on circuit or short circuit
connection fault in the proportional
the monitor turns fault
valve and wire group
red
throttle
potentiometer Use multimeter to measure if there
throttle knob open
indicator light on are open circuit or ground
17 circuit or short circuit
the diagnose connection fault in the throttle
fault
interface of the knob and wire group
monitor turns red
water temperature Use multimeter to measure if there
open circuit of the
sensor indicator are open circuit fault in the water
18 water temperature
light on diagnose temperature sensor and wire
sensor fault
interface turns red group.
fuel level sensor Use multimeter to measure if there
open circuit or short
indicatior light on are opencircuit or ground
19 circuit of the fuel level
the diagnose connection fault in fuel level
sensor fault
interface turns red sensor and wire group.
131
No. fault sorts fault diagnosis(probable processing method
cause)
main pump
Use multimeter to measure if
pressure P1
open circuit or short circuit there are opencircuit or ground
sensor indicator
20 fault in pressure sensor P1 of connection fault in the
light on the
the main pump pressure sensor P1 of the main
diagnose
pump and wire group.
interface turns red
main pump Use multimeter to measure if
pressure P2 sensor open circuit or short circuit there are opencircuit or ground
21 indicator light on fault in pressure sensor P2 of connection fault in the
the diagnose
the main pump pressure sensor P2 of the main
interface turns red pump and wire group.
throttle feedback throttle actuator fault or open Use multimeter to measure if
potentiometer circuit or short circuit in there are opencircuit or ground
22 indicator light on feedback wire connection fault in the throttle
the diagnose feedback potentiometer and
interface turns red wire group.
monitor fault
open circuit in the power Check the return circuit of the
no display on the wire group of the monitor power.
23
monitor the power fuse of the monitor Replace power fuse and check
melt if there is ground connection
fault.
no voice of the open circuit or groud Use multimeter to measure if
travel alarm connection in the wire there are open circuit or short
24
group of the travel alarm circuit in the travel alarm, or
fault it may be destroyed.
25 wiper doesn’t work wire group open circuit or
ground connection fault
132
5. Disassembly and assembly
5.1 How to read this manual
Installation and removal
Removal of parts
z Section “removal” includes procedure and instruction.
z All the warning signs and marks which have been used in the section “removal” are listed as
follow:
★ This mark is used to provide instructions and attentions to operating procedure.
★ :Lift weight.
Installation of parts
z Install parts in reverse order unless otherwise noted.
z All marks and signs used in section “installation” is as follow:
★ This mark is used to provide instruction and attention to operating procedure.
★ :Lift weight.
★ :Bolt torque.
★ :Lift weight.
Assembly
z This section “assembly” includes procedure, precaution and know-how.
z All the sighs and marks are explained and listed as follow:
★ This mark is used to provide instruction and attention to operating procedure.
★ :Lift weight.
★ :Bolt torque.
133
5.2 Instruction during operation
The following items should be followed when attempt any disassembling or assembling
procedure (removal or installation).
1. Instructions during disassembling
z Dispose properly if engine coolant contains antifreeze.
z Always cap or plug hoses when hoses or steel pipes are removed to prevent them from entry
of dirt, dust and debris.
z Provide a proper container to catch the oil discharged
z Confirm matching marks which indiceates installation position, provide mating marks to
avoid re-assembling mistake, prior to disassembling.
z Do not pull conducting wire to avoid loose from contact point. When disconnecting
conduct wire, Hold connector to avoid excessive force applied to wire.
z Attach marks on the wire or hose to make certain their positions. It helps to avoid mistake
during re-assembling.
z Calculate and inspect the number and thickness of washers, and keep them at safe place.
z Make certain to use proper lifting device with sufficient strength and reliability, when
lifting components.
z Evenly fasten screw in proper sequence when lifting bolt was used to remove any
components.
z When disassembling any devices, clean the surrounding area and cover them to prevent dust
or dirt from entering into them.
2. Instructions during the process of assembly
z Replace and fasten all the nuts (cannula nuts) and bolts with specified torque value.
z No distortion or interference is allowed during hose installation.
z Replace all bolt, nut, bushing, o-ring, cotter pin, and locking plate with new ones.
z Bent cotter pin and fix locking plate securely.
z When applying bonding compound, Clean components and remove all oil and grease. And
then apply 2 or 3 drops to all parts with thread.
z When applying sealant, clean surface and remove all oil and grease. If no dirt and damages
are recognized, evenly wipe sealant to it.
z Remove or repair all part’s damage, dent, burrs and rust.
z Grease all rotary components or sliding components.
z Apply anti-friction composites to the part surface, when press- fitting.
z Make certain snap rings have been securely located in the groove after assembling snap
rings.
z Make wire connector free of oil, dirt and water; connect securely when connecting wire with
wire connector.
z When using eye bolt, inspect it to make certain the bolt free of distortion and
134
metamorphic. Make sure to completely fasten it and align it with the lifting hook.
When fastening counter flange, always fasten them evenly to prevent that one side’s flange is
over fastened.
3.The fasten torques of main bolts\ nuts are as following table. (N.m)
tightening torque
Screw diameter opposite
Target value using limit
(mm) side(mm)
N•m N•m
6 10 13.2 11.8 - 14.7
8 13 31 27 - 34
10 17 66 59 - 74
12 19 11 98 - 123
14 22 177 157 - 196
16 24 279 245 - 309
18 27 382 343 - 425
20 30 549 490 - 608
22 32 745 662 - 829
24 36 927 824 - 1030
27 41 1320 1180 - 1470
30 46 1720 1520 - 1910
33 50 2210 1960 - 2450
36 55 2750 2450 - 3040
39 60 3280 2890 - 3630
tighten torque
screw thread standard across width target value use limit
(mm) N•m N•m
9/16-18UNF 19 44 35 - 63
11/16-16UN 22 74 54 - 93
13/16-16UN 27 103 84 - 132
1-14UNS 32 157 128 - 186
13/16-12UN 36 216 177 - 245
1-7/16-12UN-2B 41 215 176 - 234
135
★ The torque of control valve and motor should be reduced by 10% according to “bolt/ nut
fasten torque fig”. Fasten the circumferential uniform bolt in diagonal cross line. Wipe the glue
1277 when assembling.
★ After the cylinder, main pump and other hydraulic devices are disassembled and
repaired then re-assembled; bleed the air for the first time use. The operation procedures
are as follow:
136
(1) Start the engine and run it with low idle speed.
(2) Operate working device controller to operate hydraulic cylinder 4-5 times, stop
the cylinder at a position 100 mm away from the stroke end.
(3) Operate hydraulic cylinder 3-4 times to its stroke end.
(4) Make the engine run with normal speed, afterwards.
★When using the machine for the first time after long-term storage or repair, follow the
same procedure.
137
3.Disassemble plate(3),then the pin.
★ Check the shims number and thickness and put them at safety place.
4.Start the engine and retract piston rod.
★ Fix piston rod with cable and lower the oil tank on the platform or place a bearing under the
oil tank to support it.
★ Disassemble the other side of the boom oil tank with the same way.Two pieces of the oil tank
hose (5). Seal the port and make necessary labels.
★ Choke the hose to prevent oil discharging and fix it on the other side of the valve.
6. Dismantle the connector (7) on the lamp.
7. Life the working device and dismantle pressure plate(8),then the pin(9).
★ Don’t forget to check the shims number and every parts with shims.
138
8. Lift the working device ASSY and decompose it.
(1) Assembly
• Assemble in reverse order of dissemble.
Wipe butter on the inner surface of the bushing when assemble the pins and align the pin
holes. Do not put fingers into the holes.
★ Exhaust from oil tank. Refer to exhaust from the parts in chapter “testing and adjustment”.
★ Fill the oil to specified level through the oil port. Run the engine to cycle the oil in the system
and then chek the oil level.
(1) Disassembly
1. Disassemble the engine cover (1). Refer to “engine assembly and disassembly”.
2. Disassemble counterweight rubber choke plugs (2). Fit with handling bolts and lift them.
139
4. Lift counterweight slowly and horizontally.
★ Be careful not to touch the engine, radiator and cooler.
(2) Disassembly
Disassemble the cable from the negative terminal of the accumulator.
1.Disassemble rubber floor mat in the cabin.
2.Disassemble part (1). Disassemble the electric joints between every electric parts and electric
mounting plate (2) and make necessary mark.. Disassemble the bellows between evaporator and
duct, new tuyere and evaporator. Disassemble the hose of window scrubber.
140
3.Disassemble lock drag bar (3).
4.Disassemble the 6 bolts (4) which connect the cabin and the worktable.
141
5.6 Engine disassemble and assembly
80-300N.m
7 740119000011 Torque spanner
12.5mm
8 740121000011 plastic handle cross screwdriver 150 GB1064-89
(2) Disassembly
★ Lower the working device to the ground and stop the engine. Disassemble the cable
from the negative (–) terminal of accumulator. Gradually loosen the oil ejector lid of the
hydraulic oil tank to release the inner pressure.
★ Stick identification tags on each pipe to avoid making mistakes when refitting.
1.Dismantle release plug to discharge hydraulic oil from hydraulic oil tank and pipelines.
3.Lift engine cover (1) and dismantle coupling bolt and stand bar (2). Support the engine cover
with proper batten and lift device.
4.Dismantle intercooled air duct(3), cooler water inlet pipe(4), intercooled escape pipe(6),
supercharger air duct(7), intercooled escape pipe(9), cooler drain pipe(10), rubber ring(5)and
drag bar(8),make the necessary marks and seal the pipe orifice.
142
5. Dismantle engine oil pipeline, compressor pipeline and electric joint. Make the necessary
mark and seal the pipe orifice.
6.Dismantle compressor ASSY.
7.Dismantle all the oil pipelines of hydraulic pumps, electric joints(refer to “hydraulic pump
ASSY disassembly and assembly”)and its cover parts and baffles.
8.Dismantle exhaust muffler and its discharge pipe.
9.Dismantle all the construction bolts of the engine.
(3) Assembly
• Assemble in reverse order of disassemble.
★ Refer to section “check and adjust” of part” belt tension of air-conditioning compressor” in
chapter“measuring and adjustment”.
★ Screw thread glue:thread lock glue 1277.
Common box
1 740105000164
spanner
2 740119000011 Torque spanner 80-300N.m 12.5mm
Plastic handle
3 740121000011 cross screwdriver GB1064-89
150
Inner hexagon
4 740104000007 S10 GB5356-85
spanner
(2) Disassembly
★ Lower the working device to the ground and stop the engine. Disassemble the cable
from the negative (–) terminal of accumulator. Gradually loosen the oil ejector lid of the
hydraulic oil tank to release the inner pressure.
★ Stick identification tags on each pipe to avoid making mistakes when refitting.
1.Dismantle release plug to discharge hydraulic oil from hydraulic oil tank and pipelines.
144
4.Dismantle hydraulic oil pipes joint (11), cover plate(12)and auxiliary water tank hose(13),seal
the orifice.
5.Dismantle hydraulic oil pipes joint (14) and seal the orifice.
146
5.8 Hydraulic pump ASSY disassembly and assembly
Tools
Disassemble the cable from the negative (–) terminal of accumulator before starting the
engine. Lower the working device to the ground and stop the engine. Gradually loosen the oil
ejector lid of the hydraulic oil tank to release the inner pressure.
★ Stick identification tags on each pipe to avoid making mistakes when refitting. Seal the pipe
orifice and preserve all the sealing elements.
1.Discharge the hydraulic oil from the oil tank. If there is no special oil drain device to use, twist
off the discharge plug at the bottom of the oil tank.
147
(2) Two pressure sensor connector
(3) Oil drain pipe of the main pump
(4) Two main oil pipes
(5) Pilot oil supply output pipe
(6) Connector of the proportional solenoid vave
(7) Negative flux feedback pipe of the back pump
(8) Oil inlet of the proportional solenoid vave
(9) Suction pipe of the pilot oil supply
148
6.Lift the hydraulic pump, and then disassemble the connecting bolt between the engine and the
hydraulic pump.
149
5.9 Hydraulic pump body disassembly and assembly
Tools
3.Open the oil-embolus cover (468) on the pump body and extract the oil in the pump.
150
5. Unscrew the hexagon bolt (401) which is fixed on the shoe plate (251) of the swash plate,
pump body (271) and valve body (312).
★If there are connecting pieces at the back of the pump, dismantle the connecting pieces before
doing the next step.
6.Put the fitting surface of the pump and the adjustor downwards and place it on the worktable
flatly. Dismantle pump body (217) and valve body (312).
Lay rubber plate to avoid damaging the fitting surface.
7. Align pump body (271) and drive shaft, take out cylinder body (111), piston (151), pressure
plate (153), spheric bushing (156) and oil tank spring. Be careful not to destroy the slip surfaces
of the oil tank, spheric bushing, and guide track and piston shoe.
8. Dismantle inner hexagon bolt (406) and sealing cover (F) (261).
★Assemble pulling bolts in the pulling holes of the sealing cover (F) can take out the cover plate
easily.
★There is oil seal packingring on the sealing cover (F). Don’t damage oil seal packingring as
assembling and disassembling.
151
9. Disassemble hexagon bolt (408) and the back cover plate (263).
10.Slightly knock the flange tray of the support table for tilt plate (251) on the side of the pump
to disconnect the pump body and shoe plate.
11.Take out piston shoe (211) and tilted plate (212) from pump body (271).
12.Slightly knock the shaft end face of the drive shafts (111,113) with plastic hammer. Pull out
the drive shaft from the tilt plate support table.
152
13. Take valve bodies (313,314) from the valve body (312) .they will be pulled off when
operating step 6.
14.Take out hold down plates (L) (534), (S) (535), auxiliary piston (532) and tilt pin (531) from
pump body (271) if necessary. And take out needle bearing (124) and spline connect shaft (114)
from valve body (312). When dismantle the tilt pin, use clamp to prevent damaging the head of
the tilt pin.
★There is hard gum on the match surface between the tilt pin and auxiliary piston. Please avoid
damaging the piston.
★Do not pull out the needle bearing.
★Do not loosen valve body and the hexagon nuts on the tilt plate support table, otherwise the
setting flow will change.
Assembly
Fastening torque table
parts No. dimension torque N.M
401 M20 430
406 M8 29
466 G1/4 36
468 G3/4 170
490 NPTF1/16 8.8
531、532 24X2 330
806 M16 130
808 M20 240
Assemble in reverse order ofdisassemble.Fastening torque of the bolts are as the above table.
Please note following item:
★ Repair the damaged parts and prepare the new ones.
★ Clean all the parts using cleaning oil and assemble them after air scavenging.
★ Assemble the movable parts and bearings after wiping action oil for them.
153
★ Replace in principle the sealing parts, i.e. O-ring and oil seal, etc.
★Screw up construction bolts and pins with spanner as per the specified torque.
★Don’t intermix the front pump parts with the back pump parts.
1.Using hammer to knock the tilt plate support table (251) slightly into pump body (271) and fit
it.
★Assemble the auxiliary piston, tilt pin and hold down plates (L) (S) on pump body before
taking them out.
★When tightening the auxiliary piston and tilt pin, please use clamp to avoid damaging the head
of the tilt pin and feedback pin, wipe hard gum (medium intensity) on the bolt.
2.Place the fitting surface of the pump body and the adjustor downwards. Embed the bushing
into the tilt plate of tilt pin (531). Assemble the tilt plate (212) into the tilt plate support table
(251).
★Ensure the tilt plate turns well by using your fingertips.
★Wipe lubricant oil on tilt plate, tilt plate support table and drive parts for assembling drive
shaft.
3. Assemble the drive shaft with bearing (123), shaft flapper (127) and baffle ring (824) into tilt
plate support table (251).
★It is forbidden to knock the drive shaft with hammer.
154
★Knock the outer circle of the bearing slightly with rubber hammer, and then use copper bar to
knock it fully in.
4.Put the seal cover (F)(261)into pump body (271)and fix it with inner hexagon bolt(406).
★Wipe a thick lubricant oil on the oil seal of the seal cover (F).
★ Be careful not to damage the oil seal.
★Assemble the back cover (263) and seal cover (262) of the pumps in series as per the same
steps.
155
6.Align the valve block (313) with pin and then fit it into the valve body (312).
★ Please don’t make wrong assembly for inlet and outlet directions of the valve block.
7.Assemble valve body (312) on shell (271) and fix it with hexagon bolt (401).
★The operation will be easier to assemble the back pump body first.
★Please don’t fit wrong direction for the valve body. The outlet position (from inlet axes
direction): left side (the position of the adjustor: upwards).
8.The feedback pin of tilt pin is in the feedback pin of adjustor. Assemble the adjustor and fix it
with inner hexagon bolt(412,413).
★Do not make wrong assembling for the front and the back adjustors.
9.Assemble oil drain pinhole (467) and complete the whole operation steps.
156
157
5.10 Main pump adjustor disassembly and assembly
Tools
2.Use cleaning oil to wipe off the debris and rusty spot on the surface of the adjustor.
158
5.Dismantle cover(C)(629)and take out outer circle spring(625), inner circle spring(626) and
spring seat( C)(624). Pull out adjusting ring (Q) (645), guide spring (646) and spring seat (644).
★Using bolt M4 can take out adjusting ring (Q) (645) easily.
6.Please dismantle hexagon bolt (436 438) and guide cover (641). Then take out set spring (655)
from guide part.
159
8.Take out lock check ring (858), support latch (614) and adjust latch (615).
★Using bolt M6 can take out support latch (614) and adjust latch(615).
9.Take out lever (2) (613), and don’t pull out pin(875).
★Using nipper can simplify operation process.
10.Pull out pin (874) and take out feedback rod block (611).
★Using thick copper bar to push out pin (874) (its diameter is φ4) from the top down without
touching lever (1) (612).
160
11.Take out rod block (612). Do not pull out pin (875).
12.Pull out guide piston shell (643) and sliding shoe (652).
13.Pull out piston shell (622), compensation plug (621) and compensation rod (623). The
disassembly work for adjustor is completed.
Assembly
Fastening torque figure
parts NO. dimension torque N.M
412、413 M8 29
436、438 M6 12
496 NPTF1/16 8.8
630 M30X1.5 160
801 M8 16
802 M10 19
161
1.Assemble compensation plug (623)into the compensation hole of the shell(601).
2.Insert the rod block (1) (612) which has been fit with pins into the compensation plug groove.
Assemble the rod block on the pin.
3.Assemble bushing (652) and sliding shoe (651) into the sleeving hole.
★Ensure the bushing and sliding shoe can move smoothly in the adjustor shell.
★ Pay attention to the direction of the bushing.
4.Assemble feedback rod block(611).Align the pin (874)with the pin hole of feedback rod block
and insert it.
★Insert the pin to the feedback rod block beforehand will be convenient for operation.
★ Pay attention not to fit wrong direction of the feedback rod block.
5.Assemble the guide shaft (643) into the inside hole of the shell.
★Ensure the guide shaft can move smoothly.
6.Insert the pin of press-in rod block (2)(613)into the guide piston groove and assemble rod
block (2).
7.Press the pin of support latch (614) into the pin hole of rod block (2), assemble support latch
and locating ring (858).
162
8.Insert adjusting pin (651) and assemble location ring.
★ Be careful not to fit wrong positions for the support latch hole and the adjusting latch hole.
★Meanwhile, confirm if the action distance for feedback lever block is too long, and if there is
jamming problem.
9.Assemble retracting spring (654) and spring seat (653)into sleeving hole, then assemble check
ring(814).
10.Assemble setting spring (655) into sleeving hole, compensation piston (621), piston shell
(622) and guide cover (641) into compensation hole. Tighten and fix it with inner hexagon
bolts (436) (438).
11.Assemble spring seat (644), guide spring (646) and adjusting wheel (Q) (645) in spring seat.
Assemble spring seat (624), inner spring (626) and outer spring (625) in compensation hole.
★ Caution not to fit wrong direction of spring seat.
163
12.Assemble the cover (C) (629) which is fit with adjusting bolt(628)(925), adjusting
wheel(C)(627), latch nut(603), hexagon nut(801)and adjusting bolt(924). Tighten and fix the
cover with inner hexagon bolt (438). Assembly is completed.
164
165
5.11 Rotary motor ASSY disassembly and assembly
Tools
Disassembly
Release the residual pressure in hydraulice circuits. Refer to the part “Release the residual
pressure in hydraulic circuits” in chapter “measure and adjust”. Lower the working device to the
ground and stop the engine. Open the oil ejector cover on hydraulic oil tank to release the
residual pressure and turn the security lock rod to the lock position.
★Stick identification tags on each pipe to avoid making mistakes when refitting. Seal the pipe
orifice and preserve all the sealing elements.
1.Dismantle the following 7 hoses:
(1) Oil feed hose
(2) Two main oil hoses
(3) Oil drain hose
(4) Two unlocking hoses
166
2. Dismantle gear oil dranin hose (1) and 14 motor construction bolt (2).
★ Exhaust air and consult the content in section “exhaust air from the parts”in chapter “testing
and adjusting”.
167
5.12 Rotary motor noumenon disassembly and assembly
Tools
2 740104000005 S6 GB5356-85
Disassembly
★The numbers in () after the parts name are serial NO. of the parts in fig.(JPG0152、JPG0155).
Please read the content of part “rotary motor” in chapter “function and structure”.
★As the parts are precise, so be careful to dismantle them to prevent damage. When repair it, be
careful to avoid the dust get into it and damaging the O-rings and sealing plate.
1. Tie the motor down with steel cable and use crane to lift it, wash clean and dry it with
compressed air.
2. Drain working oil in the motor noumenon from outlet.
3. Put the shaft end of drive shaft (101) downwards and fix it on the worktable which is easy to
disassemble. Make combining mark at the combining site of motor noumenon (301) and valve
body (303).
168
★ Lay rubber plate or cloth when you ismantle platform to avoid damaging the parts.
4. Screw off relief valve (051) and dismantle it from valve body (303).
★ When screw off the relief valve, O-ring will be damaged. So it must be replaced.
5. Dismantle ROMH oil drain plug(469)from valve body(303),and then take out spring (355)
and plunger (351).
★As the elastic force of the brake spring (712),valve bocy (303) will eject from motor body
(301).
7. Dismantle brake plunger from brake spring (712).
169
8. Pull out brake plunger (702) from motor body (301) with disassembly tools.
★Hook the claw end of dismantle tool in the groove of the brake plunger and lift it upright.
9. Place the motor in level again.Pull out oil tank (111) from drive shaft (101), and then the
plunger (121), pressure plate (123), (121), (123), pressure spring and brake shoe plate (124).
★ Be careful not to damage the rotary mesh face between the oil tank and the brake shoe plate.
If the shoe plate can not be taken out, dismantle it in the operation of item 12.
10. Take out friction plate (742) and separator metal plate (743) from motor body (301).
170
11. Take out drive shaft (101) and brake shoe plate (124).
★When take out drive shaft, oil seal may be destroyed by splines. So use plastic tape to wind
around the splines before take it out.
Apply the following steps according to the actual situations:
Push out the inner loop of column rolling bearing with punch.
★It can also use hammer and steel bar to beat the inner loop. Be careful to beat it with uniform
force to avoid damaging. The dismantled bearing can not be used again.
1) Slightly beat the outer ring of the column rolling bearing from the side of the oil seal (491)
with hammer and steel bar and take it out gradually from motor body (301).
★The dismantled bearing can not be used again.
2) Using slip hammer bearing detacher to take out column rolling bearing (444) from valve
body (303).
171
★The dismantled bearing can not be used again.
Assembly
Fastening torque figure
parts NO. dimension torque N.M
(031-1) G1/4 0.9
033 M6 12
051 M33X1.5 177
151 G1/4 26
171 M8 29
400 M22X1.5 69
401 M20 430
469 M36X1.5 539
984 G1/2 2.7
985 G1 5.6
1. Place motor body (301) on proper plateform and one side of valve body (303) upwards.
2. Using hot pressure matched way to assemble the inner loop of column rolling bearing (443)
in drive shaft (101).
★ Pay attention to the direction of the locating pin on column rolling bearing.
3. Assemble oil seal (491) into motor body (301).
172
4. Pay attention to the direction of oil seal. Wipe thin grease on oil seal port; knock it
uniformly to avoid damaging the peripheral parts. Knock it slightly and assemble the rolling
bearing (443) into motor body (301) with hammer and steel bar.
★ Be careful not to damage oil seal port when assembling. Wind the shaft splines with plastic
tape.
Place motor body (301) in level and insert brake shoe plate (124).
173
★ Screw the bigger side of chamfering into motor body. To prevent breaking off from
combining site, wipe thin grease on the surface.
6. Connect pressure plate (123) with its spring, then assemble it on the plunger unit (12l,122).
7. Assemble the plunger unit (12l,122) which are placed on plate (123) into oil tank (111),
together with the spline of driving shaft (101).
174
8. Reset motor body (301),put one side of the oil seal downward. Assemble 4 metal plates
(743) of separator and 3 friction plates (742) into motor body (301) in order.
★Wipe thin grease on O-ring to avoid breaking the brake plunger when fit it in.
10. Assemble brake plunger (702) into motor body (301).
175
11. Assemble brake spring (712)) into brake plunger (702).
12. Assemble the external ring of column rolling bearing (444) into valve body (303) gradually
by tapping it with hammer and steel bar at the same time.
★Apply this step only after disassembling column rolling bearing (444).
★Evenly tap the periphery of external ring until it is completely fit into the holding latch groove
of valve body.
13. Assemble valve plate (131) into valve body (303),then assemble O-ring.
176
★ Wipe thin grease on the connecting face of valve plate to prevent it to be breaking off.
14. Assemble valve body (303) into motor body (301),then screw it up with inner hexagon bolt.
★Pay attention to the installation base of valve body, avoid falling down of brake spring. Screw
up the bolt evenly.
15. Assemble plunger (351) and spring (355) into valve body (303),and then assemble ROMH
oil drain spout plug (469) which fit with O-ring (488) into valve body (303).
177
5.12 Handle pilot valve disassembly and assembly
Tools
3. Disassemble the lower end of rubber sheathing (501) from valve shell (101) and take it out
from the top of the valve shell.
★If there is a switch; take down wire (456) beforehand through the hole of valve shell.
4. Screw off lock nut (315) and adjust nut (312)by spanner and take down the whole handle
body.
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5. Place spanner on the surface between adjust nut (312) and cam (302), unscrew adjust nut,
take down the nut and cam, screw off the joint to the left direction by clamp.
★If return spring (221) is tight, plate (151), bushing (211) and push rod (212) will float up when
screw off the joint.
6. Take down washer (300) and plate (151).
7. If return spring (221) is weak, spring guide sleeve (211) will still stay in valve shell as the
block act of O-ring. Using screwdriver to take it out.
★Because of the act of return spring (221), the pin may fly off when pull it out.
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8. Because of the act of return spring (221), the pin may fly off when pull it out.
★Please record the positions between pressure-relief valve module and valve shell beforehand.
9. Use inner hexagon spanner to screw off inner hexagon nut (125) and take it out. Take down
interface plate (111), O-ring (122) and bearing bush (131) from valve shell.
10. When disassembling pressure-relief valve, take down valve rod (201) and place it upright on
level worktable, lower spring seat (216), using the head of little screwdriver to take down the
two half-round washers 1 (215).
11. Disconnect valve rod (201), spring guide sleeve (216), spring (241) and washer 2(217). Pull
out push rod (212) from bushing (211) and take down O-ring (214).
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12. Cleaning and rust prevention for parts.
★First clean the contaminative part in oil will scotch the surface. So soak the parts completely
until dirt and grease out.
★If use compress air to dry parts, dirt and moisture in air will damage parts or cause rust, so this
procedure will not be applied.
Assembly
Fastening torque figure
Parts No. Dimension Torque N.M
125 M8 29.4
301 M14 47.1
302、312 M14 68.6
315 M14 49
2. Use inner hexagon bolt (125) and lock ring (121) to tighten intake plate on shell body (101).
Screw up the inner hexagon bolt (125) with specified torque.
181
★Pay attention the holding position of spring pin (126) can be inserted by the hole of shell body.
3. Insert washer 2(217),spring(241)and spring guide sleeve(216)into valve rod(201)in turn.
4. Place the bottom of valve rod uprightly on level worktable, press spring guide sleeve, insert
two washers 1(215) into spring guide sleeve. Assemble spring (221) and pressure-relief valve
module into shell body.
★Lean the wedge part of washer (215) against the top of slip valve to assemble them;pay
attention not to overlap the washers.
★Pay attention not to press spring guide sleeve over 6mm.
★Assemble as the position before being disassembled.
5. Fit O-ring (214), lock ring (213) and push rod (212) on bushing (211).
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★ Wipe butter on the surface of pressure bar.
6. Assemble bushing module into pump.
★Use plate (151) to fit in four bushing modules together and fix them temporarily with a joint.
7. Use clamp to fix joint (301) on shell body with specified torque.
★Screw in cam until it contacts with all the four pressure bars. Do not screw in too much.
9. Assemble adjust nut (312), place spanner on cam (302) to fix it, then tighten adjust nut with
specified torque.
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★ Caution not to change the position of circular flat-plate when tightening.
10. Use little bolt 3(431) to fix handle lever together with specified torque.
11. Assemble rubber jacket (501) and lock nut (315). Thus, assembly for handle module has
completed.
12. Decide the direction of handle, use spanner to fix adjust nut(311,312)and use lock nut (315)
to fix handle with specified torque.
13. Wipe lubricant on the rotating parts of the joint and the contact surface of cam and push rod.
184
14. Assemble the bottom of corrugated pipe on shell body. Fill in rust preventive from each oil
port and plug it with choke plug.
Tools
185
Disassembly
Before operation, disassemble the cable from the negative terminal of the accumulator. Lower
the working device to the ground and stop the engine, release pressure in oil tank by loosening
the cover of pouring orifice.
★ Stick identification tags on each pipe to avoid making mistakes when refitting. Seal the pipe
orifice and preserve all the sealing elements.
1. Open engine cover and disassemble the upper cover (1) of the multiple way valve.
186
4.Dismantle pipe clip (1) and left/ right travel hoses (2).
5.Dismantle hose(1)of P1 and P2,to operation valve, pilot hose (2) of solenoid valve, to
negative flow feedback pipe(3)of main pump and to oil return hose (4) of hydraulic cylinder.
6.Dismantle the steel pipes around multiple way valve from the top down, and dismantle the
mounting screw of main valve and under carriage, fit with lifting ring (1) and lift it with lifting
equipment.
187
multiple way valve weight:195kg
Lifting tap hole:M10X1.5
Assembly
Assemble in reverse order of disassemble.
★ :Apply as torque fig.5-1、5-2.
★After assembly, feed oil for the hydraulic cylinder to start engine , cycle the oil in system,
exhaust air and check the oil level.
★Air exhaust refers to “exhaust air of the parts”in chapter “testing and adjustment” of this
manual.
Special tools
188
Disassembly
Before operation, disassemble the cable from the negative terminal of the accumulator. Lower
the working device to the ground and stop the engine, release pressure in oil tank by loosening
the cover of pouring orifice on hydraulic cylinder.
★ Stick identification tags on each pipe to avoid making mistakes when refitting and seal the
pipe orifice.
1.Dismantle sprocket wheel(1),refer to chapter “dismantle sprocket wheel”in this manual.
3. Dismantle 4 travel motor hoses (1) and 18 mounting bolts, then lift.
★After assembly, feed oil for the hydraulic cylinder to start engine , cycle the oil in system,
exhaust air and check the oil level.
★Air exhaust refers to “exhaust air of the parts”in chapter “testing and adjustment” of this
manual.
Special tools
Disassembly
Release the residual pressure in hydraulic circuit. Refer to the relevant contents in chapter
“testing and adjustment”.
★Conserve well dismantled hoses, pipe orifices need to be sealed and sealing elements.
1.Dismantle the following 6 hoses:
(1) Oil drain pipe
(2) Right side travel pipe
(3) Double speed pipe
(4) Left side travel pipe
Dismantle catch bolt (5) and 4 mounting bolts (6).
190
2.Dismantle the 6 hoses connect central rotary joint with travel motor:
3.Lift it with lifting equipment
Assembly
Assemble in reverse order of disassemble.
★ :Apply as torque fig.5-1、5-2.
★ Feed oil to specified level. Start engine, cycle the oil in system and check the oil level.
★Exhaust air from travel motor refers to “exhaust air of the parts”in chapter “testing and
adjustment” of this manual.
Special tools
4 740115000025 27-30
6 740115000023 32-34
8 740119010059 SH15D×17
10 740119010065 SH22D×32
191
Disassembly
Release pressure in oil tank by loosening the cover of pouring orifice on hydraulic cylinder.
★ Stick identification tags on each pipe to avoid making mistakes when refitting and seal the
pipe orifice.
1.Discharge hydraulic oil in cylinder. If there is no special oil drain device, twist-off the drain
plug at the bottom of oil tank to discharge hydraulic oil.
4. Dismantle 5 oil return hoses (2), oil return steel pipe (1) and engine spacing plate (3).
192
6. Dismantle oil return steel pipe (1).
7. Dismantle oil water separator(5), diesel filter(3), engine oil filter(4),main pump oil drain
hose(2)and spacing plate(1).
8.Dismantle closed plate at the bottom of oil tank firstly, and then take apart the inlet hose (1)
connects with the oil tank.
193
9. Lift it with lifting equipment after disconnecting the mounting bolts of the 4 hydraulic oil
tanks.
★ Exhaust air from travel motor refers to “exhaust air of the parts”in chapter “testing and
adjustment” of this manual.
194
(2) Assembly
★ Use special tools to test the leakage air capacity from the seal by applying the standard
pressure on pouring orifice.
★ Check that the meter hand will not move down within 10 seconds when applied pressure is
lower than standard pressure.
Standard pressure:0.1 Mpa (1 kg/cm2)
195
5.19. Guiding wheel ASSY. disassembly and assembly
(1) Special tools
(2) Disassembly
1.Dismantle locating pin (1) and bearing (2).
2.Dismantle floating seal (3) from bearing (2) and guiding wheel (4)
.
3.Dismantle guiding wheel (4) from shaft (5) and bearing ASSY. (7).
★ There is 80 cc oil in guiding wheel, so the oil should be drained in disassembly stage.
4.Disasseble floating seal (6) from the reverse side of the guiding wheel (4), shaft (5) and
bearing ASS (7).
5.Dismantle locating pin (8) for easily taking down bearing (7) from shaft (5).
6.Dismantle lining (9) and (10) from guiding wheel (4).
196
(3) Assembly
3.Assemble floating seal (6) on guiding wheel (4), shaft (5) and bearing (7) ASSY.
★ Floating seal
Before assembling floating seal, clean the butter completely on the surface of the o-ring floating
seal (dashes area in fig.) and do not make dust attach on floating seal.
★ After assembling floating seal, check the gradient of the seal should be less than 1mm, and the
seal bulging qty.a should be preserved in range of 5-7 mm.
197
5.Assemble floating seal (3) on guiding wheel (4) and bearing (2).
★ Wipe oil is on the surface of floating seal. Pay attention not to make any dirt or dust attach on
it.
★ Clean all the butter and oil from O-ring and the contact surface of floating seal.
6.Assemble O-ring, and then fit bearing (2) with locating pin (1).
7.Feed oil and screw on screw plug.
:See recommended grease lubricant brand in 5.2.
★ :Apply as the torque fig. in 5.2.
198
5.20. Tension device disassembly and assembly
3 compressor compressor
4 range spacer range spacer
5 tension device tension device
7 pump pump
(2) Disassembly
1.Dismantle piton ASSY (2) from tension spring ASSY (1).
1) Place tension spring ASSY (1) on tool J1. As the tension spring is in big assembly load,
199
assemble it correctly to avoid danger.
★ Assembly load of spring:108.8 KN.
2) Apply hydraulic pressure slowly to compress spring, disassemble jam plate (3) and then
the nut (4).
★ Compress spring until the nut begins to loose.
★Release hydraulic pressure and spring tension slowly.
★ Free length of spring:558 mm
3) Disassemble york piece (6), spring seat (7) and dust seal (8) from spring(5).
3.Disassembly for plunger ASSY
1) Disassemble lock blade (10) from plunger (9), then dismantle valve (11).
2)Dismantle snap ring(12),then dismantle U-ring(13)and ring(14).
200
2)Assemble spring seat(7)and york piece(6)on spring(5),and place it on tool J1.
Sliding part of oil tank: :See recommended grease lubricant brand in 5.2.
3) Apply hydraulic pressure slowly to compress spring. Tighten nut (4) until spring mounting
length gets to size “a”, then fix it with lock blade (3).
201
5.21 Sproket wheel disassembly and assembly
socket
1 740105000164
wrench
torque 750-2000N.m
2 740119000012
wrench 25mm
(2) Disassembly
1.Disassemble track shoe ASSY. See “track shoe ASSY disassembly”.
2.Rotate working device to 90°,jack up the chassis with working device and place pad between
track frame and track shoe.
(3) Assembly
• Assemble in reverse order of disassemble.
★ screw thread glue: 1277
★ :Apply as the torque fig. in 5.2.
202
5.22. Track shoe ASSY disassembly and assembly
2. Lower working device, screw off nozzle tip (1) to release internal butter and decrease
track tensity.
★ Adjust oil tank is in extremely high pressure. Do not screw off nozzle tip over one circle. If
oil can not flow out, move the machine fore and after.
4.Dismantle tool M,move the machine forward to make temporary pin ② lie in front of idler
and place pad ①on it.
5.Dismantle temporary pin ② and dust seal, then move the machine backward to spread track
(3).
203
(3) Assembly
• Assemble in reverse order of disassemble.
★ See the content “track shoe tensity checking and adjustment” of chapter “checking and
adjustment” in this manual.
• Assembly program for the bolts and nuts of track shoe.
1) Turn the side R of track shoe nut (1) to the surface of connecting rod seat, and make the two
seat surfaces contact closely when assemble track shoe.
★ If track shoe nut is assembled reverse, the corner of nut and the surface of connecting rod seat
will interfere each other and raise the nut and make it loose.
2) Tighten track shoe bolt after checking the close contact of mating surface.
★ screw thread glue:1277
★ :Apply as the torque fig. in 5.2.
★ Press main pin with tool M. The protrude distance is the nether size a.
Main pin protrude distance a:2.5±1 mm
204
★ Before assemble dust seal, wipe butter lubricant Multifak EP2 on the contact surface with
lining.
★ If you have road gasket (rubber-type track shoe gasket), replace the track shoe gasket when
you find the rubber has worn or broken.
Otherwise, track shoe bolt will be damaged and dismantlement will turn to be difficult.
(4) Road gasket disassembly and spread
1.Stop the machine and make main pin stay over idler, so track shoe ASSY can spread forward
and backward.
2. Lower working device and screw off lubricator (1) to loose track..
★Adjust oil tank is in extremely high pressure. Do not try to screw off lubricator (1) over one
circle. If the inner butter seeps out little, move the machine fore and after.
6.Take away tool M,move the machine forward and pull out pin(2).
205
7.Disassemble dust seal and spread track shoe ASSY (4) when move machine forward.
★ Press main pin with tool M. The protrude distance is the nether size a. Main pin protrude
distance a:2.5±1 mm
206
★ Before assemble dust seal, wipe butter lubricant Multifak EP2 on the contact surface with
lining.
socket
1 740105000164
wrench
torque 750-2000N.m
2 740119000012
wrench 25mm
imitation
3 750401000006 import grease
gun
(2) Disassembly
1.Disassemle rotary table ASSY. See “rotary ASSY disassembly”.
207
★ Rotary bearing ASSY :315 kg
(3) Assembly
• Assemble in reverse order of disassemble.
★ screw thread glue:1277
★ :Apply as the torque fig. in 5.2.
★ Put the marking sides of inner race soft area and outer race soft area to the right, and assemble
them on track frame.
socket
1 740105000164
wrench
torque 750-2000N.m
2 740119000012
wrench 25mm
inner
S10
3 740104000007 hexagon
GB5356-85
wrench
208
(2) Disassembly
Extend arm and bucket completely, lower working device to the ground and turn the
securing rod to the lock position.
1.Dismantle 4 hoses (1) of boom cylinder.
★ Plug hoses to avoid oil flowing out.
2.Disassemble parts as per “working device disassembly and assembly”, “counterweight ASSY
disassembly and assembly”and “hydraulic cylinder disassembly and assembly”. Dismantle the
upper hoses of central rotary joint as per “central rotary joint disassembly and assembly”, make
necessary labels and seal the pipe orifice.
3. Dismantle 36 rotary table mounting bolts and rotary table ASSY (16) and lift it away.
★ Lift the upper carriage ASSY slowly and parallel. Pay attention not to hit the central rotary
joint ASSY.
209
★ Exhaust air
Exhaust air from travel motor. See the content of “exhaust air of the parts” of chapter“testing
and adjustment”in this manual.
(2) Disassembly
Firstly disassemble the cable of negative terminal (-) of accumulator.
1. Drain cooling water.
Cooling water:about 23L
2. Use special device to drain cooling medium from air-conditioning. Dismantle two hoses,
make necessary marks and seal the pipe orifice.
3. Disassemble drying bottle(3), condenser(4)pipelines,make necessary marks and seal the
pipe orifice.
210
7. Dismantle the two hoses (5) from drying bottle to evaporator and from compressor to
evaporator, make necessary mark and seal pipe orifice. Dismantle electric joint (6) of evaporator
and make marks.
8. Dismantle the two water pipes (7) between evaporator and engine. Dismantle fixed bolt (8)
of evaporator.
(3)Assembly
• Assemble in reverse order of disassemble.
★ When assemble the hoses in the loop of air-condition, pay attention not to make dirt, dust and
water into the hoses.
★ Assemble air-condition hoses only after checking O-ring lies behind the interconnecting
pieces.
★ Check if there is damage on O-ring.
★ Wipe compressor oil (ND-OIL8)on the screw thread of connectiong parts of refrigerant line,
and tighten the pipeline with double end wrench.
211
★ Use special device to feed the cooling medium into air-condition loop.
★ screw thread glue:1277
★ :Apply as the torque fig. in 5.2.
★ Refill coolant to specifiec level through feed water port. Engine coolant:about 23L
★ Start the engine to cycle water to release all the air bubble, then recheck.
212
6. Figures and others
6.1 Hydraulic system schematic diagram
213
6.2 Electrical system drawing
214