Bager New Holand E50

COMPACT EXCAVATORS
E50
SERVICE
MANUAL
87360588 NA
Issued 01-2006
www.newhollandconstruction.com
SHOP MANUAL
E50
HYDRAULIC EXCAVATOR
87360588
Issued January 2006
CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer
Revision History
Issue Issue Date Applicable Machine Remarks
First Edition 01-2006 E50 87360588 NA
Issued January 2006

Book/Form Number 6-80940 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO01
SHOP MANUAL
E50
HYDRAULIC EXCAVATORS
TABLE OF CONTENTS
SECTION 1
STANDARD SPECIFICATIONS AND MAINTENANCE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
(Book/Form Number: 6-80950 NA)
CHAPTER 1
GENERAL INFORMATION AND SAFETY
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
CHAPTER 2
SPECIFICATIONS
CHAPTER 3
ATTACHMENT DIMENSIONS
CHAPTER 11
TOOLS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1
CHAPTER 12
STANDARD MAINTENANCE TIME TABLE
CHAPTER 13
MAINTENANCE STANDARDS AND TEST PROCEDURES
SECTION 2
HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 22
HYDRAULIC SYSTEM
CHAPTER 23
ELECTRICAL SYSTEM
CHAPTER 24
COMPONENTS SYSTEM
SECTION 3
GENERAL DISASSEMBLY AND ASSEMBLY
6-78610NA Issued 01-06 Bur I

CHAPTER 31
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-1
CHAPTER 32
ATTACHMENTS
CHAPTER 33
UPPER SLEWING STRUCTURE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-I
CHAPTER 34
TRAVEL SYSTEM
SECTION 4
TROUBLESHOOTING
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
CHAPTER 42
TROUBLESHOOTING (HYDRAULIC SYSTEM)
CHAPTER 43
TROUBLESHOOTING (ELECTRICAL SYSTEM)
CHAPTER 44
TROUBLESHOOTING (ENGINE)
SECTION 5
ENGINE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
CHAPTER 51
THIS MANUAL EXPLAINS THE ENGINE PROPER AND IS FAITHFUL TO
YANMAR DIESEL ENGINE’S SERVICE MANUALS.
................................................................................. 1
II Issued 01-06 Bur 6-78610NA

SHOP MANUAL - SECTION 1
E50
STANDARD SPECIFICATIONS
AND MAINTENANCE
Issued January 2006

SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E50 6-80950 NA
SECTION 1
STANDARD SPECIFICATIONS AND MAINTENANCE
TABLE OF CONTENTS
CHAPTER 1
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.3 General Precautions for Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.4 International Unit Conversion System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
CHAPTER 2
SPECIFICATIONS
2.1 Components Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3 Specifications and Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4 Machine and Components Weights (Dry) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.5 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.6 Type of Track Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.7 Type of Bucket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.8 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
CHAPTER 3
3.1 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2 Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.3 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.4 Dozer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.5 Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
CHAPTER 11
TOOLS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.1 Torque Specifications for Capscrews and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
11.2 Screw and Tool Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
11.3 Torque Specifications for Joints and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
11.4 Torque Specifications for Sleeve Type Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
11.5 Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
11.6 Special Spanners for Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
11.7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11
11.8 Application of Screw Locking and Sealing Compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11
11.9 Counterweight Lifting Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
11.10 Upper Frame Lifting Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13
CHAPTER 12
12.1 Working Standards for Time Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
12.2 Time Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
6-80950 NA Issued 01-2006 Bur 0-I

CHAPTER 13
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-1
13.1 How To Use Maintenance Standards and Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-3
13.2 Performance Inspection Standard Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-4
13.3 Measuring Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-6
13.4 Measuring Hydraulic Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-8
13.5 Measuring Travel Performances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-11
13.6 Measuring Slew Performances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-13
13.7 Measuring Attachment Operating Performances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-15
13.8 Measuring Slew Bearing Performances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-17
13.9 Measuring Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-18
0-II Issued 01-2006 Bur 6-80950 NA

CHAPTER 1
E50
GENERAL INFORMATION AND

SAFETY
Issued January 2006

CHAPTER 1 - GENERAL INFORMATION AND SAFETY
Revision History
1-II Issued 01-06 Bur 6-80960 NA

CHAPTER 1
TABLE OF CONTENTS
1.1 GENERAL SAFETY INFORMATION

1.2 SAFETY PRECAUTIONS
1.3 GENERAL PRECAUTIONS FOR REPAIRS
1.3.1 Preparation Before Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.3.2 Safety In Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.3.3 Disassembling and Assembling Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.3.4 Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.3.5 Hydraulic Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.3.6 Welding Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.3.7 Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.4 INTERNATIONAL UNIT CONVERSION SYSTEM
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
6-80960 NA Issued 01-06 Bur 1-1

NOTES
1-2 Issued 01-06 Bur 6-80960 NA

1.1 GENERAL SAFETY INFORMATION

3. Messages of safety appear in the manual and on
WARNING: Do not operate or perform any the machine:
maintenance on this machine until all
All messages of safety are identified by either
instructions in the OPERATOR’S MANUAL
word of DANGER, WARNING, and CAUTION.
and this MANUAL have been thoroughly
read and understood. DANGER: Shows an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
WARNING: Improper operation or
maintenance of this machine may cause
accidents and could result in serious injury or WARNING: Shows a potentially hazardous
death. situation which, if not avoided, could result in
death or serious injury.
WARNING: Always keep the manual in
storage. CAUTION: Shows a potentially hazardous
If it is missing or damaged, place an order situation which, if not avoided, may result in
with an authorized Distributor for a minor or moderate injury. It may also be used
replacement. to alert against possible damage to the
If you have any questions, please consult machine and its components.
your dealer.
4. It is very difficult to foresee every danger that
1. Most accidents, which occur during operation, may occur during operation. However, safety can
are due to neglect of precautionary measures be ensured by fully understanding proper
and safety rules. Sufficient care should be taken operating procedures for this machine according
to avoid these accidents. Erroneous operation, to methods recommended.
lubrication or maintenance services are very
dangerous and may cause injury or death of 5. While operating the machine, be sure to perform
p e r s o n n e l . T h e r e fo r e a l l p r e c a u t i o n a r y work with great care, so no damage to the
measures, NOTES, DANGERS, WARNINGS and machine or accidents will occur.
CAUTIONS contained in the manual and on the 6. Continue studying the manual until all Safety,
machine should be read and understood by all Operation and Maintenance procedures are
personnel before starting any work with or on the completely understood by all persons working
machine. with the machine.
2. Operation, inspection, and maintenance should
be carefully carried out, safety must be given the
first priority. The safety information contained in
the manual is intended only to supplement safety
codes, insurance requirements, local laws, rules
and regulations.
6-80960 NA Issued 01-06 Bur 1-3

1.2 SAFETY PRECAUTIONS
WARNING: The proper lubrication and WARNING: Do not operate this machine
maintenance for this machine are outlined in unless you have read and understand the
the OPERATOR’S MANUAL. instructions in the OPERATOR’S MANUAL.
Improper machine operation is dangerous
and could result in injury or death.
WARNING: Improper lubrication and
maintenance procedures are dangerous and 6. Relieve all pressure in air, oil or water systems
could result in injury or death. Read and before any lines, fittings or related items are
understand the MANUAL before performing disconnected or removed. Always make sure all
maintenance or adding/changing lubricants. raised components are blocked correctly and be
alert for possible pressure when disconnecting
The serviceman may be unfamiliar with many of the any device from a system that utilizes pressure.
systems on this machine. This makes it important to
7. Lower the bucket, dozer, or other attachments to
use caution when perfor ming ser vice work. A
the ground before performing any work on the
knowledge of the system and or components is
machine. If this cannot be done, make sure the
important before the removal or disassembly of any
bucket, dozer, ripper or other attachment is
component.
blocked correctly to prevent it from dropping
Because of the size of som e of the machine unexpectedly.
components, the serviceman should check the 8. Use steps and grab handles when mounting or
weights noted in this manual. Use proper lifting dismounting a machine. Clean any mud or debris
procedures when removing any components. Weight from steps, walkways or work platforms before
of components table is shown in the using. Always face to the machine when using
SPECIFICATIONS section. steps, ladders and walkways. When it is not
The following is a list of basic precautions that must possible to use the designed access system,
always be observed. provide ladders, scaffolds, or work platforms to
1. Read and understand all Warning plates and perform safe repair operations.
decals on the machine before Operating, 9. To avoid back injury, use a hoist when lifting
Maintaining or Repairing machine. components which weigh 20kg (45lbs) or more.
2. Always wear protective glasses and protective Make sure all chains, hooks, slings, etc., are in
shoes when working around machines. Wear good condition and are the correct capacity. Be
prote ctive glasses when u sing h amm ers, sure hooks are positioned correctly. Lifting eyes
punches or drifts on any part of the machine or are n ot to be side load ed du r ing a lifting
attachments. Use welders gloves, hood/goggles, operation.
apron and the protective clothing appropriate to 10. To avoid burns, be alert for hot parts on
the welding job being performed. Do not wear machines which have just been stopped and hot
loose fitting or torn clothing. Remove all rings fluids in lines, tubes and compartments.
from fingers, loose jewelry, confine long hair and
11. Be careful when removing cover plates.
loose clothing before working on this machinery.
Gradually back off the last two capscrews or nuts
3. Disconnect the battery and hang a “Do Not located at opposite ends of the cover or device
Operate” tag in the Operators Compartment. and carefully pry cover loose to relieve any
Remove ignition keys. spring or other pressure, before removing the
4. If possible, make all repairs with the machine last two capscrews or nuts completely.
parked on a level, hard surface. Block the 12. Be careful when removing filler caps, breathers
machine so it does not roll while working on or and plugs on the machine. Hold a rag over the
under the machine. Hang a “Do Not Operate” tag cap or plug to prevent from being sprayed by
in the Operators Compartment. liquids under pressure. The danger is even
5. Do not work on any machine that is supported greater if the machine has just been stopped
only by jacks or a hoist. Always use blocks or because fluids can be hot.
jack stands capable of supporting the machine.
1-4 Issued 01-06 Bur 6-80960 NA

13. Always use the proper tools that are in good 18. Performing maintenance or repair work with the
condition and that are suited for the job. Be sure bucket raised is dangerous due to the possibility
yo u u n d e r s t a n d h ow t o u s e t h e m b e fo r e of it falling. Lower the attachment and place the
performing any service work. bucket on the ground before starting the work.
14. Reinstall all fasteners with the same part 19. Loose or damaged fuel, lubricant and hydraulic
number. Do not use a lesser quality fastener if lines, tubes and hoses can cause fires. Do not
replacements are necessary. bend or strike high pressure lines or install ones
15. Repairs which require welding should be which have been bent or damaged. Inspect lines,
performed by personnel adequately trained and tubes and hoses carefully. Do not check for leaks
knowledgeable in welding procedures. with your hands. Very small (pinhole) leaks can
Determine type of metal being welded and select result in a high velocity oil stream that will be
correct welding procedure and electrodes, rods invisible close to the hose. This oil can penetrate
or wire to provide a weld strength equivalent at the skin and cause personal injury. Use card-
least to that of the parent metal. Make sure to board or paper to locate pinhole leaks.
d i s c o n n e c t b a t t e r y b e fo r e a n y w e l d i n g 20. Tighten connections to the correct torque. Make
procedures are attempted. sure that all heat shields, clamps and guards are
16. Do not damage wiring during removal installed correctly to avoid excessive heat,
operations. Reinstall the wiring so it will not be vibration or rubbing against other parts during
damaged during operation of the machine by operation. Shields that protect against oil spray
contacting sharp corners, or by rubbing against onto hot exhaust components in event of a line,
some object or hot surface. tube or seal failure must be installed correctly.
17. Be sure all protective devices including guards 21. Do not operate a machine if any rotating part is
and shields are properly installed correctly before damaged or contacts any other par t during
star ting repair. If a guard or shield must be operation. Any high speed rotating component
removed to perform the repair work, replace the that has been damaged or altered should be
guard or shield after repair is completed. checked for balance before reusing.
22. Be careful when servicing or separating the
tracks. Chips can fly when removing or installing
a track pin. Wear safety glasses and long sleeve
protective clothing. Tracks can unroll very quickly
when separated. Keep away from front and rear
of machine. The machine can move
unexpectedly when both tracks are disengaged
from the sprockets. Block the machine to prevent
it from moving.
6-80960 NA Issued 01-06 Bur 1-5

1.3 GENERAL PRECAUTIONS FOR REPAIRS

1.3.1 PREPARATION BEFORE DISASSEMBLING 4. Identify the location of a first-aid kit and a fire
extinguisher, also who to contact in case of an
emergency.
5. Choose a hard, level and safe place, and place
1. Understand operating procedure the attachment on the ground securely.
Read OPERATOR’S MANUAL and this MANUAL 6. Use a hoist to remove heavy parts (20 kg [45 lbs]
carefully prior to operating the machine. or more) from the machine.
2. Cleaning machines 7. Use proper tools, and replace or repair defective
tools.
Remove soil, mud, and dust from the machine
before service. This will prevent loss of work 8. Support the machine and attachment with
efficiency, damaged parts, and difficulty in rust supports or blocks if the work is performed in the
p r ev e n t i o n a n d d u s t p r o t e c t i o n w h i l e lifted condition.
reassembling.
1.3.3 DISASSEMBLING AND ASSEMBLING
3. Inspecting machines HYDRAULIC EQUIPMENT
Identify the parts to be disassembled before
star ting work, determine the disassembling
procedure considering the workshop situations
etc., request necessary parts in advance.
1. Removing hydraulic equipment
4. Record the following items
A. Before disconnecting pipes, release the
A. Inspection date and place hydraulic pressure in the system.
B. Model name, applicable machine number, and B. Carefully drain oil from the removed pipes into
hour meter reading a containers without spilling on the floor.
C. Trouble condition, place and cause. C. Install plugs or caps on the pipe ends to avoid
D. Visible oil leakage, water leakage and damage oil spillage and contamination.
E. Clogged filters, oil level, oil quality, oil D. Clean off the external surface of the
contamination and loose connections equipment before disassembling, drain
hy d r a u l i c a n d g e a r o i l b e fo r e p l a c i n g
F. Is it a recurring fault at approximately the
component on the workbench.
same amount of operating hours?
2. Disassembling hydraulic equipment
5. Arrangement and cleaning in service shop
A. Do not modify the hydraulic equipment without
A. Tools required for repair work.
t h e p e r m i s s i o n o f t h e m a n u fa c t u r e r.
B. Prepare space to place the disassembled Manufacturer will not be responsible for the
parts. performance and function of the product after
C. Prepare oil containers for draining oil etc. modification.
B. When disassembling and reassembling for
1.3.2 SAFETY IN DISASSEMBLING AND repair, refer the work to qualified personnel
ASSEMBLING who have the knowledge or have completed
the service training.
C. Provide aligning markings to facilitate
reassembly.
1. Wear appropriate clothes with long sleeves, D. Before starting the work, read the manual for
safety shoes, safety helmet and protective disassembly procedures and decide whether
glasses. the work can be performed by yourself or if
2. Suspend warning tag DO NOT OPERATE from assistance is required.
the doorknob or the operating lever. E. Use the special jig or tools if they are
3. Stop the engine before starting inspection and specified.
maintenance.
1-6 Issued 01-06 Bur 6-80960 NA

F. If it is hard to remove a part according to the C. Perform air bleeding of the hydraulic pump
procedure, do not force it, investigate the and slewing motor after loosening the upper
cause. drain plug, start and run the engine at low idle.
G. Place the removed parts in order and attach Air bleeding is completed when clear hydraulic
tags to facilitate the reassembly. oil is visible, tighten plug.
H. Note the location and quantity of parts D. Perform air bleeding of the travel motor and
commonly applied to multiple locations. the hydraulic cylinders by running the engine
3. Inspecting parts for more than 5 minutes at low speed without
load.
A. Ensure that the disassembled parts are free
from seizure, interference and uneven contact. NOTE: Do not allow hydraulic cylinders to bottom
out on the stroke end just after maintenance.
B. Measure and record wear condition of parts
and clearance. E. Perform air bleeding of pilot line by performing
a ser ies of digg ing, slewing and travel
C. If the problem is found in a part, repair or
operations.
replace it.
F. Check hydraulic oil level after placing the
4. Reassembling hydraulic equipment
attachment to the oil check position, and
A. Turn ON the ventilation fan or open windows replenish oil if necessary.
to maintain good ventilation prior to cleaning
parts.
B. Perform rough and finish cleaning before
assembling.
C. Remove solvent by air and apply clean
hydraulic or gear oil for assembling.
D. Always replace the removed O-rings, backup
rings and oil seals with new ones. Apply SPW01000004E01 Figure 1
grease in to aid installation.
1.3.4 ELECTRICAL EQUIPMENT
E. Remove dirt and moisture from and perform
degreasing on the surface where liquid gasket
is to be applied.
F. Remove rust preventive agent from the new
parts before use. 1. Turn the key OFF prior to connecting and
disconnecting connectors.
G. Fit bearings, bushings and oil seals using
proper tools. 2. Disconnect the connector by holding it and
pressing the lock. Do not pull on the wires to
H. Assemble the parts utilizing matching marks. separate connectors.
I. Ensure all the parts are completely assembled 3. Connect the connector and ensure it is
after the work. completely locked.
5. Installing hydraulic equipment 4. Turn the key OFF prior to touching the terminal of
A. Ensure hydraulic oil and lubricants are at starter or generator.
proper levels. 5. Remove the ground terminal of battery when
B. Perform air bleeding when: handling tools around the battery or its relay.
• Hydraulic oil is changed 6. Do not splash water on the electrical equipment
• Parts of suction piping is replaced and connectors during machine washing.
• Hydraulic pump is installed
• Slewing motor is installed 7. Check for moisture inside the waterproof
• Travel motor is installed connector after disconnection it. If moisture is
• Hydraulic cylinders installed found, dry it completely before reconnecting.
WARNING: Operation of the hydraulic

equipment without filling hydraulic oil or
lubricant or without performing air bleeding
will result in damage to the equipment.
6-80960 NA Issued 01-06 Bur 1-7

2. Flexible hose
WARNING: Battery electrolyte is • Use approved parts.
hazardous. • Tighten the fitting at the specified torque.
Battery electrolyte is diluted sulfuric acid. • Ensure there are no kinks, tension, interference
Exposure of skin or eyes will cause burning nor oil leakage present.
or loss of eyesight.
If the exposure occurs, take the following 1.3.6 WELDING REPAIR
emergency measures and seek the advice of 1. Refer welding repair to qualified personnel.
a medical specialist.
2. Disconnect the ground cable of the battery
• When skin exposed:
before starting the repair. Failure to do so will
Wash with water and soap sufficiently.
cause damage to the electrical equipment.
• When eyes exposed:
Immediately wash away with water 3. Move away the articles in advance that may
continuously for more than 10 minutes. cause fire if exposed to sparks.
• If a large spill occurs: 4. Before starting the repair of the attachment,
Neutralize with sodium bicarbonate or cover the plated surface of the piston rod with
wash away with water. flameproof sheet to prevent it from being
• When swallowed: exposed to sparks.
Drink a large amount of milk or water.
1.3.7 ENVIRONMENTAL PROTECTION
• When clothes exposed:
Immediately undress and wash. 1. Run the engine in a place that has sufficient
ventilation.
1.3.5 HYDRAULIC PARTS 2. Industrial waste disposal
Dispose of the following parts according to the
relevant regulations:
• Waste oil and waste container
1. O-ring • Battery
• Make sure O-rings have elasticity and are not 3. Precautions for handling hydraulic oil
damaged before use. Exposure of eyes to hydraulic oil will cause
• Use the appropriate O-rings. O-rings are made inflammation. Wear protective glasses before
of various kinds of materials having different handling to avoid an accident. If eyes are
hardness to apply to a variety of parts, such as exposed to the oil, take the following emergency
the part for moving or fixed portion, subjected to measures:
high pressure, and exposed to corrosive fluid,
When eyes are exposed:
even if the size is the same.
• Immediately wash away with water until
• Install the O-rings without distortion.
stimulative feeling vanishes.
• Replace floating seals as a pair.
When swallowed:
• Do not let vomit, seek medical treatment
immediately.
When skin exposed:
• Wash with water and soap sufficiently.
4. Others
Use genuine replacement parts and lubricants
authorized by the manufacturer.
1-8 Issued 01-06 Bur 6-80960 NA

1.4 INTERNATIONAL UNIT CONVERSION SYSTEM

INTRODUCTION 3. Supplementary units
NOTE: Information based on MARKS’ STANDARD QUANTITY UNIT SYMBOL
HANDBOOK FOR MECHANICAL ENGINEERS
Plane angle radian rad
Although this manual includes International System Solid angle steradian sr
of Unit and Foot-Pound System of Units, if you need
SI unit, refer to the following international system of 4. Derived Units bearing Peculiar Designations
units.
SYMB
Given is an excerpt of the units that are related to this QUANTITY UNIT FORMULA
OL
manual. Frequency hertz Hz 1/s
1. Etymology of SI Unites Force newton N kg · m/s2
French: Le Systeme International d’ Unites Pressure and Stress pascal Pa N/m2
English: International System of Units Energy, Work and
joule J N·m
2. Construction of SI Unit System Quantity of heat
Power watt W J/s
coulom
Quantity of electricity C A·s
b
Electric potential
difference, Voltage,
volt V W/A
and Electromotive
force
Quantity of static
electricity and farad F C/V
Electric capacitance
Electric resistance ohm Ω V/A
Celsius
degree (t+273.15
SPW01000007E01 Figure 2 Celsius temperature
or
°C )K
1. Base units degree
QUANTITY UNIT SYMBOL

Illuminance lux lx l m/m2
Length meter m
5. Prefixes of SI
Mass kilogram kg
Time second s MULTIPLICATION
PREFIX SYMBOL
Electric current ampere A FACTORS
Thermodynamic temperature kelvin K giga G 109

Amount of substance mol mol mega M 106
Luminous intensity candela cd kilo k 103
2. Derived Units hecto h 102

deca da 10
QUANTITY UNIT SYMBOL
deci d 10–1
Area square meter m2 centi c 10–2
Volume cubic meter m3 milli m 10–3
Velocity meter per second m/s
micro m 10–6
Acceleration meter per second squared m/s2
nano n 10–9
Density kilogram per cubic meter kg/m3
pico p 10–12
6-80960 NA Issued 01-06 Bur 1-9

6. Unit Conversion
QUANTITY GRAVITATIONAL SI CONVERSION FACTOR

Mass kg kg
Force kgf N 1 kgf=9.807 N
Torque kgf·m Nm kgf m=9.807 Nm
Pressure kgf/cm2 MPa 1 kgf/cm2=0.09807 MPa
Motive Power PS kW 1 PS=0.7355 kW
Revolution rpm min–1 r/min *1
*1 Units that are allowed to use.
1-10 Issued 01-06 Bur 6-80960 NA

CHAPTER 2
E50
SPECIFICATIONS
Issued January 2006

CHAPTER 2 - SPECIFICATIONS
Revision History
2-II Issued 01-2006 Bur 6-80970 NA

CHAPTER 2
SPECIFICATIONS
TABLE OF CONTENTS
2.1 COMPONENTS NAME

2.2 MACHINE DIMENSIONS
2.3 SPECIFICATIONS AND PERFORMANCE
2.3.1 SPEED AND GRADEABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.2 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.3 HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.4 SIDE DIGGING & DOZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.5 WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4 MACHINE AND COMPONENTS WEIGHTS (DRY)
2.5 TRANSPORTATION
2.5.1 Loading Machine on a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5.2 Transportation Dimension and Weight of Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5.2.1 Boom with Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5.2.2 Arm and Bucket (Standard Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5.2.3 Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.5.2.4 Bucket (Standard Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.5.2.5 Dozer (Without Cylinder Weight) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.6 TYPE OF TRACK SHOES
2.7 TYPE OF BUCKET
2.8 ENGINE SPECIFICATIONS
2.8.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.8.2 Engine Performance Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
6-80970 NA Issued 01-2006 Bur 2-1

NOTES
2-2 Issued 01-2006 Bur 6-80970 NA

2.1 COMPONENTS NAME
SPH02000001E01 Figure 1
6-80970 NA Issued 01-2006 Bur 2-3

2.2 MACHINE DIMENSIONS
UPY00600001E01 Figure 2
(CANOPY) UNIT: MM. (FT.•IN)
UPJ00600002E01 Figure 3
(CAB) MM. (FT. IN)
2-4 Issued 01-2006 Bur 6-80970 NA
2.3 SPECIFICATIONS AND PERFORMANCE

2.3.1 SPEED AND GRADEABILITY
Applicable Machines PJ04-03001~

Shoe Type Rubber shoe Iron shoe (OPT)
Slewing Speed min.-1 {rpm} 8.8 {8.8}
Low (1st) High (2nd) Low (1st) High (2nd)
Travel Speed km/h (mph)
2.8 4.6 2.8 4.6
Grade ability % (degree) 58(30)
2.3.2 ENGINE
Model (YANMAR) 4TNV88-XYB
Type Water-cooled, 4-cycle type Swirl chamber type diesel engine
Number of cylinders-Bore x Stroke 4 - ø88 mm x 90 mm (3.46 in x 3.54 in)
Total Displacement L 2.189 (134 cu. in)
Output Rating -1 30.4/2,400 {41.3/2,400}

kW/min {PS/rpm}
-1
Nm/min 139/1,440 (103/1,440)
Maximum Torque
(lb. ft./rpm)
Starting Motor V x kW 12 x 2.3
Generator VxA 12 x 55
2.3.3 HYDRAULIC COMPONENTS
Hydraulic Pump Variable displacement axial piston + gear pump
Hydraulic Motor Axial piston
Hydraulic Motor w/Reducer (Travel) 2-Axial piston, 2-Speed motor
Control Valve 11-spool multiple control valve
Cylinder (Boom, Arm, Swing, Bucket, Dozer) Double action cylinder
Return Filter Safety valve containing/Filter Type (30)
2.3.4 SIDE DIGGING & DOZER
Type Boom swing by hydraulic cylinder
Right 60°
Boom Swing Angle
Left 70°
Stroke of Dozer (above/below) mm (in) 495 / 375 (19.5/14.8)
2.3.5 WEIGHT
Rubber shoe Iron shoe

Machine Weight kg (lb.)
4,660 (10,300) 4,760 (10,500)
Upper slewing body kg (lb.) 2,310 (5,100) ¨
Travel system kg (lb.) 1,720 (3,790) 1,820 (4,010)
Attachment
kg (lb.) 535 (1,180)
(Boom + STD Arm + STD Bucket)
Oil & Water kg (lb.) 95 (209)
6-80970 NA Issued 01-2006 Bur 2-5

2.4 MACHINE AND COMPONENTS WEIGHTS (DRY)

RUBBER SHOE Unit; kg (lb.) STEEL SHOE Unit; kg (lb.)
CANOPY CAB CANOPY CAB
COMPLETE MACHINE 4,660 (10,300) 4,800 (10,600) 4,760 (10,500) 4,900 (10,800)
UPPER FRAME ASSEMBLY (ASSY OF FOLLOWINGS) 2,280 (5,030) 2,420 (5,340) 2,280 (5,030) 2,420 (5,340)
UPPER FRAME 570 (1,260) 570 (1,260) 570 (1,260) 570 (1,260)
CANOPY / CAB 120 (265) 250 (550) 120 (265) 250 (550)
ENGINE 170 (375) 170 (375) 170 (375) 170 (375)
HYDRAULIC PUMP 35 (77) 35 (77) 35 (77) 35 (77)
RADIATOR 5 (11) 5 (11) 5 (11) 5 (11)
HYDRAULIC TANK 37 (82) 37 (82) 37 (82) 37 (82)
FUEL TANK 4 (9) 4 (9) 4 (9) 4 (9)
SWING BRACKET 110 (243) 110 (243) 110 (243) 110 (243)
SWING CYLINDER 39 (86) 39 (86) 39 (86) 39 (86)
SLEWING MOTOR 40 (88) 40 (88) 40 (88) 40 (88)
CONTROL VALVE 35 (77) 35 (77) 35 (77) 35 (77)
COUNTERWEIGHT 580 (1,280) 580 (1,280) 580 (1,280) 580 (1,280)
GUARD HOOD 145 (320) 145 (320) 145 (320) 145 (320)
BOOM CYLINDER 58 (128) 58 (128) 58 (128) 58 (128)
LOWER FRAME ASSEMBLY (ASSY OF FOLLOWINGS) 1,720 (3,790) 1,720 (3,790) 1,820 (4,010) 1,820 (4,010)
LOWER FRAME 545 (1,200) 545 (1,200) 545 (1,200) 545 (1,200)
SLEWING BEARING 76 (168) 76 (168) 76 (168) 76 (168)
TRAVEL MOTOR 65x2 (143x2) 65x2 (143x2) 65x2 (143x2) 65x2 (143x2)
UPPER ROLLER 5x2 (11x2) 5x2 (11x2) 5x2 (11x2) 5x2 (11x2)
LOWER ROLLER 9x10 (20x10) 9x10 (20x10) 9x10 (20x10) 9x10 (20x10)
FRONT IDLER 42x2 (93x2) 42x2 (93x2) 42x2 (93x2) 42x2 (93x2)
IDLER ADJUSTER 30x2 (66x2) 30x2 (66x2) 30x2 (66x2) 30x2 (66x2)
SPROCKET 14x2 (31x2) 14x2 (31x2) 14x2 (31x2) 14x2 (31x2)
RUBBER CRAWLER SHOE 210x2 (463x2) 210x2 (463x2) — —
400mm (15.7") IRON SHOE — — 275x2 (606x2) 275x2 (606x2)
SWIVEL JOINT 22 (49) 22 (49) 22 (49) 22 (49)
DOZER 175 (386) 175 (386) 175 (386) 175 (386)
DOZER CYLINDER 27 (60) 27 (60) 27 (60) 27 (60)
LOWER FRAME ASSEMBLY (ASSY OF FOLLOWINGS) 535 (1,180) 535 (1,180) 535 (1,180) 535 (1,180)
LOWER FRAME 240 (529) 240 (529) 240 (529) 240 (529)
SLEWING BEARING 165 (364) 165 (364) 165 (364) 165 (364)
TRAVEL MOTOR 50 (110) 50 (110) 50 (110) 50 (110)
UPPER ROLLER 180 (397) 180 (397) 180 (397) 180 (397)
LOWER ROLLER 115 (256) 115 (256) 115 (256) 115 (256)
FRONT IDLER 27 (60) 27 (60) 27 (60) 27 (60)
IDLER ADJUSTER 13 (29) 13 (29) 13 (29) 13 (29)
SPROCKET 4x2 (9x2) 4x2 (9x2) 4x2 (9x2) 4x2 (9x2)
RUBBER CRAWLER SHOE 112 (247) 112 (247) 112 (247) 112 (247)
400mm (15.7") IRON SHOE 95 (210) 95 (210) 95 (210) 95 (210)
SWIVEL JOINT 45 (99) 45 (99) 45 (99) 45 (99)
FUEL 44 (97) 44 (97) 44 (97) 44 (97)
COOLANT 6 (13) 6 (13) 6 (13) 6 (13)
2-6 Issued 01-2006 Bur 6-80970 NA

2.5 TRANSPORTATION
2.5.1 LOADING MACHINE ON A TRAILER
A. Clean the trailer bed. Put chocks against truck F. Fasten machine to trailer with chains or
wheels. cables.
B. Use a ramp or loading dock. Ramps must be During transportation, the bucket or attachments may
strong enough, have a low angle, and correct hit the canopy or the cab. Therefore, set the machine
height. Load and unload machine on a level in the transporting position by observing following
surface. points:
C. Center the machine on the trailer. A. 1Extend the bucket cylinder fully.
D. Lower all attachments. B. Extend the arm cylinder fully.
E. Stop engine. Remove key from switch. C. Lower the boom.
D. If machine cannot be transported with arm
WARNING: Do not put chains over or
cylinder fully extended, remove bucket or
against hydraulic lines or hoses.
attachment and extend arm cylinder.
2.5.2 TRANSPORTATION DIMENSION AND WEIGHT OF ATTACHMENT
2.5.2.1 BOOM WITH ARM CYLINDER

L x H x W mm (ft. in) 2,910 x 1,040 x 310 (9’6.6”) (3’4.9”) (12.2")
Weight w/Arm cyl. kg (lb.) 237 (523)
SPH02000003J01 Figure 4
2.5.2.2 ARM AND BUCKET (STANDARD BUCKET)

L x H x W mm (ft. in) 2,770 x 510 x 650 (9’1.1”) (20.1") (25.6")
Weight kg (lb.) 175 (386)
6-80970 NA Issued 01-2006 Bur 2-7

2.5.2.3 ARM
L x H x W mm (ft. in) 2,010 x 420 x 250 (6’ 7.1") (16.5") (9.84")
2.5.2.4 BUCKET (STANDARD BUCKET)

Heaped capacity m3(cu. yd) 0.16 (0.21)
L x H x W mm (in) 780 x 690 x 650 (30.7") (27.2") (25.6")
UPW00500011J01 Figure 7
2.5.2.5 DOZER (WITHOUT CYLINDER WEIGHT)

L x H x W mm (in) 1,190 x 335 x 1,960 (3’ 11") (13.2") (6’ 5.2")
UPW00500012J01 Figure 8
2-8 Issued 01-2006 Bur 6-80970 NA

2.6 TYPE OF TRACK SHOES
Total Crawler width Number of Ground pressure kPa (psi)

Type Shoe width mm (in)
mm (ft. in) Links CANOPY CAB
Rubber shoe
400 (15.7") 1,960 (6'5") 72 26 (3.77) 27 (3.92)
SPW02000003J01 Figure 9
Steel shoe (option)
400 (15.7") 1,960 (6'5") 38 27 (3.92) 28 (4.06)
2.7 TYPE OF BUCKET
Heaped Outer width mm (in)

Number of Weight
Type capacity without side Remarks
with side cutter tooth kg (lb.)
m3 (cu.yd) cutter
Back hoe bucket
Standard
0.16 (0.21) 650 (25.3") 600 (23.6") 4 112 (247) size
NOTE 1: This table shows standard bucket.
6-80970 NA Issued 01-2006 Bur 2-9

2.8 ENGINE SPECIFICATIONS

2.8.1 SPECIFICATIONS
Engine Model 4TNV88-XYB

Type Vertical, 4-cycle water-cooled diesel engine
No. of cylinders - Bore x Stroke 4 - 88 mm (3.46 in) x 90 mm (3.54 in)
Total displacement 2.189 liter (134 cu. in)
Compression ratio 19.1
Rated output 30.4 kW (41.3 PS) at 2400 rpm
Maximum torque 139.3 ~ 147.1 Nm (103 ~ 109 lb. ft.) at 1440 rpm
Low idling 1175±25 rpm
High idling 2600±25 rpm
Fuel consumption rate Less than 242 g / kWh (178 g / PSh)
Allowable tilting angles Continuous; 30 for all direction
Rotating direction Counterclockwise as seen from flywheel side
Firing order 1-3-4-2-1
Fuel injection timing (b.T.D.C.) 15.5±1°
Fuel injection pressure 19.6 +1 -0 MPa (2840 +145 -0 psi)
Open Close
Valve action Intake valve b.T.D.C. 15±5° a.B.D.C. 45±5°
Exhaust valve b.T.D.C. 56±5° a.B.D.C. 18±5°
Intake valve 0.2 mm (0.008 in) in cold condition
Valve clearance
Exhaust valve 0.2 mm (0.008 in) in cold condition
Thermostat action Start 71° ± 1.5°C (160° ± 3°F) / Full open 85°C (185°F)
Compression pressure 3.4 ± 0.1 MPa (500 ± 14 psi) at 250 rpm
Lubrication oil pressure 0.44 MPa (64 psi) at 2300 rpm
Dimensions L x W x H 684 x 554 x 662 mm (26.9 x 21.8 x 26.1 in)
Dry weight 170 kg (375 lb.)
Governor Mechanical centrifugal governor (All speed type)
Fuel filtration cartridge type paper filter
Lubrication system Forced lubrication with trochoid pump
Cooling system Liquid cooling / Radiator
Starter capacity 12 V x 2.3kW
Generator capacity 12 V x 55 A
Starting aid Air heater (12 V - 400 W)
Cooling water capacity: Max / Engine 6.0 / 2.7 liter (1.59 / 0.71 gal)
Engine oil volume: Max / Effective 7.4 / 4.0 liter (1.96 / 1.06 gal)
2-10 Issued 01-2006 Bur 6-80970 NA

2.8.2 ENGINE PERFORMANCE CURVE

Model: 4TNV88-XYB
Rated Output: 30.4 kW / 2400 min-1 (41.3 PS / 2,400 rpm)
6-80970 NA Issued 01-2006 Bur 2-11

NOTES
2-12 Issued 01-2006 Bur 6-80970 NA

CHAPTER 3
E50
Issued January 2006

CHAPTER 3 - ATTACHMENT DIMENSIONS
Revision History
3-II Issued 01-2006 Bur 6-80980 NA

CHAPTER 3
TABLE OF CONTENTS
3.1 BOOM
3.1.1 Boom Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.1.2 Boom Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.1.2.1 Clearance of Pin and Bushing on Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.1.2.2 Clearance in Thrust Direction on Boom and Cylinder Installation Section . . . . . . . . . . . . . . . . . . . 3-6
3.2 ARM
3.2.1 Arm Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.2.2 Arm Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.2.2.1 Clearance of Pin and Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.2.2.2 Clearance in Thrust Direction on Arm and Cylinder Installation Section . . . . . . . . . . . . . . . . . . . . 3-11
3.3 BUCKET
3.3.1 Bucket Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.3.2 Detail Dimensional Drawings of Lug Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.3.3 Detail Dimensional Drawings of Boss Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.4 DOZER
3.4.1 Dozer Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.4.2 Dozer Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.4.2.1 Clearance of Pin and Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.4.2.2 Clearance in Thrust Direction on the Dozer and Cylinder Installation Section . . . . . . . . . . . . . . . 3-17
3.5 SWING
3.5.1 Swing Bracket Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.5.2 Swing Portion Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.5.2.1 Clearance in Thrust Direction on Swing Bracket and Cylinder Installation Section . . . . . . . . . . . 3-19
6-80980 NA Issued 01-2006 Bur 3-1

NOTES
3-2 Issued 01-2006 Bur 6-80980 NA

3.1 BOOM
3.1.1 BOOM DIMENSIONAL DRAWINGS
Boom DimensionS
No. NAME DIMENSIONS Unit: MM. (ft-in)
A Boom length 2790 (9'1.84")
B Distance between pins of boss R1434 (4'8.46")
C Distance between pins of bracket R1487.5 (4'10.6")
D Height of boom cylinder rod pin 457.5 (18.0")
E Height of arm cylinder (head side) pin 908 (35.7")
F Boom foot width 250 (9.84")
G Inner width of bracket for boom cylinder (rod side) mounting 76 (2.99")
H Boom end inner width 175 (6.89")
J Boom end outer width 265 (10.4")
K Inner width of bracket for arm cylinder (head side) 66 (2.60")
d1 Boom foot pin dia. [Bushing outer dia.] ø50 (1.97") [ø60 (2.36")]
d2 Boom cylinder (rod side) pin dia. ø50 (1.97")
d3 Pin dia. of arm end ø60 (2.36")
d4 Arm cylinder (head side) pin dia. ø45 (1.77")
Unit: MM. (in)
6-80980 NA Issued 01-2006 Bur 3-3

3.1.2 BOOM MAINTENANCE STANDARDS

3.1.2.1 CLEARANCE OF PIN AND BUSHING ON BOOM SECTION
CLEARANCE OF PIN AND BUSHING ON BOOM SECTION

Standard dimensions Clearance
Tolerance on Standard
Pos. Item Pin part No. Tolerance on Standard Service Remedy
Pin dia. bushing bore value for
pin dia. value ability limit
dia. repair
+0.061 0.02~
0 0.141
A Boom foot PH02B01046P1
(+0.0024) (0.0008~0.
50 –0.02 (0) 0056)
Replace
Boom cylinder (1.97) –0.08
B PH02B01052P2 0.7 (0.028) 1.0 (0.039) bushing
(Head side) (-0.0008) +0.25 0.07~
or pin
Boom cylinder (-0.0031) +0.05 0.33
C PH02B01054P1
(Rod side) (+0.0098) (0.0028~
Arm cylinder 45 (+0.0020) 0.0130)
D PH02B01060P1
(Head side) (1.7717)
NOTE 1: The tolerance for bushing inside diameter means the dimension after pressing into place.
NOTE 2: The part number for pins may be changed because of improvements, use them only for reference
Unit: MM. (in)
3-4 Issued 01-2006 Bur 6-80980 NA

NOTES
6-80980 NA Issued 01-2006 Bur 3-5

3.1.2.2 CLEARANCE IN THRUST DIRECTION ON BOOM AND CYLINDER INSTALLATION SECTION
SPW03000003E01 Figure 3
3-6 Issued 01-2006 Bur 6-80980 NA

CLEARANCE IN THRUST DIRECTION ON BOOM SECTION

Clearance X adjusted with shim
Standard dimensions Pin length
(total of both sides)
Sec. Item Standard Remedy
Dimensions Standard Serviceability Dimensions
No. value for No.
MM. (in) value limit MM. (in)
repair
250 -0.2
-0.3
Boom
(9.84 -0.008 0.1~0.5
Boom 377
A-A L1 -0.012) (0.004~ PL1
foot (14.8)
250 -0.5 0.020)
Swing bracket (9.84
-0.020)
75 -0.5
Boom Boom cylinder (2.95
0.1~0.5
cylinder -0.020) 264
B-B L2 (0.004~ PL2
(Head 77 +1 (10.4)
0.020)
side) Swing bracket (3.03
Adjusted
+0.039) 1.0 (0.039) 1.5 (0.059)
with shim
75 -0.5
Boom Boom cylinder (2.95
0.5~0.9
C-C L3 (0.020~ PL3
(Rod 76 +1 (8.39)
0.035)
side) Boom (2.99
+0.039)
65 -0.5
Arm Arm cylinder (2.56
0.1~0.5
D-D L4 (0.004~ PL4
(Head 66 +1 (7.87)
0.020)
side) Boom (2.60
+0.039)
6-80980 NA Issued 01-2006 Bur 3-7

3.2 ARM
3.2.1 ARM DIMENSIONAL DRAWINGS
3-8 Issued 01-2006 Bur 6-80980 NA

CLEARANCE OF PIN AND BUSHING ON ARM SECTION

No. Name Dimensions
1560
A Arm length
(5'1.42")
R405
B Distance between pins of boss and bracket
(15.9")
R1118
C Distance between pins of boss and bracket
(3'8.02")
R230.5
D Distance between pins of boss and boss
(9.07")
311
E Height between pins of boss and bracket
(12.2")
191.5
F Height between pins of boss and bracket
(7.54")
12
G Height between pins of boss and center
(0.472")
150
H Boss width
(5.91")
175
J Boss width
(6.89")
61
K Bracket inner width
(2.40")
66
L Bracket inner width
(2.60")
320
M Idler link dimension
(12.6")
310
N Bucket link dimension
(12.2")
ø55
D1 I.D. of boss
(2.17")
ø55
D2 I.D. of boss
(2.17")
ø75
D3 I.D. of boss
(2.95")
ø45
d1 Pin dia.
(1.77")
ø45
d2 Pin dia.
(1.77")
ø60
d3 Pin dia.
(2.36")
ø45
d4 Pin dia.
(1.77")
ø45
d5 Pin dia.
(1.77")
Unit: MM. (ft-in)
6-80980 NA Issued 01-2006 Bur 3-9

3.2.2 ARM MAINTENANCE STANDARDS

3.2.2.1 CLEARANCE OF PIN AND BUSHING
CLEARANCE OF PIN AND BUSHING ON ARM SECTION

Standard dimensions Clearance
Tolerance Standard
Pos. Item Pin part No. Tolerance Standard Serviceab Remedy
Pin dia. on bushing value for
on pin dia. value ility limit
bore dia. repair
Arm point
(Connecte
A +0.064 0.025~
d part of
PH12B011 +0.005 0.114
bucket)
14P1 (+0.0025) (0.0010~
Bucket link
(+0.0002) 0.0045)
B (Bucket
side)
Idler link +0.076 0.055~
(Connecte PY12B011 +0.035 0.126
C
d part of 58P1 (+0.0030) (0.0022~
ø45
arm) (+0.0014) 0.0050)
(1.77)
+0.073 0.052~
Bucket link
+0.032 0.123
D (Idler link –0.02
(+0.0029) (0.0020~
side) PY12B011 –0.05 0.7 1.0 Replace bushing or
(+0.0013) 0.0048)
59P1 (-0.0008) (0.028) (0.039) pin
Bucket
(-0.0020)
D’ cylinder +0.25 0.07~
(Rod side) +0.05 0.30
Bucket (+0.0098) (0.0028~
PH12B010
E cylinder (+0.0020) 0.0118)
84P1
(Head side)
Arm foot +0.061 0.02~
(Connecte PY12B011 ø60 0 0.111
F
d part of 52P1 (2.36) (+0.0024) (0.0008~
boom) (0) 0.0044)
+0.25 0.07~
Arm
PH12B010 ø45 +0.05 0.30
G cylinder
84P1 (1.77) (+0.0098) (0.0028~
(Rod side)
(+0.0020) 0.0118)
Unit: MM. (in)
3-10 Issued 01-2006 Bur 6-80980 NA

3.2.2.2 CLEARANCE IN THRUST DIRECTION ON ARM AND CYLINDER INSTALLATION SECTION
6-80980 NA Issued 01-2006 Bur 3-11

CLEARANCE IN THRUST DIRECTION ON ARM SECTION

Clearance X adjusted with shim
(total of both sides)
Sec. Item Standard Remedy
Standard Serviceabi
No. Dimensions value for No. Dimensions
value lity limit
repair
150
Arm
(5.91)
287.5
A-A Arm point L1 151 +0.9 _0.5 PL1
(11.3)
Bucket (5.94 +0.035
-0.020) 0.7~2.2
150 -0.2 -0.3 (0.028~ See NOTE 1
Link side (5.91 -0.008 0.087)
-0.012) 287.5
B-B Bucket link L2 PL2
151 +0.9 -0.5 (11.3)
Bucket (5.94 +0.035
-0.020)
150
Idler link Arm 0.1~0.5
(5.91) 210.5
C-C (Connected L3 (0.004~ — PL3
— (8.29)
part of arm) Link side 0.020)
(—)
55 -0.5
Rod side 0.6~1.0
Bucket link (2.165 -0.020) 1.5 2.0
L4 (0.024~
(Rod side) 57±0.4 (0.059) (0.079)
Link side 0.039)
(2.24±0.016) Adjusted
210.5
D-D 150 -0.2 -0.3 with shim PL5
(8.29)
Bucket link (5.91 -0.008 0.1~0.5
Bucket link
L5 -0.012) (0.004~ —
(Idler link side)
— 0.020)
Idler link
(—)
60 -0.5
Head side 0.5~0.9
Bucket cylinder (2.36 -0.020) 183
E-E L6 (0.020~ PL6
(Head side) 61 +1 (7.20)
Arm 0.035)
(2.40 +0.039)
175 -0.2 -0.3
Arm (6.89 -0.008
Less than
-0.012) 1.0 1.5 265
F-F Arm foot L7 0.5 PL7
175 +0.3 +0.1 (0.039) (0.059) (10.4)
(0.020)
Boom (6.89 +0.012
+0.004)
65 -0.5
Rod side 0.5~0.9
Arm cylinder (2.56 -0.020) 183
G-G L8 (0.020~ PL8
(Rod side) 66 +1 (7.20)
Arm 0.035)
(2.60 +0.039)
NOTE 1: Clearance X is adjusted using shims if clearance exceeds the standard value for repair.
Unit: MM. (in)
3-12 Issued 01-2006 Bur 6-80980 NA

3.3 BUCKET
3.3.1 BUCKET DIMENSIONAL DRAWINGS
BUCKET DIMENSIONS
No.
Heaped Capacity m3 (cu.yd) 0.16 (0.20)
A Distance between pin and bracket 228.5 (9)
B Distance between bucket pin and tooth end R800 (31.5)
C Inner width of bucket top end 568 (22.4)
D Inner width of lug 197 (7.76)
E Inner width of bracket 151 (5.49)
F Outer width of side cutter 650 (25.6)
G Outer width of bucket bottom plate 511 (20.1)
H Outer tooth distance 501 (19.7)
J Pitch between teeth 167 (6.57)
J0 Pitch between teeth 167 (6.57)
d1 Pin dia. ø45 (1.77)
d2 Pin dia. ø45 (1.77)
NOTE 1: Standard bucket.
Unit: MM. (ft-in)
6-80980 NA Issued 01-2006 Bur 3-13

3.3.2 DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION
DIMENSION OF LUG SECTION

Portion Plate outer dia. A Boss thickness B Pin bore dia. C Lug plate thickness D
Dimensions 85 (3.35) 26 (1.02) 40 (1.578) 14 (0.551)
Unit: MM. (in)
3.3.3 DETAIL DIMENSIONAL DRAWINGS OF BOSS SECTION
Dimension of boss section

Portion A B C D E F G
Dimensions 65 (2.56) 43 (1.69) 60 (2.36) 63 (2.48) 12 (0.472) 24 (0.945) 11 (0.433)
Unit: MM. (in)
3-14 Issued 01-2006 Bur 6-80980 NA

3.4 DOZER
3.4.1 DOZER DIMENSIONAL DRAWINGS
DOZER DIMENSIONS
No. NAME Dimensions
A Blade width 1960 (6'5.17")
B Blade height 346 (1'1.62")
C Distance from dozer attaching pin center to cutting edge end R1149 (3'9.24")
D Inner width of dozer attaching bracket 531 (20.9")
E Width of dozer attaching bracket 69 (2.72")
F Distance from dozer attaching pin center to attaching pin on dozer cylinder head side R712 (28.0")
G Attaching bracket inner width on dozer cylinder head side 62 (2.44")
H Horizontal distance from dozer attaching pin center to edge end 1105.3 (3'5.72")
J Vertical distance from dozer attaching pin center to edge end 313 (12.3")
d1 Dozer attaching pin diameter. ø40 (1.57")
d2 Attaching pin diameter on dozer cylinder head side ø55 (2.17")
Unit: MM. (ft-in)
6-80980 NA Issued 01-2006 Bur 3-15

3.4.2 DOZER MAINTENANCE STANDARDS

3.4.2.1 CLEARANCE OF PIN AND BUSHING
DOZER MAINTENANCE STANDARDS

Clearance of pin and bushing
Standard dimension Clearance
Item Tolerance on Standard
Pos. Pin part No. Tolerance on Standard Serviceability Remedy
Dozer blade Pin dia. bushing value for
pin dia. value limit
bore dia. repair
Cylinder –0.15 +0.25 0.20~
A
(Head side) ø55 –0.21 +0.05 0.46
YJ51B01009P1
Cylinder (2.17) (-0.0059) (+0.0098) (0.0079~
B Replace
(Rod side) (-0.0083) (+0.0020) 0.0181) 1.5 2.0
bushing
–0.06 +0.215 0.175~ (0.059) (0.079)
or pin
Dozer blade 40 –0.09 +0.115 0.305
C PH51B01001P1
foot (1.575) (-0.0024) (+0.0085) (0.0069~
(-0.0035) (+0.0045) 0.0120)
NOTE 1: The tolerance for bushing inside diameter means the dimension after pressing into place.
NOTE 2: The part number for pins may be changed because of improvements, use them only for reference.
3-16 Issued 01-2006 Bur 6-80980 NA

3.4.2.2 CLEARANCE IN THRUST DIRECTION ON THE DOZER AND CYLINDER INSTALLATION SECTION
DOZER MAINTENANCE STANDARDS
Clearance in thrust direction on the dozer and cylinder installation section
Clearance X
Pos. Item Remedy
No. Dimensions (total of both No. Dimensions
sides)
60 0 to -0.5
Head side (2.362 0
Dozer blade
to -0.020) 141
A cylinder L1 PL1
62 +1 to 0 (5.55)
(Head side) Dozer
(2.441 +0.039 0.6~2.0
blade
to 0) (0.023~0.079) When clearance X exceeds 3.5
60 0 to -0.5 After shim MM., adjust it with shim.
Rod side (2.362 0 adjustment
Dozer blade
to 0.020) 141
B cylinder L2 PL2
62 +1 to 0 (5.55)
(Rod side) Lower
(2.441 +0.039
frame
to 0)
Dozer 69±0.5
Dozer blade blade (2.72±0.020) 2.5~4.5 When clearance X exceeds the 137
C L3 PL3
foot Lower 72 (0.079~0.177) upper limit, adjust it with shim. (5.39)
frame (2.83)
Unit: MM. (in)
6-80980 NA Issued 01-2006 Bur 3-17

3.5 SWING
3.5.1 SWING BRACKET DIMENSIONAL DRAWINGS
SWING BRACKET DIMENSIONS

No. NAME Dimensions MM. (in)
A Distance between swing center pin and boom foot pin 67 (2.64)
B Distance between boom foot pin and boom cylinder pin 207.6 (8.17)
C - ditto - 320.7 (12.6)
D Distance between swing center pin and swing cylinder pin 307.5 (12.1)
E - ditto - 290 (11.4)
F Inside width of swing center 329 (13.0)
F1 - ditto - 78.5 (3.09)
F2 - ditto - 76 (2.99)
G Inside width of boom foot 250 (9.84)
H Inside width for installing boom cylinder 77 (3.03)
J Inside width for installing swing cylinder 73 (2.87)
d1 Pin dia. of swing center ø80 (3.15)
d2 Pin dia. of boom foot ø50 (1.97)
d3 Pin dia. of boom cylinder ø50 (1.97)
d4 Pin dia. of swing cylinder ø50 (1.97)
3-18 Issued 01-2006 Bur 6-80980 NA

3.5.2 SWING PORTION MAINTENANCE STANDARDS

3.5.2.1 CLEARANCE IN THRUST DIRECTION ON SWING BRACKET AND CYLINDER INSTALLATION
SECTION
6-80980 NA Issued 01-2006 Bur 3-19

CLEARANCE IN THRUST DIRECTION ON SWING PORTION

Standard Clearance X adjusted with shim
Pin length
Dimension (total of both sides)
Sec. Item Remedy
Standard Standard Serviceability
No. Dimensions No. Dimensions
value value for repair limit
Swing 70 -0.5
Cylinder 0.5~0.9
(2.76 -0.020) 146.5
A-A cylinder L1 (0.020~ 1.5 (0.059) — PL1
73 +2 (5.77)
(Rod side) Bracket 0.035)
(2.87 +0.079) Adjusted
Swing 70 -0.5 with shim
Cylinder 0.5~0.9
(2.76 -0.020) 151
B-B cylinder L2 (0.020~ 1.0 (0.039) — PL2
72 +1 (5.94)
(Head side) Upper frame (2.83 +0.039)
0.035)
Swing 73 +0.5
Upper frame
(2.87 +0.020) Adjusted 155
C-C center L3 — PL3
78.5 +0.5 with shim (6.1)
(Upper side) Bracket
(3.09 +0.020)
Swing 73 +0.5
Upper frame Less than
(2.87 +0.020) Adjusted 142
D-D center L4 0.5 1.5 (0.059) — PL4
78.5 +0.5 with shim (5.59)
(Lower side) Bracket (0.020)
(2.99 +0.020)
3-20 Issued 01-2006 Bur 6-80980 NA

CHAPTER 11
E50
TOOLS
Issued January 2006

CHAPTER 11 - TOOLS
Revision History
First edition 01-2006 E50 6-80990 NA
11-II Issued 01-2006 Bur 6-80990 NA

CHAPTER 11
TOOLS
TABLE OF CONTENTS
11.1 TORQUE SPECIFICATIONS FOR CAPSCREWS AND NUTS

11.1.1 Metric Coarse Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
11.1.2 Metric Fine Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
11.2 SCREW AND TOOL SIZES
11.2.1 Capscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
11.2.2 Capscrew (Socket bolt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES
11.3.1 Joints for Piping (O-ring Sealing Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
11.3.2 Hydraulic Hose (30 Degree Flare TypE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS
11.4.1 Sleeve Type Tube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
11.4.2 Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
11.5 PLUGS
11.5.1 Plug for Hydraulic Pipe Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
11.5.1.1 Cap Nut (Joint Plug) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
11.5.1.2 Plug (Tube Plug) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
11.5.1.3 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
11.5.2 Plug for Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
11.5.2.1 PF Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
11.5.2.2 PT Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
11.5.2.3 Plug for Flare Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
11.6 SPECIAL SPANNERS FOR TUBES
11.7 SPECIAL TOOLS
11.8 APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS
11.9 COUNTERWEIGHT LIFTING JIG
11.10 UPPER FRAME LIFTING JIG
6-80990 NA Issued 01-2006 Bur 11-1

CHAPTER 11 - TOOLS
NOTES
11-2 Issued 01-2006 Bur 6-80990 NA

CHAPTER 11 - TOOLS
11.1 TORQUE SPECIFICATIONS FOR CAPSCREWS AND NUTS

The following Torque Specifications are provided for use when actual torque value of a fastener is not known.
Check the capscrews and nuts for their tightness and the loss of before starting work and at periodic maintenance
intervals. Retighten and replace as needed. For a new machine, check and retorque after the first 50 hours of
operation. Replace with genuine parts.
Refer to the table below for the tightening and 3. Numerical indication on the capscrew head
retightening of capscrews. shows the classification for strength (e.g., 7=7 T).
1. The table below is not applicable for the No indication is provided for smaller size of
capscrews that secure plastic covers. For the capscrews, M5 or less.
tightening torque for such capscrews, contact
your dealer. Over-tightening may cause damage
to the plastic parts.
2. In case that the tightening torque is specified in
the manual, use those torque values regardless
to the table below.
11.1.1 METRIC COARSE THREAD STANDARD TIGHTENING TORQUE VALUES

Make sure to tighten all Capscrews and Nuts to proper torque values.
METRIC COARSE THREAD STANDARD TIGHTENING TORQUE VALUES

Classification 4.8T 7T 10.9T
Nominal size No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
4.4±0.5 3.7±0.4 9.6±1.0 8.1±0.8 17.4±1.8 14.7±1.5
M6 P=1
(3.2±0.4) (2.7±0.3) (7.1±0.7) (6.0±0.6) (12.8±1.3) (10.8±1.1)
10.7±1.1 9.0±0.9 23.5±2.0 19.6±2.0 42.2±3.9 35.3±3.9
M8 P=1.25
(7.9±0.8) (6.6±0.7) (17.3±1.5) (14.5±1.5) (31.1±2.9) (26.0±2.9)
21.6±2.0 17.9±1.8 46.1±4.9 39.2±3.9 83.4±8.8 70.6±6.9
M10 P=1.5
(15.9±1.4) (13.2±1.3) (34.0±3.6) (28.9±2.9) (61.5±6.5) (52.1±5.1)
36.3±3.9 31.4±2.9 79.4±7.8 66.7±6.9 143±15 121±12
M12 P=1.75
(26.8±2.9) (23.2±2.1) (58.6±5.8) (49.2±5.1) (105±11) (89.2±8.9)
57.9±5.9 49.0±4.9 126±13 106±10 226±20 191±19
M14 P=2
(42.7±4.4) (36.1±3.6) (92.9±9.6) (78.2±7.4) (167±15) (141±14)
88.3±8.8 74.5±6.9 191±20 161±16 343±39 284±29
M16 P=2
(65.1±6.5) (55.0±5.1) (141±15) (119±12) (253±29) (209±21)
122±12 103±10 265±29 226±20 481±49 402±39
M18 P=2.5
(90.0±8.9) (75.8±7.2) (195±21) (167±15) (355±36) (297±29)
172±17 144±14 373±39 314±29 667±69 559±59
M20 P=2.5
(127±13) (106±10) (275±29) (232±21) (492±51) (412±44)
226±20 192±20 500±49 422±39 902±88 755±78
M22 P=2.5
(167±15) (142±15) (369±36) (311±29) (665±65) (557±58)
294±29 235±29 637±69 520±49 1160±118 941±98
M24 P=3
(217±21) (173±21) (470±51) (383±36) (856±87) (694±72)
431±39 353±39 941±98 765±78 1700±167 1370±137
M27 P=3
(318±29) (260±29) (694±72) (564±58) (1250±123) (1010±101)
588±59 490±49 1285±127 1079±108 2300±235 1940±196
M30 P=3.5
(434±44) (361±36) (948±94) (796±80) (1700±173) (1430±145)
794±78 667±69 1726±177 1451±147 3110±314 2610±265
M33 P=3.5
(586±58) (492±51) (1270±131) (1070±108) (2290±232) (1930±195)
1030±98 863±88 2226±226 1863±186 4010±402 3360±333
M36 P=4
(760±72) (637±65) (1640±167) (1370±137) (2960±297) (2480±246)
6-80990 NA Issued 01-2006 Bur 11-3

CHAPTER 11 - TOOLS
Torque value Unit: Nm (lb ft)
11.1.2 METRIC FINE THREAD STANDARD TIGHTENING TORQUE VALUES

Make sure to tighten all Capscrews and Nuts to proper torque values.
METRIC FINE THREAD STANDARD TIGHTENING TORQUE VALUES

Classification 4.8T 7T 10.9T
Nominal size No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
11.3±1.1 9.5±1.0 24.5±2.0 20.6±2.0 44.1±3.9 37.3±3.9
M8 P=1.0
(8.3±0.8) (7.0±0.7) (18.1±1.5) (15.2±1.5) (32.5±2.9) (27.5±2.9)
22.6±2.0 18.7±1.9 48.1±4.9 41.2±3.9 87.3±8.8 73.5±6.9
M10 P=1.25
(16.7±1.5) (13.8±1.4) (35.5±3.6) (30.3±2.9) (64.4±6.5) (54.2±5.1)
39.2±3.9 33.3±2.9 85.3±8.8 71.6±6.9 154±16 129±13
M12 P=1.25
(28.9±2.9) (24.6±2.1) (62.9±6.5) (52.8±5.1) (114±12) (95.2±9.6)
92.2±8.8 77.5±7.8 196±20 169±17 363±39 304±29
M16 P=1.5
(68.0±6.5) (57.2±5.8) (145±15) (125±13) (268±29) (224±21)
186±19 155±16 402±39 333±29 726±69 608±59
M20 P=1.5
(137±14) (114±12) (297±29) (246±21) (535±51) (448±44)
314±29 265±29 686±69 569±59 1240±118 1030±98
M24 P=2
(232±21) (195±21) (506±51) (420±44) (915±87) (760±72)
637±59 530±49 1390±137 1157±118 2500±255 2080±206
M30 P=2
(470±44) (391±36) (1030±101) (853±87) (1840±188) (1530±152)
853±88 706±70 1860±186 1550±155 3350±334 2790±275
M33 P=2
(629±65) (521±52) (1370±137) (1140±114) (2470±246) (2060±203)
1070±108 892±88 2330±226 1940±196 4200±422 3500±353
M36 P=3
(789±80) (658±65) (1720±167) (1430±145) (3100±311) (2580±260)
Torque value Unit: Nm (lb ft)
11-4 Issued 01-2006 Bur 6-80990 NA

CHAPTER 11 - TOOLS
11.2 SCREW AND TOOL SIZES

11.2.1 CAPSCREW
Nominal B MM. Nominal B MM.

screw size screw size
Tool size Tool size
(d) (d)
M6 10 M24 36
M8 13 M30 46
M10 17 M36 55
M12 19 M42 65
M16 24 M48 75
M20 30
11.2.2 CAPSCREW (SOCKET BOLT)
Nominal B MM. B MM.

Nominal
screw size
Tool size screw size(d) Tool size
(d)
M6 5 M20 17
M8 6 M24 19
M10 8 M30 22
M12 10 M36 27
M14 12 M42 32
M16 14 M48 36
(M18) 14
6-80990 NA Issued 01-2006 Bur 11-5

CHAPTER 11 - TOOLS
11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES

11.3.1 JOINTS FOR PIPING (O-RING SEALING TYPE)
Nominal screw size Spanner size Tightening torque

(PF) (MM.) Nm (lb ft)
1/8 14 17±2 (12±1)
1/4 19 36±2 (27±1)
3/8 22 74±5 (54±4)
1/2 27 108±9.8 (80±7)
3/4 36 162±9.8 (119±7)
1 41 255±9.8 (188±7)
11.3.2 HYDRAULIC HOSE (30 DEGREE FLARE TYPE)
Nominal screw size Spanner size Tightening torque

(PF) (MM.) Nm (lb ft)
1/8 17 15±2.0 (11±1)
1/4 19 29±4.9 (22±4)
3/8 22 49±4.9 (36±4)
1/2 27 78±4.9 (58±4)
3/4 36 118±9.8 (87±7)
1 41 137±15 (101±11)
The application of the tightening torque is subject to a dry condition.
11-6 Issued 01-2006 Bur 6-80990 NA

CHAPTER 11 - TOOLS
11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS

11.4.1 SLEEVE TYPE TUBE FITTINGS
Tube size Spanner size Tightening Torque

OD x Thickness (MM.) (MM.) Nm (lb ft)
10 x 1.5 19 44±4.9 (33±4)
15 x 2.0 27 147±20 (110±14)
18 x 2.5 32 177±20 (130±14)
22 x 3.0 36 216±20 (160±14)
28 x 4.0 41 275±29 (200±22)
35 x 5.0 55 441±44 (330±33)

11.4.2 PART NUMBER
SLEEVE NUT
SPW11000004E01 Figure 7 SPW11000005E01 Figure 8

Part NO. Opposing flats Part NO.
Tube size Tube size
(HEX)
OD Ihara Koatu Nippon A.M.C OD Ihara Koatu Nippon A.M.C
B
6 ZF93S06000 — 6 14 ZF93N06000 —
8 ZF93S08000 — 8 17 ZF93N08000 —
10 ZF93S10000 ZA93S10000 10 19 ZF93N10000 ZA93N10000
12 ZF93S12000 — 12 22 ZF93N12000 —
15 ZF93S15000 ZA93S15000 15 27 ZF93N15000 ZA93N15000
18 ZF93S18000 ZA93S18000 18 32 ZF93N18000 ZA93N18000
22 ZF93S22000 ZA93S22000 22 36 ZF93N22000 ZA93N22000
28 ZF93S28000 ZA93S28000 28 41 ZF93N28000 ZA93N28000
32 ZF93S32000 — 32 50 ZF93N32000 —
35 ZF93S35000 ZA93S35000 35 55 ZF93N35000 ZA93N35000
38 ZF93S38000 — 38 60 ZF93N38000 —
6-80990 NA Issued 01-2006 Bur 11-7

CHAPTER 11 - TOOLS
11.5 PLUGS
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT
11.5.1.1 CAP NUT (JOINT PLUG)
11.5.1.2 PLUG (TUBE PLUG)
11.5.1.3 NUT
11-8 Issued 01-2006 Bur 6-80990 NA

CHAPTER 11 - TOOLS
11.5.2 PLUG FOR HYDRAULIC EQUIPMENT

11.5.2.1 PF SCREW
11.5.2.2 PT SCREW
11.5.2.3 PLUG FOR FLARE HOSE
6-80990 NA Issued 01-2006 Bur 11-9

CHAPTER 11 - TOOLS
11.6 SPECIAL SPANNERS FOR TUBES
Applicable tube diameter Dimensions of a special spanner

Part No. HEX
MM. (in) MM. (in)
15 (0.591) 2421T160 MM.
18 (0.709) 2421T138 27
22 (0.866) 2421T130 32
28 (1.102) 2421T115 36
11-10 Issued 01-2006 Bur 6-80990 NA

CHAPTER 11 - TOOLS
11.7 SPECIAL TOOLS
No. Tools name Tools No. Shape Use
Torx driver
(with tamper
For instrument R.H
1 proof) —
cover
T25
(for M5)
11.8 APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS
Manufacturer
Service Features
Loctite Three-Bond
#242 1360K Low strength
Screw locking compound #262 1374 Middle strength
#271 1305 High strength
Sealing compound #515 1215 Sealing
6-80990 NA Issued 01-2006 Bur 11-11

CHAPTER 11 - TOOLS
11.9 COUNTERWEIGHT LIFTING JIG
FIG. 11-1 COUNTERWEIGHT LIFTING JIG
11-12 Issued 01-2006 Bur 6-80990 NA

CHAPTER 11 - TOOLS
11.10 UPPER FRAME LIFTING JIG
FIG. 11-2 UPPER FRAME LIFTING JIG
6-80990 NA Issued 01-2006 Bur 11-13

CHAPTER 11 - TOOLS
NOTES
11-14 Issued 01-2006 Bur 6-80990 NA

CHAPTER 12
E50
STANDARD MAINTENANCE TIME

TABLE
Issued January 2006

CHAPTER 12 - STANDARD MAINTENANCE TIME TABLE
Revision History
12-II Issued 01-2006 Bur 6-81000 NA

CHAPTER 12
TABLE OF CONTENTS
12.1 WORKING STANDARDS FOR TIME TABLES

12.1.1 Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
12.1.2 Applicable Range of Standard Maintenance Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
12.1.3 Excluded Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
12.1.4 Applicable Machine for Estimation of Standard Maintenance Time . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
12.1.5 Standard Maintenance Time Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
12.1.6 Classification of Work Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
12.2 TIME TABLES
12.2.1 Attachment - Group 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
12.2.2 Canopy and Guard - Group 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
12.2.3 Upper Structure - Group 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7
12.2.4 Under Carriage - Group 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10
6-81000 NA Issued 01-2006 Bur 12-1

NOTES
12-2 Issued 01-2006 Bur 6-81000 NA

12.1 WORKING STANDARDS FOR TIME TABLES

12.1.1 WORKING CONDITIONS 12.1.4 APPLICABLE MACHINE FOR ESTIMATION
OF STANDARD MAINTENANCE TIME
1. Technicians:
One or more technicians who are qualified by 1. Standard machine.
Manufacturer are needed. The technicians need 2. A well maintained machine combined with
five years or more experience, they have to standard attachments which has operated in a
complete the training in the operation of this normal circumstances.
machine.
2. Facilities: 12.1.5 STANDARD MAINTENANCE TIME TABLE
General jigs, tools, apparatus, testers to be 1. Units of working time:
provided. The maintenance workshop should be 6 minutes = 0.1 hour
equipped with a crane and inspection
2. Calculating method of standard maintenance
instruments necessary for specific self inspection
time:
activities.
Maintenance time = Working time × Number of
3. Place: workers
The workshop should be located on a flat land Working time = Maintenance time / Number of
with a service truck and a crane are available. workers)
3. When more than one job is done,
12.1.2 APPLICABLE RANGE OF STANDARD
MAINTENANCE TIME A. Add each standard maintenance time
1. Standard maintenance time: B. A time is given except for covers that are
Direct maintenance time plus spare time. easily removed by hand.
2. Direct maintenance time: C. Assembly (Assy) works include the following
Net time actually spent for maintenance. works marked with black dot •
3. Additional time: 4. O / H:
Time for transpor tation of the machine for Th e rem oving a nd installin g tim e are n ot
maintenance, preparation for a safe work site. included.
12.1.3 EXCLUDED TIME 5. Abbreviations used in the Standard Working

Time Table.
NOTE: Not included in standard maintenance
time. Abbreviations
1. Repairing time: Assembly ASSY Engine E/G Solenoid SOL
Time for machining, sheet metal processing, Attachment ATT Flexible hose F hose Switch SW
welding, gas cutting, removing broken screw, Bearing BRG Installation Inst. Valve V
taking care of parts and painting.
Control
C/V Overhaul O/H
2. Items excluded from maintenance time because valve
of uncertainty in time: Cylinder Cyl Removal Rem.
Receiving the vehicle into shop, transportation,
delivery, final inspection and investigation of 12.1.6 CLASSIFICATION OF WORK CODE
causes for trouble, diagnosis and inspection.
GROUP
3. Indirect time: REMARKS
Time for field work, preparation of required parts, No. Description
etc., before starting work, going to and from the 01 Attachment
To indicate removing,
site, waiting due to user’s convenience at the site 02 Canopy and Guard
installing, replacement
and paper work for reports, bills, etc. 03 Upper Structure
and overhaul.
04 Under carriage
4. Over time:
Over time should be calculated separately.
5. Separate calculation:
The cost for service cars, trucks with crane and
truck cranes should be calculated separately.
6-81000 NA Issued 01-2006 Bur 12-3

12.2 TIME TABLES

12.2.1 ATTACHMENT - GROUP 01
Group 01 - Attachment
GROUP WORK TO BE UNIT:
EQUIPMENT PORTION UNIT REMARKS
No. DONE HOUR
00 Bucket portion Refer to 32.1.2
01 Bucket ASSY Rem.l/Inst. 1 pc. Include adjustment 0.4
02 • Bucket removing / installing position Preparation 1 pc. 0.1
03 • Bucket installing pin Rem./Inst. 1 pc. Include stopper pin. 0.1
04 • Bucket drive pin - ditto - 1 pc. 0.1
05 • Bucket sling and transfer Preparation 1 pc. 0.1
06 Bucket (Single) O/H 1 pc. Not include removal / inst. 0.6
07 • Bushing Replace 1 pc. 0.5
10 Arm portion Refer to 32.1.3
11 Arm ASSY Rem./Inst. 1 pc. 0.8
• Bucket cylinder removing / installing
12 Preparation 1 pc. 0.2
position and piping
13 • Bucket cylinder rod pin Rem./Inst. 1 pc. Include stopper pin. 0.1
14 • Bucket cylinder head pin - ditto - 1 pc. Include stopper pin. 0.1
15 • Bucket cylinder assy - ditto - 1 pc. 0.1
16 • Arm cylinder rod pin - ditto - 1 pc. Include stopper pin. 0.1
17 • Boom top pin - ditto - 1 pc. 0.1
18 • Arm sling and transfer - ditto - 1 pc. 0.1
20 Boom portion Refer to 32.1.4
21 Boom ASSY Rem./Inst. 1 pc. 1.0
22 • Boom removing / installing position Preparation 1 pc. 0.1
23 • Boom cylinder temporary slinging - ditto - 1 pc. 0.1
24 • Boom cylinder rod pin Rem./Inst. 1 pc. Include stopper pin. 0.1
25 • Boom cylinder piping - ditto - 1 pc. 0.1
26 • Arm & Bucket piping - ditto - 1 pc. 0.2
27 • Boom assy temporary slinging Rem. / Inst. 1 pc. 0.1
28 • Boom foot pin - ditto - 1 pc. Include stopper pin. 0.1
29 • Boom assy slinging - ditto - 1 pc. 0.1
30 Arm cylinder removing / installing - ditto - 1 pc. 0.3
31 • Arm cylinder piping - ditto - 1 pc. 0.1
32 • Arm cylinder head pin - ditto - 1 pc. Include stopper pin. 0.1
33 • Arm cylinder slinging - ditto - 1 pc. 0.1
40 Boom cylinder removing / installing - ditto - 1 pc. 0.3
41 • Boom cylinder piping - ditto - 1 pc. 0.1
42 • Boom cylinder head pin - ditto - 1 pc. 0.1
43 • Boom cylinder slinging - ditto - 1 pc. 0.1
50 Bucket cylinder O/H 1 pc. 2.5
51 • Pin bushing Replace 1 set Include seal. 1.0
60 Arm cylinder O/H 1 pc. 2.5
70 Boom cylinder O/H 1 pc. 2.5
80 Swing portion Refer to 32.1.5
81 Swing bracket assy Rem. / Inst. 1 pc. After removing boom. 0.4
12-4 Issued 01-2006 Bur 6-81000 NA

Group 01 - Attachment
No. DONE HOUR
82 • Swing cylinder rod pin - ditto - 1 pc. 0.1
83 • Swing bracket slinging - ditto - 1 pc. 0.1
84 • Swing center pin - ditto - 1 pc. 0.1
85 Swing cylinder removing / installing - ditto - 1 pc. After removing swing bracket. 0.3
86 • Swing cylinder hose Rem. / Inst. 2 pcs. 0.2
87 • Swing cylinder head pin - ditto - 1 pc. 0.1
88 Swing cylinder O/H 1 pc. 2.5
89 • Pin bushing Replace 1 pc. Include seal. 1.0
Other necessary works Rem. / Inst. 1 set Panel assy (3) 0.1
90 Dozer portion Refer to 32.1.6
91 Dozer ASSY Rem. / Inst. 1 pc. 0.6
92 • Dozer cylinder hose - ditto - 2 pcs. 0.2
93 • Dozer cylinder rod pin - ditto - 1 pc. 0.1
94 • Dozer installing pin - ditto - 2 pcs. 0.2
95 Dozer cylinder O/H 1 pc. 2.5
6-81000 NA Issued 01-2006 Bur 12-5

12.2.2 CANOPY AND GUARD - GROUP 02
Group 02 - Canopy and Guard

No. DONE HOUR
00 Canopy portion Refer to 33.1.1
01 Canopy assy Rem. / Inst. 1 pc. 0.2
02 • Hand rail - ditto - 1 pc. 0.1
10 Cab portion Refer to 33.1.1
11 Cab assy Rem. / Inst. 1 pc. 0.4
12 • Harness - ditto - 1 pc. 0.1
20 Bonnet & Guard Refer to 33.1.2
21 Cover assy (1) Rem. / Inst. 1pc. 0.1
22 Bonnet assy (2) - ditto - 1pc. 0.1
23 Cover assy (3) - ditto - 1pc. 0.1
24 Cover assy (4) - ditto - 1pc. 0.1
25 Cover assy (5) Rem. / Inst. 1pc. 0.1
30 Control stand portion Refer to 33.1.15
31 Control stand ASSY Rem. / Inst. 1 pc. 1.0
32 • Air cleaner - ditto - 1 pc. 0.1
33 • E / G control cable - ditto - 1 pc. 0.2
34 • Deceleration motor (OPT) - ditto - 1 pc. 0.1
35 • Filler neck - ditto - 1 pc. 0.1
36 • Fuel air bleed hose - ditto - 1 pc. 0.1
37 • Harness - ditto - 1 set 0.3
Other necessary works Rem. / Inst. 1 set Canopy 0.2
- ditto - 1 set Floor cover 0.1
- ditto - 1 set Guard (Cover, support) 0.4
- ditto - 1 pc. Counterweight 0.4
- ditto - 1 pc. Negative terminal of battery 0.1
40 Floor plate portion Refer to 33.1.3
41 Floor plate assy Rem. / Inst. 1 set 0.5
Other necessary works - ditto - 1 pc. Canopy removal / inst 0.2
50 Counterweight portion Refer to 33.1.5
51 Counterweight ASSY Rem. / Inst. 1 pc. 0.4
52 • Lifting tools Preparation 1 set 0.1
53 • Slinging Rem. / Inst. 1 pc. 0.1
54 • Counterweight fixing bolt - ditto - 1 set 0.1
Other necessary works - ditto - 3 pcs. Guards 0.3
12-6 Issued 01-2006 Bur 6-81000 NA

12.2.3 UPPER STRUCTURE - GROUP 03
Group 03 - Upper Structure

No. DONE HOUR
00 Control portion
01 E / G control cable Rem. / Inst. 1 pc. 0.2
04 Other necessary works - ditto - 1 set Cover and Hose 0.4

10 Intake portion Refer to 33.1.12
11 Air cleaner ASSY Rem. / Inst. 1 pc. 0.4
12 • Hose (1) - ditto - 1 pc. 0.1
13 • Hose (2) - ditto - 1 pc. 0.1
14 • Element Replace 1 pc. 0.1
20 Exhaust portion Refer to 33.1.14
21 Muffler ASSY Rem. / Inst. 1 pc. 0.4
22 Clamp - ditto - 1 pc. 0.1
23 Exhaust manifold attaching nuts - ditto - 4 pcs. 0.1
24 Muffler fixing bolt - ditto - 4 pcs. 0.1
Other necessary works - ditto - 1 set Heat insulation cover 0.1
30 E / G Accessory portion Refer to 33.1.13 & 33.1.16
31 Generator Rem. / Inst. 1 pc. 0.6
32 • Connector - ditto - 1 pc. 0.1
33 • Generator fixing bolt - ditto - 2 pcs. 0.1
34 • V-belt - ditto - 1 pc. Include tension adjusting 0.3
Other necessary works - ditto - 1 set Covers 0.1
36 Starter Rem. / Inst. 1 pc. 0.5
37 • B-terminal - ditto - 1 pc. 0.1
38 • S-terminal connector - ditto - 1 pc. 0.1
39 • Starter fixing bolt - ditto - 2 pcs. 0.2
Other necessary works - ditto - 1 set Cover and Floor plate 0.1
- ditto - 1 set Seat and Stand cover 0.3
40 Fuel portion Refer to 33.1.10
41 Fuel tank ASSY Rem. / Inst. 1 pc. 0.6
42 • Fuel Replace 1 pc. 0.2
43 • Hose (Supply; water separator side) Rem. / Inst. 1 pc. 0.1
44 • Hose (Return; filter side) - ditto - 1 pc. 0.1
45 • Level sensor connector - ditto - 1 pc. 0.1
46 • Fuel tank fixing bolt - ditto - 2 pcs. 0.1
Other necessary works - ditto - 1 pc. Covers 0.4
50 Hydraulic oil tank portion Refer to 33.1.11
51 Hydraulic oil tank ASSY Rem. / Inst. 1 pc. After removing fuel tank; 1.6
Include pressure releasing & replacing O-
52 • Return filter Replace 1 pc. 0.2
ring
53 • Hydraulic oil - ditto - 1 pc. 0.2
54 • Suction hose Rem. / Inst. 1 pc. 0.2
55 • Strainer Replace 1 pc. Include replacing O-ring 0.1
56 • Pilot return hose Rem. / Inst. 1 pc. 0.1
57 • Swivel drain hose - ditto - 1 pc. 0.1
6-81000 NA Issued 01-2006 Bur 12-7


No. DONE HOUR
58 • SOL. valve return hose - ditto - 1 pc. 0.1
59 • Slewing, C / V return hose - ditto - 2 pcs. 0.2
60 • Tank fixing bolt - ditto - 4 pcs. 0.2
Other necessary works - ditto - 1 pc. Covers 0.2
- ditto - 1 pc. Control valve 1.6
- ditto - 1 pc. Solenoid valve 0.1
Preparation 1 pc. Hyd. oil tank pressurizing 0.1
70 Pump portion Refer to 33.1.6
71 Pump ASSY Rem. / Inst. 1 pc. After removing counterweight 1.2
72 • Hydraulic oil Replace 1 pc. Include pressure releasing 0.2
73 • Pilot delivery oil hose Rem. / Inst. 1 pc. 0.1
74 • Suction hose - ditto - 1 pc. 0.2
75 • Suction tube (pump side) - ditto - 1 pc. 0.2
76 • Main pump delivery hose - ditto - 3 pcs. 0.3
77 • Pump fixing bolt - ditto - 2 pcs. 0.2
78 Pump ASSY O/H 1 pc. 3.0
Other necessary works Feed 1 pc. Hyd. oil in pump 0.1
Preparation 1 pc. Hyd. oil tank pressurizing 0.1
80 Radiator portion Refer to 33.1.17

81 Radiator ASSY Rem. / Inst. 1 pc. 1.2
82 • Coolant (LLC) Replace 1 pc. 0.2
83 • • Coolant density Measuring 1 pc. (0.2)
84 • Reserve tank hose Rem. / Inst. 1 pc. 0.1
85 • Radiator hose - ditto - 2 pcs. 0.2
86 • Cooler hose - ditto - 2 pcs. 0.2
87 • Radiator fixing bolt - ditto - 3 pcs. 0.1
88 • Radiator lifting or slinging - ditto - 1 pc. 0.1
Other necessary works - ditto - 1 pc. Counterweight 0.4
- ditto - 1 set Covers 0.2
- ditto - 1 pc. Duct 0.1
90 Engine (E / G) Installing portion Refer to 33.1.18
91 Engine ASSY Rem. / Inst. 1 pc. 1.0
For injection pump - 2 pcs. &
92 • Fuel hose - ditto - 4 pcs. 0.2
For feed pump - 2 pcs.
93 • Harness, connector and cable Rem. / Inst. 1 set 0.3
94 • Engine fixing nut - ditto - 1 pc. 0.2
95 • Engine slinging - ditto - 1 set 0.2
Other necessary works - ditto - 1 set Covers 0.2
- ditto - 1 pc. Canopy 0.2
- ditto - 1 set Control stand 1.0
- ditto - 1 pc. Air cleaner 0.2
- ditto - 1 pc. Muffler 0.4
- ditto - 1 pc. Pump 1.2
- ditto - 1 pc. Radiator 1.2
- ditto - 1 pc. Battery negative terminal 0.1
100 Control valve portion Refer to 33.1.7
101 Control valve ASSY Rem. / Inst. 1 pc. 1.6
12-8 Issued 01-2006 Bur 6-81000 NA


No. DONE HOUR
102 • Piping connector, hose - ditto - 1 set Include attaching hose’s tag and plug 1.0
104 • Fixing bolt - ditto - 1 set 0.1

105 Control valve ASSY O/H 1 pc. 3.0
Other necessary works Rem. / Inst. 1 set Covers 0.1
- ditto - 1 set Hoses 0.2
110 Slewing motor portion Refer to 33.1.20
111 Slewing motor ASSY Rem. / Inst. 1 pc. 1.0
112 • Piping connector, hose - ditto - 8 pcs. Include attaching hose’s tag and plug 0.5
113 • Fixing bolt - ditto - 1 pc. 0.3
114 Slewing motor ASSY O/H 1 pc. 3.0
Other necessary works Rem. / Inst. 1 set Floor plate, Covers 0.2
Feed 1 pc. Hyd. oil in motor 0.1
120 Swivel joint portion Refer to 33.1.21
121 Swivel joint ASSY Rem. / Inst. 1 pc. After removing slewing motor 2.5
122 • Under cover - ditto - 1 pc. 0.1
123 • Piping connector, hose - ditto - 1 set Include attaching hose’s tag and plug 1.5
124 • Stopper - ditto - 1 pc. 0.1
125 • Fixing bolt - ditto - 1 set 0.2
126 Swivel joint ASSY O/H 1 pc. 2.0
Removal / Inst. position.
Other necessary works Preparation 1 pc. 0.1
(Secure working space.)
Canopy removal / inst.
1 pc. 0.2
(for easy working)
1 pc. Floor plate cover (2) removal / inst. 0.1
130 Upper frame portion Refer to 33.1.22
131 Upper frame ASSY Rem. / Inst. 1 pc. 1.0
132 • Fixing bolt - ditto - 1 set Apply sealant 0.3
133 • Upper frame slinging - ditto - 1 pc. 0.3
134 • Cleaning Cleaning 1 pc. 0.2
Other necessary works Rem. / Inst. 1 pc. Canopy 0.2
- ditto - 1 pc. Guard (Cover, support) 1.5
Drain / Feed 1 pc. Hydraulic oil 0.2
Rem. / Inst. 1 set Swivel joint hose 0.5
- ditto - 1 set Boom, Swing bracket 1.5
6-81000 NA Issued 01-2006 Bur 12-9

12.2.4 UNDER CARRIAGE - GROUP 04
Group 04 - Undercarriage
GROUP WORK TO BE UNIt:
No. DONE HOUR
01 Rubber crawler Rem. / Inst. One side 0.6
02 • Rubber shoe removing / inst. position. Preparation One side 0.1
03 • Tension adjusting Adjusting One side 0.2
04 • Crawler shoe Rem. / Inst. One side 0.2
10 Upper roller portion Refer to 34.1.3
11 Upper roller ASSY Rem. / Inst. 1 pc. After removing crawler shoe 0.2
12 Upper roller O/H 1 pc. 1.0
20 Lower roller portion Refer to 34.1.6
21 Lower roller ASSY Rem. / Inst. 1 pc. 0.2
22 Lower roller O/H 1 pc. 1.0
30 Front idler & Idler adjuster portion Refer to 34.1.7 & 34.1.8
31 Idler & Idler adjuster ASSY Rem. / Inst. One side After removing crawler shoe 0.5
32 Idler & Idler adjuster ASSY O/H One side 0.1
33 Idler ASSY O/H One side 1.0
34 Idler adjuster ASSY - ditto - One side 0.5
40 Sprocket portion Refer to 34.1.9
41 Sprocket Replace One side After removing crawler shoe 0.5
50 Travel motor portion Refer to34.1.10
51 Travel motor ASSY Rem. / Inst. One side After removing crawler shoe 1.0
52 • Motor cover - ditto - One side 0.1
53 • Hydraulic connector, hose - ditto - One side Include attaching hose’s tag and plug 0.6
54 • Motor fixing bolt - ditto - One side 0.3
55 • Motor slinging - ditto - One side 0.1
56 Travel motor O/H One side 3.0
57 Travel reduction unit - ditto - One side 3.0
Other necessary works Feed One side Hyd. oil in motor 0.1
60 Slewing bearing portion Refer to 34.1.11
61 Slewing bearing ASSY Rem. / Inst. 1 pc. After removing upper frame 0.6
62 • Slewing bearing fixing bolt - ditto - 1 pc. 0.3
63 • Slewing bearing Cleaning 1 pc. Decreasing / Replenishment 0.1
64 • Slewing bearing slinging Rem. / Inst. 1 pc. 0.2
12-10 Issued 01-2006 Bur 6-81000 NA

CHAPTER 13
E50
MAINTENANCE STANDARDS
AND TEST PROCEDURES
Issued January 2006

CHAPTER 13 - MAINTENANCE STANDARDS AND TEST PROCEDURES
Revision History
13-II Issued 01-06 Bur 6-81010 NA

CHAPTER 13
TABLE OF CONTENTS
13.1 HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS

13.1.1 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
13.1.2 Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
13.1.3 Precautions for Judgment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
13.1.4 Other Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
13.2 PERFORMANCE INSPECTION STANDARD TABLES
13.3 MEASURING ENGINE SPEED
13.3.1 Engine Speed Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
13.4 MEASURING HYDRAULIC OIL PRESSURE
13.4.1 Standard For Hydraulic Oil Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
13.4.2 Pressure Measurement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
13.4.2.1 Main Circuit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
13.4.2.2 Pilot Circuit Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-10
13.5 MEASURING TRAVEL PERFORMANCES
13.5.1 Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
13.5.2 Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
13.5.3 Travel Deviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
13.5.4 Movement Drift due to gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
13.5.5 Drain Rate on Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
13.6 MEASURING SLEW PERFORMANCES
13.6.1 Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
13.6.2 Slew Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
13.6.3 Overrun when Slewing Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
13.6.4 Slew Drift due to Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13
13.6.5 Drain Rate of Slew Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES
13.7.1 Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15
13.7.2 Cylinder Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15
13.7.3 Gravity Drift of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-16
13.8 MEASURING SLEW BEARING PERFORMANCES
13.8.1 Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17
13.8.2 Slew Bearing-Bucket Tip Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17
13.8.3 Slew Bearing Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17
13.9 MEASURING TRACK TENSION
13.9.1 Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-18
6-81010 NA Issued 01-06 Bur 13-1

NOTES
13-2 Issued 01-06 Bur 6-81010 NA

13.1 HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS

13.1.1 APPLICATION 13.1.3 PRECAUTIONS FOR JUDGMENT
1)For New Machine; 1. Evaluation for Measured Data:
This manual is to be used to check the actual It is inevitable some variation on the measured
perfor mance and functions of the machine data due to differences between measuring
compared with the PERFORMANCE conditions, peculiar variability on a new machine,
STANDARDS. old and new versions of the machine and
1. Self-Inspection (per LOCAL GUIDLINES); measuring characteristics.
The maintenance standards are used as a The judgment for the measured data should be
criteria to determine if reconditioning, adjustment comprehensively conducted based on the extent
and replacement are required. of level of the measured data, instead of mere
comparison with the standard values.
2. Deterioration of Performance;
2. Determination for Reconditioning, Adjustment or
This manual has criteria for safe and economical Replacement:
judgment whether the deterioration of
performance on the machine would be caused There are two kinds of deterioration of machine
by faults or normal deterioration due to machine performance; one is due to normal wear and the
operation for a long period. other is recoverable to the standard values with
the adjustments.
3. Replacement of Major Components;
The determination for reconditioning, adjustment
This manual has standards to determine the time or replacement should be conducted taking
for replacement of major components such as various factors into consideration such as
pump, etc. o p e ra t i n g h o u r s, wo r k i n g c o n d i t i o n s a n d
maintenance conditions of the machine, so that
13.1.2 TERMINOLOGY the machine is able to be operated at the
1. Standard Values: optimum performance level.
These are the values to maintain a new machine.
Where special notes are not given, these values 13.1.4 OTHER PRECAUTIONS
are based on the machine with standard 1. Parts with Aging Effect:
structure (the machine with standard The rubber products such as hydraulic hoses, O-
attachments and track). rings, oil seals, etc. deteriorated with age. It is
2. Standard Values for Repair: necessary to replace them at periodic intervals
These are the values at which reconditioning is or at every overhaul.
required. 2. Parts requiring Periodic Replacement:
In order to ensure perfor mance and safety It is recommended to designate critical hoses
machines should not be used with parts and and periodically replace them.
components worn beyond the standard values.
3. Inspection & Replacement of Lubricants:
3. Serviceability Limit:
It is necessary for the user of the machine to fully
This is the ser vice limit for each par t and familiarize himself with the procedures and
component which reconditioning is impossible precautions to operate the machine in a safe
and they must be replaced. manner and conduct maintenance, as well as the
All the par ts and components which are procedures for inspection and lubrication. Refer
estimated to exceed the serviceability limit up to to the OPERATION & MAINTENANCE MANUAL
the next periodical inspection and scheduled as well.
maintenance, should be also replaced.
Machines operated with the and components
which have exceeded the serviceability limit
cause and increase of faults and down time of
the machine, it can also cause safety problems.
6-81010 NA Issued 01-06 Bur 13-3

13.2 PERFORMANCE INSPECTION STANDARD TABLES
Applicable machines PJ04-30001

Div. Item Unit Standard value Repairable value
Hyd. oil cleanliness Class 8±1 --
Measuring
Hyd. oil temperature (Tank surface) 50-60 (122-140) --
condition °C (°F)
Coolant temperature (Radiator surface) 60-90 (140-194) --
Low idle 1150 ± 50 --
Engine speed High idle rpm 2550 ± 50 --
Deceleration 1150 ± 50 --
23.0 +0.5 to 0
Boom, Bucket, Travel (LH) P1 --
(3340 +73 to 0)
Main relief valve 23.0 +0.5 to 0
Arm, Swing, Travel (RH), Service P2 MPa --
pressure (3340 +73 to 0)
(psi)
23.0 +0.5 to 0
Dozer P3 --
(3340 +73 to 0)
Pilot relief valve pressure Pilot Line -- 3.5 ± 0.4 (508 ± 58) --
27.5 0 to -4.9
Boom Head Rod --
(3990 0 to -710)
25.5 0 to -2.9
2 Port (Overload) Arm Head Rod --
(3700 0 to -420)
relief valve kgf/cm2 25.5 0 to -2.9
Bucket Head --
pressure (psi) (3700 0 to -420)
(See Note 2) 25.5 0 to -5.9
Dozer Head --
(3700 0 to -856)
21.0 +1.0 to 0
Slew (See Note 1) LH/RH --
(3050 +145 to 0)
Low 40.2±2.3 51
Rubber Track
Track Speed high 23.5±1.2 30
sec.
(5 rev.) Low 37.5±2.1 48
Iron Track
High 21.9±1.1 28
Low 13.7±0.7 18
Rubber Track
Travel Speed High 8.1±0.4 10
Travel sec.
10 m (32.8 ft.) Low 15.0±0.7 19
Iron Track
High 8.8±0.4 11
140 0 to -140
Travel deviation 280 (11.0)
(5.5 0 to -5.5)
mm (in)
w / P.B. (5
Drift due to gravity 0 (0) 1 (0.04)
min.)
Slew time per 2 revolution sec. 13.9±0.7 17
Slew Overrun when slewing stops
mm (in)
Drift due to gravity 0 —
Ext. 3.0±0.4 3.8
Canopy
Ret. 2.6±0.4 3.3
Boom
Ext. 2.9±0.4 3.7
Cab
Ret. 2.5±0.4 3.2
Ext. 3.3±0.4 4.2
Arm
Cylinders Ret. 2.5±0.4 3.2
sec.
(Cylinder speed) Ext. 2.8±0.4 3.6
Bucket
Ret. 1.8±0.4 2.3
Ext. 5.5±0.8 7.0
Swing
Ret. 4.0±0.6 5.1
Ext. 2.7±0.4 3.5
Dozer
Ret. 1.9±0.4 2.4
NOTE 1:The pressure for slew is controlled by the relief valve attached to the slew motor.
NOTE 2:Reference value for checking of pressure (tighten up the adjusting nut of main relief valve. Refer to item 13.4.2.1)
13-4 Issued 01-06 Bur 6-81010 NA

Applicable machines PJ04-30001

Div. Item Unit Standard value Repairable value
Boom 12 -12 (0.47 -0.47) 18 (0.71)
Arm 6 -6 (0.24 -0.24) 12 (0.47)
Cylinders (10 min.)
mm (in)
(Gravity Move) Dozer 6 -6 (0.24 -0.24) 12 (0.47)
Bucket tip 150 -150 (5.9 -5.9) 260 (10.2)
Bucket tip play 40 +20 -10 (1.6 +0.8 -0.4) 80 (3.1)

Slew bearing mm (in)
Slew bearing play
Rubber 85~95 (3.35~3.14) —
Track Track tension mm (in)
Iron 130~150 (5.12~5.91) —
NOTE 1:The pressure for slew is controlled by the relief valve attached to the slew motor.
NOTE 2:Reference value for checking of pressure (tighten up the adjusting nut of main relief valve. Refer to item 13.4.2.1)
6-81010 NA Issued 01-06 Bur 13-5

13.3 MEASURING ENGINE SPEED

13.3.1 ENGINE SPEED MEASUREMENT 2. Engine Warming up Operation
1. Measuring Instruments Start up the engine, and run until the coolant
A. Diesel Tachometer (Measuring engine speed temperature is within the operating range, 60 to
by means of applying a pick-up to one of 90°C (140 to 194°F).
injection lines) C h e ck t h e c o o l a n t t e m p e r a t u r e w i t h t h e
B. Surface Thermometer (Measuring the surface temperature gauge in the instrument panel. The
temperature with contact of a probe with the white color zone shows approximately 67 to
surface of hydraulic reservoir or radiator) 105°C (153 to 221°F) temperature range.
When the indicator is located at around center of
the white zone, it is suitable for the engine
operation.

FIG. 13-1 ENGINE SPEED MEASUREMENT (THE ABOVE
FIGURE SHOWS CONCEPT) 3. Engine Speed Measurement
A. Attach the pick up of the tachometer to one of
injection lines. (Refer to Fig. 13-1)
B. Measure the engine speed at idling with no
load, and compare it to the figure in the
STANDARD VALUE TABLE.
13-6 Issued 01-06 Bur 6-81010 NA

4. Speed Adjustment
Low / High Idling Speed is low;
The proper engine speed is obtained with the
length of accelerator cable as shown. When the
engine speed is lower than the standard speed,
adjust the length of cable by loosening the
capscrew (9) of throttle lever side.
NOTE: If the proper high idling speed is not
obtainable, see the engine service manual.
DETAIL Z [WITH DECEL]
FIG. 13-2 ACCELERATOR CABLE ADJUSTMENT
6-81010 NA Issued 01-06 Bur 13-7

13.4 MEASURING HYDRAULIC OIL PRESSURE

13.4.1 STANDARD FOR HYDRAULIC OIL C. If the main relief pressure is low, adjust the
PRESSURE MEASUREMENT main relief valve by half turns [pressure
1. Hydraulic Instruments increase by 12.2 MPa (1770 psi)], then
• 6.86 MPa (1000 psi) pressure gauge: 1 set measure the pressure at overload relief valve.
• 49 MPa (7100 psi) pressure gauge: 3 sets D. After adjustment for the overload relief
• Surface Thermometer: 1 set pressure, recheck the main relief pressure
• Pressure Measuring Kit and Oil Analyzing and adjust as needed.
Equipment: 1 set
2. Measuring cleanliness of hydraulic oil
NOTE: After releasing air pressure in the hydraulic
oil resolver, take an oil sample for analysis. If the oil is
contaminated, replace the return filter and/or change
the hydraulic oil.
13.4.2 PRESSURE MEASUREMENT AND

ADJUSTMENT
13.4.2.1 MAIN CIRCUIT PRESSURE
1. Measuring Conditions
Engine speed: High idling
Hydraulic oil temperature: 50-60°C (122-140°F)
Coolant temperature (on radiator surface):
60~90°C (140-194°F)
SPJ13000006E01 Figure 6
2. Pressure Measuring Procedures
A. Release the pressure in the hydraulic
reservoir, attach a 49 MPa (7100 psi) pressure SPJ13000005E01 Figure 7
gauge to either of the pressure test ports (G1,
FIG. 13-3 MAIN HYDRAULIC OIL PRESSURE MEASUREMENT
G2 or G3, PF1/4), operate the circuit to be
tested and record the results.
B. When the main relief pressure is within the
standard range, testing the overload relief
pressure is not required.
13-8 Issued 01-06 Bur 6-81010 NA

3. Pressure Adjustment D. Slewing Motor: Relief Valve

A. Control Valve: Main Relief Valve and Overload 1. Loosen the lock nut (2) adjust the
Relief Valve pressure setting by turning the setscrew
1. Loosen the lock nut (2), and adjust the (1). Approximately one full turn:
setting pressure turning the setscrew (1). Approximately 9.8 MPa (1420 psi)
CW: Increases pressure setting
Roughly with one full turn: CCW: Decreases pressure setting
Main relief valve & Overload relief valve: 2. After the adjustment, tighten the lock nut
Approximately 12.2 MPa (1770 psi) h o l d i n g t h e a d j u s t m e n t s c r ew f r o m
CW: Increases pressure setting turning.
Tightening torque for nut (2): . . . . . . 34.3 Nm
CCW: Decreases pressure setting
(25.3 lb ft)
B. After the adjustment, tighten the lock nut
holding the adjustment screw from turning.
C. Recheck the pressure setting.
Tightening torque for nut (2):
19.6 Nm (14.5 lb ft)
FIG. 13-6 RELIEF VALVE (SLEWING MOTOR)
FIG. 13-5 RELIEF VALVE
6-81010 NA Issued 01-06 Bur 13-9

13.4.2.2 PILOT CIRCUIT PRESSURE 3. Pressure Adjustment

1. Measuring Conditions Adjust pressure at the relief valve.
Engine: High idling 1. Loosen the lock nut (2), then turn the
Hydraulic oil temperature: 50-60°C (122-140°F) setscrew (1) to adjust the set pressure.
Coolant temperature: 60-90°C (140-194°F) CW: Increases pressure setting
2. Measurement CCW: Decreases pressure setting
Releasing pressure in the hydraulic reservoir, 2. After the adjustment, tighten the lock nut
connect a 6.86 MPa (1000 psi) pressure gauge h o l d i n g t h e a d j u s t m e n t s c r ew f r o m
to the pressure test port (G4, PF 1/4), measure turning.
the pilot relief pressure. 3. Check pressure setting.
Tightening Torque:
Lock Nut (2): 7.8 Nm (5.8 lb ft)
Relief valve (PR1): 44 Nm (32 lb ft)
Capscrew (3): 7.8Nm (5.8 lb ft)
FIG. 13-8 RELIEF VALVE
FIG. 13-7 PILOT OIL PRESSURE MEASUREMENT
13-10 Issued 01-06 Bur 6-81010 NA

13.5 MEASURING TRAVEL PERFORMANCES

13.5.1 TEST PROCEDURE
1. Measure 3-times each
2. .Compare to chart.
13.5.2 TRAVEL
1. Travel Speed (5 Revolutions)
• Engine: High Idle
• Hydraulic Oil temperature: 50-60°C (122-140°F)
• Measurement Posture: Machine Body is raised
using the hoe attachment and dozer blade.
• Starting after one full revolution, measure the
time required for 5 revolutions.
13.5.3 TRAVEL DEVIATION

• Engine: Rated r.p.m.
2. Travel Speed (10 m)
• Engine: Rated r.p.m.
• Measurement Posture: Travel Posture
• Measure the deviation (X) at the point of half of 10
• Measurement Posture: Travel Posture
m (32.8 ft) travel after 5m preliminary running.
• Set machine in motion. Starting after a running Measure on level and hard ground.
of 5 meters, measure the time required to travel
10 meters. Do this on level and hard ground.
• Travel Posture: Fully extend the arm and bucket
cylinders and place the hoe attachment so that
its lowest part is even with the machine’s
minimum ground clearance level. The dozer
blade must not touch the ground.
6-81010 NA Issued 01-06 Bur 13-11

13.5.4 MOVEMENT DRIFT DUE TO GRAVITY

Measure the movement distance of machine on a
slope due to machine’s own weight, holding the
machine for 5 minutes on the slope.
Measuring Conditions:
• Engine: Stopped
• Hydraulic Oil Temperature: 50-60°C (122-140°F)
• 15 degree grade (Approximately 1/3.73)
• Machine posture: Fully extending the boom, arm
and bucket cylinders, and fully contracting the
dozer cylinder.
2. Measurement:
SPW13000016J01 Figure 16 • Engine: At rated speed
• Hydraulic oil temperature: 50-60°C (122-140°F)
13.5.5 DRAIN RATE ON TRAVEL MOTOR • Machine posture: Locked travel and over
1. Preparation running the relief on the travel motor
• Measure the drain volume of oil for 30 seconds.
A. Apply stopper pins for both travel sprockets of
left and right.
B. Stop the engine, and release air in the
hydraulic reservoir.
C. Connect a hose to the drain port of travel
motor and place in a container.
D. Install a plug to the drain line at the tank side.
WARNING: Make sure of the rotating

direction of travel motor. Otherwise, rib “A”
may be broken by the stopper pin.
13-12 Issued 01-06 Bur 6-81010 NA

13.6 MEASURING SLEW PERFORMANCES

13.6.1 TEST PROCEDURE 13.6.4 SLEW DRIFT DUE TO GRAVITY
1. Measure 3-times each • Engine: Stopped
2. Take the average of the three and compare to the • Hydraulic Oil temperature: 50-60°C (122-140°F)
chart. • 15 degree grade (Approximately 1/3.73)
• Measurement Posture:
13.6.2 SLEW TIME Same as that for measuring slew time.
• Slew the upper structure and stop at right angle
• Engine: High Idle to the slope, then draw matching marks on the
• Hydraulic Oil temperature: 50-60°C (122-140°F) slew bearing’s outer race and the lower frame.
• Measurement Posture: Completely retract the Measure the distance between the marks after
arm cylinder, fully extend the bucket cylinder 5 minutes. Measure for both RH and LH
and place so that boom foot pin and bucket pin directions.
are at matching height. Place the dozer blade
on the ground.
• Turn 1 rotation, then measure the time required
for the next 2 rotations.
13.6.3 OVERRUN WHEN SLEWING STOPS

Same as that for measuring slew time.
• Prior to measuring, draw matching marks on the
outer race of the slew bearing and lower frame
at exactly 180 degrees from the starting point.
Then slew 180 degrees from starting point,
return the operating lever to neutral. Measure
the distance between the position marks and
the point the hoe attachment stops.
6-81010 NA Issued 01-06 Bur 13-13

13.6.5 DRAIN RATE OF SLEW MOTOR 2. Measurement:

1. Preparation • Engine: At rated speed
A. Stop the engine, and release the pressure • Hydraulic oil temperature: 50-60°C (122-140°F)
from the hydraulic reservoir. • Machine posture: Swing against a fixed object.
• Measure the drained volume of oil for 30
B. Disconnect the slew motor drain hose at the seconds.
return side to the hydraulic reservoir. Then
catch the drain oil in a container.
Install plug on bore of tank after removing
drain hose.
13-14 Issued 01-06 Bur 6-81010 NA

13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES

13.7.1 TEST PROCEDURE 3. Bucket Cylinder Speed
1. Measure 3-times each • Engine: High Idle
2. .Take the average of the three and compare to • Hydraulic Oil temperature: 50-60°C (122-140°F)
the chart. • Measurement Posture: Completely retract the
arm cylinder, position the arm horizontally and
13.7.2 CYLINDER SPEED place the dozer blade on the ground.
• Measure the time required for the bucket
1. Boom Cylinder Speed cylinder to completely retract from a fully
• Engine: High Idle extended position.
• Measurement Posture: Completely retract the
arm cylinder, fully extend the bucket cylinder
and place the dozer blade on the ground.
• Measure the time required for the bucket to
reach its highest point from its lowest point. (Do
not include the cushioning time.)
4. Swing Cylinder Speed
• Measurement Posture: Same as that for
measuring slew time.
• While swinging the boom left to right and right to
left, measure the time required for a full stroke
each way.
2. Arm Cylinder Speed
arm cylinder, fully extend the bucket cylinder,
position the arm horizontally and place the
dozer blade on the ground.
• Measure the time required for the arm cylinder SPW13000027J01 Figure 27
to completely retract from a fully extended
position.
6-81010 NA Issued 01-06 Bur 13-15

5. Dozer Cylinder Speed 2. Swing Cylinder

• Engine: High Idle • Engine: Stopped: Hydraulic Oil temperature: 50-
• Hydraulic Oil temperature: 50-60°C (122-140°F) 60°C (122-140°F)
• Measurement Posture: Using the hoe • 15 degree grade (Approximately1/3.73)
attachment lift up the dozer blade side. • Measurement Posture:
• Raise and lower the dozer blade full stroke, Same as slew time.
measure the time required in each direction. • Slew the upper slewing structure and stop at
right angle to the slope, then measure the
change in rod length after 5 minutes.
13.7.3 GRAVITY DRIFT OF CYLINDERS

1. Boom, Arm, Bucket, Dozer, Bucket Tip
• Engine: Stopped
dozer and arm cylinders, fully extend the bucket
cylinder and position the bucket pin to the same
height as the boom foot pin.
• Maintain the position for 10 minutes then
measure the change of rod length and distance
of the bucket tip.
13-16 Issued 01-06 Bur 6-81010 NA

13.8 MEASURING SLEW BEARING PERFORMANCES

13.8.1 TEST PROCEDURE 13.8.3 SLEW BEARING PLAY
1. Measure 3-times each 1. Attach a dial gauge to the bottom face of the slew
2. .Compare to the chart. bearing’s outer-race located in front of the upper
slewing structure.
13.8.2 SLEW BEARING-BUCKET TIP PLAY
Completely retract the arm cylinder and fully
extend the bucket cylinder.
• Move the tip of the bucket from side to side (left
and right) and measure the play.
2. Raise the track on one side off the ground and
set the dial gauge to zero.
3. Then raise the opposite track and read the dial
gauge.
6-81010 NA Issued 01-06 Bur 13-17

13.9 MEASURING TRACK TENSION

13.9.1 TRACK TENSION
1. Raise the machine completely off the ground
using the hoe attachment and dozer blade.
Then measure the distance (of sag) between the
center point on the track frame and top of the
track shoe.
NOTE: Rubber track measurements should be
taken by placing the marked joint at the top
center position.
13-18 Issued 01-06 Bur 6-81010 NA

E50
HYDRAULIC, ELECTRICAL, AND

COMPONENT SYSTEMS
Issued January 2006

SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
Revision History
SECTION 2
HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
TABLE OF CONTENTS
CHAPTER 22
HYDRAULIC SYSTEM
22.1 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-3
22.2 Hydraulic Circuits and Component Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-4
22.3 Hydraulic Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-5
CHAPTER 23
ELECTRICAL SYSTEM
23.1 How To Read Circuit Diagram and Harness Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-3
23.2 Electrical Equipment and Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-4
CHAPTER 24
COMPONENTS SYSTEM
24.1 Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-3
24.2 Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-62
6-81020 NA Issued 01-2006 Bur 0-I

NOTES
CHAPTER 22
E50
HYDRAULIC SYSTEM
Issued January 2006

CHAPTER 22 - HYDRAULIC SYSTEM
CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring
any obligation to install them on units previously sold.
Revision History
22-2 Issued 01-2006 Bur 6-81030 NA

CHAPTER 22
HYDRAULIC SYSTEM
TABLE OF CONTENTS
22.1 SUMMARY
22.1.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-3
22.2 HYDRAULIC CIRCUITS AND COMPONENT MODELS
22.2.1 STANDARD SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-4
22.3 HYDRAULIC CIRCUIT OPERATION
22.3.1 COLOR CODING STANDARD FOR HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-5
22.3.2 NEUTRAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-5
22.3.3 TRAVEL OPERATING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-6
22.3.3.1 2nd Speed Operating Circuit (Independent-forward travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-6
22.3.4 SLEW OPERATING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-7
22.3.4.1 Slew (left) Operating Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-7
22.3.5 BUCKET OPERATING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-7
22.3.5.1 Bucket Digging Operation Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-7
22.3.5.2 Bucket Dumping Operating Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-7
22.3.6 BOOM OPERATING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-8
22.3.6.1 Boom Raise Operating Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-8
22.3.6.2 Boom Lower Operating Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-8
22.3.7 ARM OPERATING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-8
22.3.7.1 Arm In Operating Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-8
22.3.7.2 Operating Circuit for Arm Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-8
22.3.8 SWING OPERATING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-9
22.3.8.1 Swing (left) Operating Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-9
22.3.9 DOZER OPERATING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-9
22.3.9.1 Dozer Down Operating Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-9
22.3.10 NIBBLER & BREAKER OPERATING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-10
22.3.10.1 Nibbler Close Operating Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-10
22.3.10.2 Nibbler Open Operating Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-10
22.3.10.3 Breaker Blow Operating Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-10
22.3.11 TRAVEL / DOZER COMBINED OPERATING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-11
22.3.11.1 Travel (1st speed forwarding) /Dozer Down Operating Circuit . . . . . . . . . . . . . . . . . . . . . . . . 22-11
22.3.12 TRAVEL / BOOM COMBINED OPERATING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-11
22.3.12.1 Travel (1st speed forward) / Boom Up Operating Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-11
6-81030 NA Issued 01-2006 Bur 22-1

NOTES
22-2 Issued 01-2006 Bur 6-81030 NA

22.1 SUMMARY
22.1.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT
The hydraulic circuits are built up with the following functions and features in order to achieve easy operation,
safety and high working efficiency.
PERFORMANCE DEVICE FUNCTION FEATURES

Straight traveling secured by independent travel
Straight traveling
function in combined operations
Travel Preventing overrunning of travel motor
Preventing overrunning on a slope
Parking brake
Automatic braking at parking
Constant slewing speed when operating in
Slewing (with dozer) independent circuit simultaneous operation condition
Slew Auto slewing parking brake Protecting against slewing drift on a slope
Slewing shockless function Smooth feeling when starting and stopping
slewing operation
Easy Operation
Responsive operability
and Safety
Hydraulic pilot control system Secure the travel straight when travelling and
Attachment Dozer (with slewing) independent circuit. working with dozer.
Multi-control valve Capable of selecting operation pattern from two
types using one lever
Preventing contamination of hydraulic oil and
Closed pressurized hydraulic oil tank
improving self sucking up efficiency
Suction strainer
Others Removing dirt of suction side
Line filter in pilot circuit
Preventing malfunction in pilot operating circuit
Return filter
Preventing contamination of hydraulic oil
Effective use of engine power with variable pump
Pump Total power control (Pumps: P1 + P2 + P3)
(Power shifting by P3 pump)
High Working Improving working efficiency with 2 travel speeds
Travel 2 speeds traveling
Performance shifting
Speed increased by conflux P3 pump oil piping
Attachment P3 pump oil flow conflux in arm
(when no dozer or slewing used)
When waiting for dump truck, the engine speed is
Low fuel
Electricity Push button deceleration repeatedly changed and the fuel consumption
Consumption
and noise are reduced
6-81030 NA Issued 01-2006 Bur 22-3

22.2 HYDRAULIC CIRCUITS AND COMPONENT MODELS

22.2.1 STANDARD SPECIFICATIONS
For the Hydraulic circuit diagram, refer to Fold Out Schematics.
STANDARD SPECIFICATION PH01Z00018P1
No. NAME PART No.

1 Pump Assy PH10V00010F2 AP2D25LV1RS7
2 Control Valve PY30V00035F1 BCV65-AR11
3 Slewing Motor PY15V00012F1 PLC-120-18B-1FS2-8284A
4 Travel Motor PH15V00012F1 GM06VA
Boom Canopy PY01V00037F1 ø100-ø55-699
5
Cylinder Cab PY01V00038F1 ø100-ø55-666
6 Arm Cylinder PY01V00042F1 ø90-ø50-716
7 Bucket Cylinder PH01V00034F1 ø75-ø45-546
8 Swing Cylinder PH01V00031F1 ø90-ø50-567
9 Dozer Cylinder PY01V00040F1 ø95-ø55-200
10 Swivel Joint 24100J12703F1
11 Pilot Valve (Att) PX30V00043F1 PV48M2042
12 Pilot Valve (Travel) PM30V00019F1 PVD6P4001
13 Solenoid Valve PX35V00003F1 2KWE5G-30/G12WS-249A
14 Pilot Valve (Dozer) PB30V00002F1 PV6P
15 Shuttle Valve PH26V00001F1
16 Multi Control Valve PX30V00060F1
17 Return Filter (Element) YR52V01001F2
18 Suction Strainer PW50V00011F1
19 Inline Filter PY50V00001F1 Y-426800
20 Check Valve 2436R1062D62 S15AO-K2
23 Stop Valve PF25V00001F1
24 Selector Valve PA30V00005F1
25 Oil Cooler PH53V00008P1
26 Hydraulic Oil Tank PH33H00018P1
27 Solenoid Valve PE35V00001F2 16351-00000
28 Solenoid Valve PY35V00005F2 16363-00000
29 Elbow PV64H01042P1
NOTE: This is for reference only, because the model number might be changed due to improvement.
22-4 Issued 01-2006 Bur 6-81030 NA

22.3 HYDRAULIC CIRCUIT OPERATION

22.3.1 COLOR CODING STANDARD FOR 2. Pilot secondary pressure circuit
HYDRAULIC
While the pilot valves (11),(12) and (14) are in
neutral, pilot secondar y pressure is not
HYDRAULIC SCHEMATIC COLOR CODING
generated.
less than 0.34 MPa
Blue: Feed, drain circuit By operating the control lever, secondar y
(50 psi)
pressure is generated and sent to the control
Return, make-up 0.34~ 0.59 MPa
Green: valve (2) from the pilot valve to shift each spool of
circuit (50~86 psi) shifting valve.
Secondary pilot 0.59~3.5 MPa
Purple: 2. MAIN CIRCUIT
pressure (85~508 psi)
Primary pilot 3.5~3.9 MPa 1. Variable pump circuit
Red:
pressure (508~ 566 psi) The oil from A1 and A2 ports on the variable
Main pump drive 4.9~23 MPa pump goes to the P1 and P2 ports on control
Orange: valve (2).
pressure 711~3340 psi)
Blue tone: At valve selection The oil from these two por ts returns to the
When proportional valve (reducing) is hydraulic oil tank (24), through each valve of
Red valve:
operating travel left, boom and bucket for the P1 oil, and
Red solenoid: Activated through each valve of travel right, swing, service
Displaying the flow circuit and standby circuit when and arm for the P2 oil.
operating. 2. Third pump circuit
Regarding the electrical symbols in this manual, refer to The oil from A3 port on 3rd pump goes to the P3
the electric circuit diagram. port on control valve (2).
NOTE: For the hydraulic circuit operation, refer to The oil from P3 returns to the hydraulic oil tank
Fold Out Schematics. (24) through the selector valves for the dozer,
slewing, and the independent travel and flow
22.3.2 NEUTRAL CIRCUIT conflux valves.
(Refer to Fold Out Schematics)

1. PILOT CIRCUIT
1. Pilot primary pressure circuit
Oil from port A4 on the pump (1) enters the
solenoid valve (13) through the line filter (19)
Pressurized oil from port A2 of the solenoid valve
(13) with the safety lock lever released (in the
operating position) is supplied to the P ports of
the pilot valves for attachment (11), travel (12)
and dozer (14).
Since the operating circuit is fully closed in the
neutral position, the oil from the pump, except the
oil supplied to the Pp1 port of the control valve, is
returned to the hydraulic tank (24) through the
relief valve (set pressure: 3.5MPa [508 psi]) built
in the solenoid valve (13).
Hydraulic oil to Pp1 port provides pressure to the
service spool and pilot controls for the travel
circuit.
6-81030 NA Issued 01-2006 Bur 22-5

22.3.3 TRAVEL OPERATING CIRCUIT 2. Travel Motor

(Refer to Fold Out Schematics) A. Oil supplied to the travel motor shifts the
Pilot oil hydraulic system with operating lever spool of the counterbalance valve (brake
valve) (408), releases the parking brake
22.3.3.1 2ND SPEED OPERATING CIRCUIT (403), opens the hydraulic circuit closed by
(INDEPENDENT-FORWARD TRAVEL) the check valve (407) and rotates the travel
1. PILOT CIRCUIT motor.
1. Shifting signal for 2nd speed travel When the speed shifting valve (404) is
activated when the 2nd speed signal is sent.
When the Rabbit and Turtle mark on the knob of The high pressure oil pumped through the
right travel lever is pushed down, it actuates the shuttle valve (406) passes the speed change
1st or 2nd speed travel shifting valve of solenoid valve (404), actuates the 2-speed shifting
valve (13). piston (401) and provides the motor with high
The oil signal for 2nd speed is generated from speed and low torque.
the A1 port of solenoid valve(13), and supplied to B. When the motor reaches a self-running
the P port on travel motor (4) through swivel joint condition (over-running) while going down a
(10) and shifts the 2-speed valve (404). slope, the oil pressure of the supply side drops
2. Changing travel valve spool to a low pressure state, then the counter
The pilot secondary pressure is generated from balance valve [brake valve] (408) spool moves
pilot valve (12) by moving the control lever to the to the neutral position.
forward travel position. Oil is supplied to the Pb7 C. With the passage in return oil side restricted,
and Pb6 ports on control valve (2) to shift the the motor speed is suppressed by a back-
travel valve spool. pressure, then the motor is controlled to the
speed corresponding to the supplied oil
2. MAIN CIRCUIT
volume of the pump.
1. Circuit up to Travel Motor (4)
D. The counterbalance valve spool is designed
The oil from A1 and A2 ports on variable that it is gradually shifted by a throttle effect to
pump enters the P1 and P2 ports of control stop or start the motor absorbing shock at the
valve (2). This is supplied to the B7 and B6 starting and stopping of the machine.
ports through the travel valve.
E. When load increases during high speed
It is then supplied to the A and B ports on left travel, the speed automatically shifts to 1st
and right travel motors through the swivel joint resulting in low speed and high torque.
(10).
22-6 Issued 01-2006 Bur 6-81030 NA

22.3.4 SLEW OPERATING CIRCUIT 22.3.5 BUCKET OPERATING CIRCUIT

(Refer to Fold Out Schematics) (Refer to Fold Out Schematics)
Pilot oil hydraulic system with operating lever Pilot oil hydraulic system with operating lever
22.3.4.1 SLEW (LEFT) OPERATING CIRCUIT 22.3.5.1 BUCKET DIGGING OPERATION CIRCUIT
1. PILOT CIRCUIT 1. PILOT CIRCUIT
1. Slew Valve Spool Shifting 1. Bucket Spool Shifting
Operating slew (left), the pilot secondar y When the operating lever is placed in the bucket
pressure is generated from the pilot valve (11), digging position, pilot secondary pressure is
and supplied to the Pb2 port of control valve (2) generated from the pilot valve (11). The oil enters
through solenoid valve (25) to shift the slew valve into the Pb9 port on control valve (2) and shifts
spool. the bucket valve spool.
2. Releasing the Slewing Brake 2. MAIN CIRCUIT
The pilot primary pressure is always supplied to 1. Supply Circuit for Cylinder (7)
PB port on the timer valve (303).
The oil from the A1 port on variable pump (1)
While operating the slew, the pilot secondary enters P1 port on control valve (2). The oil from
pressure is supplied to PP port on the timer valve B9 port through bucket valve is supplied to the
(303) through the shuttle valve (14) to shift the head side of bucket cylinder (7) to activate the
spool. digging work.
It supplies the pilot primary pressure 3.5 MPa The return oil from the rod side of cylinder (7)
(508 psi) to the slewing brake to release it. enters into A9 por t on control valve (2) and
3. Activating the Slewing Brake returns to the tank through bucket valve.
When the slew lever is retur ned to neutral 22.3.5.2 BUCKET DUMPING OPERATING
position to stop slewing, the pilot secondary CIRCUIT
pressure is stopped causing the timer valve (303)
1. PILOT CIRCUIT
to shift, the pressurized oil to the brake is
stopped. 1. Bucket Spool Shifting
The oil in the brake cylinder is discharged due to When the operating lever is placed in the bucket
spring force, and drained through the restrictor in dumping position, the pilot secondary pressure
the timer valve (303). oil is supplied from pilot valve (11) to the Pa9 port
on control valve (2) to shift the bucket valve
The brake is activated with a lag time of 2.5 to
spool.
5.0 seconds to smoothly stop the slewing motion.
2. MAIN CIRCUIT
2. MAIN CIRCUIT
1. Supply Circuit for Cylinder (7)
1. Supply Circuit for Slewing Motor (3)
Similar to bucket digging, the pressurized oil
The oil from the A3 port on hydraulic oil pump (1)
delivered from A1 port on variable pump enters
is supplied to the B port on slewing motor (3)
P1 port on control valve (2).
through the P3 port on control valve (2) and slew
valve to drive the slewing motor. The oil supplied from A9 port through bucket
valve enters the rod side of bucket cylinder (7) to
2. Slewing Motor (3)
activate the bucket dumping.
A. The relief valve (304) relieves rapidly
increased pressure at start and stop of the
machine to ease shock.
B. The make-up valve (check valve) (305) has a
function to replenish oil from the return oil
circuit that is returned to the tank [T2 port on
control valve (2)] to the slewing motor, to
prevent the slewing motor from cavitation due
to negative pressure generated because of
the inertia of the slewing mass.
6-81030 NA Issued 01-2006 Bur 22-7

22.3.6 BOOM OPERATING CIRCUIT 22.3.7 ARM OPERATING CIRCUIT

Pilot oil hydraulic system with operating lever Pilot system with operating lever
22.3.6.1 BOOM RAISE OPERATING CIRCUIT Oil flow conflux function for the third pump.
1. PILOT CIRCUIT 22.3.7.1 ARM IN OPERATING CIRCUIT

1. Boom spool shifting 1. PILOT CIRCUIT
When the operating lever placed in the boom 1. Arm spool shifting
raise position, pilot secondar y pressure is When the operating lever is placed in the arm in
generated from pilot valve (11). The oil enters position, the pilot pressure from the pilot valve
Pb8 port on control valve (2) shifts the boom (11) is supplied to Pa3 port on control valve (2) to
spool. shift the arm valve spool.
2. MAIN CIRCUIT When the spool of the arm valve shifts to close
1. Supply circuit for cylinder (5) the pilot passage, the pressure of pilot oil through
the Pp1 port equalizes to supply pressure.
The oil delivered from port A1 on variable pump
(1) enters into P1 port on control valve (2). The The pressure then overcomes the spring forces
oil from B8 port goes through boom valve and of the independent travel and flow conflux valves
lock valve and enters the head side of boom to shifts the spool.
cylinder (5) to raise the boom. 2. MAIN CIRCUIT
22.3.6.2 BOOM LOWER OPERATING CIRCUIT 1. Supply circuit for cylinder (6)
1. PILOT CIRCUIT The oil from the A2 port on variable pump enters
1. Boom spool shifting P2 port on control valve (2).
When the operating lever is placed in the boom The flow conflux valve is activated and P-3
lower position, the pilot secondary pressure is pressure is added to the circuit. The joined oil
generated from pilot valve (11), it enters Pa8 port flows out from the A3 port through the arm valve
on control valve (2) to shift the boom spool. and is supplied to the head side of the arm
cylinder (6) to perform arm in work.
The pilot secondary pressure is also supplied to
the boom lock valve (206) to open the check 2. Return line from cylinder (6)
valve. The return oil from the rod side of arm cylinder
enters into the B3 port on control valve (2), and is
2. MAIN CIRCUIT
routed to the return line on the T1 port through
1. Supply circuit for cylinder (5) and return oil circuit arm valve, then returned to the tank.
The pressurized oil from A1 port on variable 22.3.7.2 OPERATING CIRCUIT FOR ARM OUT
pump is supplied to the control valve (2) and the
boom valve, pressure is then supplied to the rod 1. PILOT CIRCUIT
side of boom cylinder (5) to lower the boom. When the operating lever is placed in the arm out
The oil returning from the head side of cylinder position, the pilot pressure is generated from the
(5) returns to the tank through the boom lock pilot valve (11), and supplied to the Pb3 port on
valve (206) and B8 port of the boom valve (2). control valve (2) to shift the arm spool.
Its flow rate is restricted by the boom valve, The independent travel and flow conflux valves
accordingly the boom is lowered at a stable are actuated as in the excavating operation.
speed. 2. MAIN CIRCUIT
A. Boom lock valve (206) As in the case of excavating operation, the joined
This is a check valve to prevent the boom pressurized oil from P2 and P3, flows out from
from lowering while the boom valve is in the the B3 port and is supplied to the rod side of the
neutral position. arm cylinder to push the arm out.
22-8 Issued 01-2006 Bur 6-81030 NA

22.3.8 SWING OPERATING CIRCUIT 22.3.9 DOZER OPERATING CIRCUIT

Pilot hydraulic control type with control lever Pilot oil system with operating lever
22.3.8.1 SWING (LEFT) OPERATING CIRCUIT 22.3.9.1 DOZER DOWN OPERATING CIRCUIT
1. SWING OPERATION 1. DOZER OPERATION
The pilot secondary pressure oil is released from When the operating lever is pushed forward, the
the pilot valve (11) by a left swing operation. pilot secondary pressure is generated from the
Oil flows into Pa5 port on the control valve (2) pilot valve (14) to shift the dozer valve spool
through solenoid valve (25), and shifts the swing through the Pb1 port of the control valve (2).
valve spool. 2. MAIN CIRCUIT
1. Pressing the switch on the upper part of the 1. Supply circuit for cylinder (9)
left control lever, the function of pilot line for
The oil from A3 port of the hydraulic pump (1)
slewing changes to swing function while the
enters into P3 port on control valve (2), and is
solenoid valve (25) is actuated, and the swing
supplied to B1 port through dozer valve. The oil
operation starts.
is then passed through swivel joint (10) and
If the switch is released, swing operation will supplied to the head side of dozer cylinder (9) to
continue until the left control lever is placed in activate dozer lowering motion.
neutral position.
When returning left control lever to neutral
position, the solenoid valve (25) changes to
former state and the pilot control line returns
to slewing circuit.
2. MAIN CIRCUIT
1. Supply circuit for the cylinder (8)
The oil from A2 port on the variable pump enters
P2 port on control valve (2). The pressurized oil
from the A5 port of the cylinder valve is supplied
to the head side of cylinder (8) to activate the
swing (left).
A. When activating the swing valve spool for
either left or right swing, an appropriate
volume of oil is returned to the tank through
the P2 bypass circuit through the restriction
porting on the spool.
The supplied volume of oil to the cylinder is
restricted to ensure slow and stable swinging
motions.
6-81030 NA Issued 01-2006 Bur 22-9

22.3.10 NIBBLER & BREAKER OPERATING 3. PILOT CIRCUIT

CIRCUIT
1. Service spool shifting
(Refer to Fold Out Schematics)
P r e s s th e w h i t e O P E N bu t t o n o n t h e l e f t
Pilot oil hydraulic system with operating pedal and operating lever, and pilot pressure flows out from
3rd. pump conflux function B port of solenoid valve (26).
22.3.10.1 NIBBLER CLOSE OPERATING CIRCUIT The oil which entered Pa4 port of control valve
(2) switches the spool for Nibbler/Breaker.
1. PILOT CIRCUIT
By this shift of the service spool, the independent
• Service spool shifting
and flow conflux valves are actuated like the
Press the red colored CLOSE button on the left Nibbler-close operation.
operating lever, secondary pilot pressure flows
out from A port of solenoid valve (26). 4. MAIN CIRCUIT
The oil that enters Pb4 port of control valve (2) 1. Supply circuit for breaker
switches the spool for Nibbler/Breaker. The oil from the A2 port of the 2nd pump flows
The ser vice spool shifts to close the pilot into the P2 por t of control valve (2) and is
passage, the pressure of pilot oil thorough Pp1 supplied to the A4 port through nibbler/breaker
port equalizes to supply pressure. valve. This supplied to the breaker inlet and the
breaker starts operating. Selector valve (22) of
The pressure overcomes the spring force of the the return circuit is switched to the breaker side,
travel independent and flow conflux valves to consequently the return oil return in hydraulic oil
shift the spool. tank (24) directly.
2. MAIN CIRCUIT 2. Return Line from Breaker
• Supply circuit for nibbler cylinder The return oil of Breaker flows through the
The delivery oil from the A2 port of the 2nd pump selector valve (24), and the oil returns directly to
of pump assy (1) flows in the P2 port of control hydraulic tank.
valve (2) and is fed in the B4 port through nibbler/
breaker valve. And it is fed in the H side of the
nibbler cylinder and consequently the nibbler
“close” operation is executed.
• Return line from nibbler cylinder
The return oil from Nibbler cylinder enters into A4
port on control valve (2) and then returns from T1
port to the hydraulic tank.
22.3.10.2 NIBBLER OPEN OPERATING CIRCUIT
1. PILOT CIRCUIT
P r e s s t h e w h i t e O P E N bu t t o n o n t h e l e f t
operating lever, pilot pressure flows from B port
of solenoid valve (26).
The pressurized oil enters Pa4 port of control
valve (2) switches the spool for Nibbler/Breaker.
The independent and flow conflux valves are
actuated as in the Nibbler-close operation.
2. MAIN CIRCUIT
The confluent oil flows from A4 port, enters into
R side of Nibbler cylinder, and opens the Nibbler.
22.3.10.3 BREAKER BLOW OPERATING CIRCUIT
Change the position of selector (24) to the position
for Breaker.
22-10 Issued 01-2006 Bur 6-81030 NA

22.3.11 TRAVEL / DOZER COMBINED 22.3.12 TRAVEL / BOOM COMBINED

OPERATING CIRCUIT OPERATING CIRCUIT
Combined operation of travel and dozer, straight At the combined operation of travel and boom at the
traveling is possible with the combined operating same time, straight traveling is secured with the
circuit. following function.
22.3.11.1 TRAVEL (1ST SPEED FORWARDING) / 22.3.12.1 TRAVEL (1ST SPEED FORWARD) /
DOZER DOWN OPERATING CIRCUIT BOOM UP OPERATING CIRCUIT
1. PILOT CIRCUIT 1. PILOT CIRCUIT
Both the travel and dozer are operated by the The traveling/boom raise of the pilot oil hydraulic
lever using the pilot oil system system with lever operation.
The operation of each lever directly shifts the Pushing forward of travel operating lever and
travel valve spool and dozer valve spool in the pulling the boom raise operating lever, the pilot
control valve (2) respectively. pressure shifts the travel valve spool and/or
boom spool in the control valve (2).
2. MAIN CIRCUIT
The pilot passage of the boom valve is closed,
The oil delivered from A1 and A2 ports on the
this makes the pressure in the Pp1 port equal to
variable pump (1) enters into P1 and P2 ports on
the supply pressure. The pressure overcomes
control valve (2), and each flow for left and right
the spring force of the independent travel and
is supplied to the swivel joint (10) and travel
flow conflux valve to shift the valve.
motor (4) through each travel valve.
The oil from A3 port on the third pump enters P3 2. MAIN CIRCUIT
port on the control valve (2), then it is supplied to The oil from A1 and A2 ports on the variable
the dozer cylinder (9) through the dozer valve pump enters P1 and P2 ports on the control
and swivel joint (10). valve (2).
1. The dozer is operated by the oil supplied by The oil from the P1 and P2 ports are supplied to
the third pump which has no relation with the travel motor in the same way as operating
travel circuit. There is no variation on the independent travel. The oil flows from the travel
supply volume of oil for both travel motors valve through the B7 and B6 ports and the swivel
even though the dozer is operated during joint (10) to the right and left travel motors (4).
traveling. The oil from the A3 port of the hydraulic pump (1)
is supplied to the boom cylinder. The oil through
the P3 port of the control valve (2) flows through
the dozer and slewing valves and through the
shifted independent travel and flow conflux
valves to the boom valve.
The oil from the B9 port through the boom and
block valves is supplied to the head side of the
boom cylinder (5).
When travel and other attachments (boom, arm,
bucket, swing, and ser vice (for N & B) are
operated in combination, the independent travel
and flow conflux valves are actuated. The
attachments are actuated only by oil supplied
from the P3 port. The oil of the P1 and P2 ports
is utilized only by the travel to secure stable travel
in the combined operation.
6-81030 NA Issued 01-2006 Bur 22-11

NOTES
22-12 Issued 01-2006 Bur 6-81030 NA

CHAPTER 23
E50
ELECTRICAL SYSTEM
Issued January 2006

CHAPTER 23 - ELECTRICAL SYSTEM
Revision History
23-II Issued 01-2006 Bur 6-81040 NA

CHAPTER 23
ELECTRICAL SYSTEM
TABLE OF CONTENTS
23.1 HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION

23.1.1 ELECTRIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-3
23.1.2 HARNESS CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-3
23.2 ELECTRICAL EQUIPMENT AND HARNESS
23.2.1 ELECTRICAL EQUIPMENT LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-4
23.2.2 HARNESS & CABLE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-5
23.2.3 ARRANGEMENT DRAWING FOR COMPONENTS & HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . 23-6
23.2.3.1 Upper Frame Portion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-6
23.2.3.2 Engine Portion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-14
23.2.3.3 Relay Unit Portion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-16
23.2.3.4 Fuel Tank Portion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-18
23.2.3.5 Work Light Portion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-20
23.2.3.6 Cab Portion (OPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-22
23.2.3.7 Air Filter Portion (Restriction Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-24
23.2.4 DETAIL OF HARNESS & CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-26
23.2.4.1 Inst • Main Harness (No. H-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-26
23.2.4.2 Engine Harness (No. H-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-34
23.2.4.3 Starter Cable (+) (No. H-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-36
23.2.4.4 Battery Ground Cable (–) (No. H-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-36
23.2.4.5 Engine Ground Cable (No. H-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-37
23.2.4.6 Boom Harness (No. H-7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-37
23.2.4.7 Key Switch Harness (No. H-8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-38
23.2.4.8 Canopy Working Light Harness (No. H-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-38
23.2.4.9 Boom Work Light Extension Harness (No. H-10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-39
23.2.4.10 Connection Harness with Cab (No. H-11) (OPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-40
23.2.4.11 Air Filter Harness (No. H-12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-41
23.2.4.12 Hand Control and Slew/Swing Harness (No. H-16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-42
23.2.4.13 Horn Switch Harness (No. H-17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-43
23.2.4.14 Instrument Panel Harness (Left) (No. H-18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-44
6-81040 NA Issued 01-2006 Bur 23-1

NOTES
23-2 Issued 01-2006 Bur 6-81040 NA

23.1 HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION

23.1.1 ELECTRIC CIRCUIT DIAGRAM 2. The connector is to be connected by engaging
NOTE: For the electric circuit diagram, refer to Fold the male (M) and female (F) connectors of the
Out Schematic. same number.
In the diagram, the number, size and color of wires is Example: CN-101M and CN-101F
shown on the wiring line. Where: M for Male, and F for Female.
The size of the wire is to be 0.75 sq. (square mm =
mm2) unless otherwise specified.
3. This mark means a connector with a diode. The
direction for diode is shown by the arrow.
4. The AVSS wires are to be used for the size
between 0.75 sq. and 2 sq. AVS wires between 3
SPW23000001E01 Figure 1 sq. and 5 sq. and others are AV wires, unless
otherwise specified.
SYMBOL COLOR SYMBOL COLOR
B Black P Pink 5. The wire size is 0.75 sq., unless otherwise
Br Brown R Red specified.
G Green Sb Sky Blue 6. The treatment for the harness end is to be as
Gr Gray V Violet follows:
L Blue W White
Lg Light Green Y Yellow
O Orange
23.1.2 HARNESS CONNECTION SPW23000038J01 Figure 4

1. After applying harness taping, wires are
installed in a corrugated tube.
2. Harness taping by two plies.
1. Indication for Connector
3. No harness treatment for connection.
1. The figure for the connector pin arrangement
is shown by putting the lock (nail) to upper 7. The length for the above (6)-3) is to be 30 ± 10
portion, and looking from the fitting face. mm. (1.2 ± 0.4 in), and the length includes in the
total length of wire shown in the diagram.
2. The numbers in the connector show the wire
No., and alphabetical letters show the wire
color.
3. On the side face of connector, the connector
name and serial number of the connector No.
are indicated.
4. At the place indicated as DOUBLE SPLICE,
Two wires are connected to one place.
6-81040 NA Issued 01-2006 Bur 23-3

23.2 ELECTRICAL EQUIPMENT AND HARNESS

23.2.1 ELECTRICAL EQUIPMENT LIST
NOTE: Refer to fold out schematics.
Group Code Name Part No.

D-1 DIODE
D-2 DIODE
D-3 DIODE
Diode D-4 DIODE YN02D01001P1
D-12 DIODE
D-13 DIODE
D-14 DIODE
E-1 FUSE BOX PW73E00001F1
E-2 GENERATOR (ALTERNATOR) E/G accessory (119626–77210)
E-3 HORN PY53S00002P1
E-4 FUSIBLE LINK PH73S00001P1
E-6 GAUGE CLUSTER PH59S00005F1
E-8 AIR HEATER E/G accessory (129100–77501)
Electrical
E-10 RADIO (OPT) Cab accessory (PY54S00001P1)
Fittings
E-12 HEATER (OPT) PM21M00005F1
E-13 BATTERY YJ72S00001P1
E-14 SEQUENCE BOX PA24S00002P3
E-15 FUSE BOX FOR COOLER (OPT) PH73E00004F1
E-20 TRAVEL ALARM PW53S00002F1
E-26 HOUR METER YT58S00006P1
L-1 ROOM LAMP PM80S00006P1
Light L-2 BOOM WORKING LIGHT PM80S00007F1
L-5 CANOPY WORKING LIGHT PW80S00003F1
M-1 STARTER MOTOR E/G accessory (129136-77011)
M-2 WIPER MOTOR (CAB) Cab accessory (PM76S00001F1)
Motor
M-3 WASHER MOTOR (CAB) Cab accessory (PE54C00002S002)
M-4 DECELERATION MOTOR PH20S00008F1
R-1 BATTERY RELAY PH24S00001P1
R-2 SAFETY RELAY PX24S00001P1
R-3 DECELERATION RELAY PA24E01001P1
R-6 TIMER UNIT PH25S00002P1
R-7 E/G STOP RELAY PH24S00001P1
R-8 CHARGE INDICATOR RELAY
Relay
R-9 CAB / CANOPY WORKING LIGHT RELAY
R-14 SLEW / SWING SELECT RELAY
R-22 SW. SELECT RELAY PA24E01001P1
R-23 SLEW / SWING PRESERVATION RELAY
R-24 NIBBLER OPEN RELAY
R-25 NIBBLER CLOSE RELAY
SE-1 FUEL SENSOR PX52S00006F1
Sensor
SE-2 ENGINE THERMO SENSOR PA24S00003P1
NOTE: The part number may be changed because of modification, use them only for reference.
NOTE: NA: North America, AUST: Australia.
23-4 Issued 01-2006 Bur 6-81040 NA

Group Code Name Part No.

SV-1 LEVER LOCK SOL.
PX35V00003F1
SV-2 2-SPEED SELECT SOL.
SV-3 E/G STOP SOL. E/G accessory (119233–77932)
Solenoid SV-5 POWER SHIFT SOL. (Cooler Spec) YJ35V00004F2
SV-9 NIBBLER OPEN SOL.
PY35V00005F1
SV-10 NIBBLER CLOSE SOL.
SV-12 SLEW/SWING SELECT SOL. PE35V00001F2
SW-1 KEY SWITCH PH50S00008S002
SW-2 WORKING LIGHT SW. PV24E01001P1
SW-3 2-SPEED SELECT SW. YN03M01286S002
SW-4 WIPER WASHER SW. PY50S00004P2
SW-5 E/G COOLANT TEMP. SW. PM50S00006P1
SW-6 E/G OIL PRESSURE SW. E/G accessory (114250–39450)
SW-7 HORN SW. YN50E01001P1
SW-9 LEVER LOCK SW. PA50S00001P1
SW-10 HEATER SW. (OPT) PY50S00003P2
SW-11 DECELERATION SW. PM50S00005P1
Switch SW-14 AIR FILTER RESTRICTION SW. PW11P00010S004
SW-23 TRAVEL ALARM SELCT SW. (OPT) 2479U1190F16
SW-24 TRAVEL RIGHT (FORWARD) PRESSURE SW. (OPT)
SW-25 TRAVEL RIGHT (REVERSE) PRESSURE SW. (OPT)
GB50S00049F2
SW-26 TRAVEL LEFT (FORWARD) PRESSURE SW. (OPT)
SW-27 TRAVEL LEFT (REVERSE) PRESSURE SW. (OPT)
SW-28 SLEW/SWING SELECT SW. LF03M01005F3
SW-30 SLEW/SWING LEVER PRESS. SW. (LEFT) GB50S00049F2
SW-31 SLEW/SWING LEVER PRESS. SW. (RIGHT)
SW-33 NIBBLER OPEN SW.
LF03M01005F3
SW-34 NIBBLER CLOSE SW.
M-6 FUEL PUMP PW22P00001P1
NOTE: NA: North America, AUST: Australia.
23.2.2 HARNESS & CABLE LIST
Code Name Part No. Remarks

H-1 Inst • Main Harness PH14E01019P2
H-3 Engine Harness PH16E01011P2
H-4 Starter Cable (+) PH13E01074D1
H-5 Battery Ground Cable (–) PH13E01076D2
H-6 Engine Ground Cable PW13E01043D1
H-7 Boom Harness PM15E01012D4
H-8 Key Switch Harness PW50E01002P1
H-9 Canopy Work Light Harness PW11E01026D4
H-10 Boom Work Light Extension Harness PH14E01018D1
H-11 Connection Harness with Cab PW14E01041P1 (OPT.)
H-12 Air Filter Harness PW11E01032D2
H-16 Hand Control and Slew/Swing Harness PW14E01037P1
H-17 Horn Switch Harness PH14E01013D1
H-18 Instrument Panel Harness (Left) PH14E01016P1
6-81040 NA Issued 01-2006 Bur 23-5

23.2.3 ARRANGEMENT DRAWING FOR COMPONENTS & HARNESS

23.2.3.1 UPPER FRAME PORTION
FIG. 23-1 UPPER FRAME PORTION (1/8)
23-6 Issued 01-2006 Bur 6-81040 NA

6-81040 NA Issued 01-2006 Bur 23-7

23-8 Issued 01-2006 Bur 6-81040 NA

6-81040 NA Issued 01-2006 Bur 23-9

23-10 Issued 01-2006 Bur 6-81040 NA

6-81040 NA Issued 01-2006 Bur 23-11

SPH23000007E02. Figure 13
23-12 Issued 01-2006 Bur 6-81040 NA

6-81040 NA Issued 01-2006 Bur 23-13

23.2.3.2 ENGINE PORTION
FIG. 23-9 ENGINE PORTION (1/2)
23-14 Issued 01-2006 Bur 6-81040 NA

FIG. 23-10 ENGINE PORTION (2/2)
6-81040 NA Issued 01-2006 Bur 23-15

23.2.3.3 RELAY UNIT PORTION
FIG. 23-11 RELAY UNIT PORTION (1/2)
23-16 Issued 01-2006 Bur 6-81040 NA

FIG. 23-12 RELAY UNIT PORTION (2/2)
6-81040 NA Issued 01-2006 Bur 23-17

23.2.3.4 FUEL TANK PORTION
FIG. 23-13 FUEL TANK PORTION (1/2)
23-18 Issued 01-2006 Bur 6-81040 NA

FIG. 23-14 FUEL TANK PORTION (2/2)
6-81040 NA Issued 01-2006 Bur 23-19

23.2.3.5 WORK LIGHT PORTION

1. BOOM WORK LIGHT
23-20 Issued 01-2006 Bur 6-81040 NA

2. CANOPY WORK LIGHT
6-81040 NA Issued 01-2006 Bur 23-21

23.2.3.6 CAB PORTION (OPT)
FIG. 23-15 CAB PORTION (OPT) (1/2)
23-22 Issued 01-2006 Bur 6-81040 NA

FIG. 23-16 CAB PORTION (OPT) (2/2)
6-81040 NA Issued 01-2006 Bur 23-23

23.2.3.7 AIR FILTER PORTION (RESTRICTION SWITCH)
FIG. 23-17 AIR FILTER PORTION
23-24 Issued 01-2006 Bur 6-81040 NA

NOTES
6-81040 NA Issued 01-2006 Bur 23-25

23.2.4 DETAIL OF HARNESS & CABLE

23.2.4.1 INST • MAIN HARNESS (NO. H-1)
FIG. 23-18 INST • MAIN HARNESS (NO. H-1) — (1/8)
23-26 Issued 01-2006 Bur 6-81040 NA

6-81040 NA Issued 01-2006 Bur 23-27

23-28 Issued 01-2006 Bur 6-81040 NA

6-81040 NA Issued 01-2006 Bur 23-29

23-30 Issued 01-2006 Bur 6-81040 NA

6-81040 NA Issued 01-2006 Bur 23-31

23-32 Issued 01-2006 Bur 6-81040 NA

6-81040 NA Issued 01-2006 Bur 23-33

23.2.4.2 ENGINE HARNESS (NO. H-3)
FIG. 23-26 ENGINE HARNESS (NO. H–3) — (1/2)
23-34 Issued 01-2006 Bur 6-81040 NA

FIG. 23-27 ENGINE HARNESS (NO. H–3) — (2/2)
6-81040 NA Issued 01-2006 Bur 23-35

23.2.4.3 STARTER CABLE (+) (NO. H-4)
23.2.4.4 BATTERY GROUND CABLE (–) (NO. H-5)
23-36 Issued 01-2006 Bur 6-81040 NA

23.2.4.5 ENGINE GROUND CABLE (NO. H-6)
23.2.4.6 BOOM HARNESS (NO. H-7)
6-81040 NA Issued 01-2006 Bur 23-37

23.2.4.7 KEY SWITCH HARNESS (NO. H-8)
23.2.4.8 CANOPY WORKING LIGHT HARNESS (NO. H-9)
23-38 Issued 01-2006 Bur 6-81040 NA

23.2.4.9 BOOM WORK LIGHT EXTENSION HARNESS (NO. H-10)
6-81040 NA Issued 01-2006 Bur 23-39

23.2.4.10 CONNECTION HARNESS WITH CAB (NO. H-11) (OPT)
23-40 Issued 01-2006 Bur 6-81040 NA

23.2.4.11 AIR FILTER HARNESS (NO. H-12)
6-81040 NA Issued 01-2006 Bur 23-41

23.2.4.12 HAND CONTROL AND SLEW/SWING HARNESS (NO. H-16)
23-42 Issued 01-2006 Bur 6-81040 NA

23.2.4.13 HORN SWITCH HARNESS (NO. H-17)
6-81040 NA Issued 01-2006 Bur 23-43

23.2.4.14 INSTRUMENT PANEL HARNESS (LEFT) (NO. H-18)
23-44 Issued 01-2006 Bur 6-81040 NA

6-81040 NA Issued 01-2006 Bur 23-45

NOTES
23-46 Issued 01-2006 Bur 6-81040 NA

CHAPTER 24
E50
COMPONENTS SYSTEM
Issued January 2006

CHAPTER 24 - COMPONENTS SYSTEM
Revision History
24-II Issued 01-2006 Bur 6-81050 NA

CHAPTER 24
COMPONENTS SYSTEM
TABLE OF CONTENTS
24.1 HYDRAULIC COMPONENTS

24.1.1 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-3
24.1.1.1 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-3
24.1.1.1.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-3
24.1.1.2 Construction Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-4
24.1.1.3 Inner Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-8
24.1.1.3.4 Control spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-9
24.1.1.3.5 Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-10
24.1.1.3.6 Gear pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-11
24.1.1.3.8 Trochoid pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-12
24.1.2 PILOT VALVE (ATT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-13
24.1.2.1 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-13
24.1.2.1.1 General view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-13
24.1.2.1.2 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-14
24.1.2.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-15
24.1.3 Pilot Valve (Travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-16
24.1.3.1 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-16
24.1.3.1.1 General View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-16
24.1.3.1.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-16
24.1.3.1.3 Performance Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-16
24.1.3.1.4 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-17
24.1.3.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
24.1.3.2.1 Reducing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-18
24.1.4 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-19
24.1.4.1 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-19
24.1.4.1.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-19
24.1.4.1.8 Main relief valve (P3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
24.1.4.1.9 Overload relief valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22
24.1.4.1.10 Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-23
24.1.4.2 Explanation of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-24
24.1.5 SLEWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-33
24.1.5.1 General View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-33
24.1.5.2 Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-33
24.1.5.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-33
24.1.5.4 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-34
24.1.5.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-36
24.1.6 TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-40
24.1.6.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-40
24.1.6.1.1 General View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-40
24.1.6.1.3 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-42
24.1.6.1.4 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-43
24.1.6.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-45
24.1.6.2.1 Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-45
24.1.6.2.2 Hydraulic Motor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-45
24.1.7 SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-52
24.1.7.1 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-52
24.1.7.1.1 General View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-52
24.1.7.1.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-52
24.1.7.1.4 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-53
24.1.8 CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-54
24.1.8.1 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-54
6-81050 NA Issued 01-2006 Bur 24-1
24.1.8.1.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-54

24.1.8.2 Construction and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-55
24.1.8.2.1 Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-55
24.2 ELECTRICAL EQUIPMENT
24.2.1 ELECTRICAL EQUIPMENT LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-62
24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-64
24.2.2.1 Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-64
24.2.2.2 Fuse Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-64
24.2.2.3 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-65
24.2.2.4 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-66
24.2.2.5 Fusible Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-66
24.2.2.6 Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-67
24.2.2.7 Intake Air Heater (Grid Heater) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-67
24.2.2.8 Radio (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-68
24.2.2.9 Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-68
24.2.2.10 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-69
24.2.2.11 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-69
24.2.2.12 Fuse (Optional Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-70
24.2.2.13 Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-70
24.2.2.14 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-71
24.2.2.15 Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-71
24.2.2.16 Boom Working Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-72
24.2.2.17 Canopy Working Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-72
24.2.2.18 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-73
24.2.2.19 Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-74
24.2.2.20 Windshield Washer Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-74
24.2.2.21 Decelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-75
24.2.2.22 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-76
24.2.2.23 Battery Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-76
24.2.2.24 Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-77
24.2.2.25 Deceleration Relay, Charge Indicator Relay, Slew/swing Relay, Etc. . . . . . . . . . . . . . . . . . . .24-77
24.2.2.26 Delay Timer Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-78
24.2.2.27 Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-78
24.2.2.28 Engine Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-79
24.2.2.29 Safety Lever Lock Travel 2-speed Select Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-79
24.2.2.30 Engine Stop Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-80
24.2.2.31 Power Shift Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-80
24.2.2.32 Nibbler Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-81
24.2.2.33 Slew/Swing Select Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-81
24.2.2.34 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-82
24.2.2.35 Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-82
24.2.2.36 Travel 1 2 Speed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-83
24.2.2.37 Windshield Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-83
24.2.2.38 Engine Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-84
24.2.2.39 Engine Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-84
24.2.2.40 Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-85
24.2.2.41 Lever Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-85
24.2.2.42 Heater Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-86
24.2.2.43 Deceleration Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-86
24.2.2.44 Travel Alarm Switch (OPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-87
24.2.2.45 Travel Alarm (Australia) Slew/swing Lever (North America) Switch . . . . . . . . . . . . . . . . . . . .24-87
24.2.2.46 Nibbler open SW., Nibbler close SW.,
Slew/Swing select SW. (North America) Grip and Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-88
24-2 Issued 01-2006 Bur 6-81050 NA

24.1 HYDRAULIC COMPONENTS

24.1.1 HYDRAULIC PUMP
24.1.1.1 SUMMARY
FIG. 24-1 GENERAL VIEW OF HYDRAULIC PUMP
24.1.1.1.1 SPECIFICATIONS
Model (Type) AP2D18LV3RS7–898–0
Item Piston pump P1 + P2 Gear pump P3 Trochoid pump P4
Working pressure MPa (psi) 23.0 (3340) 20.0 (2900) 3.5 (508)
Displacement cc/rev (cu in/rev) 16.0 (0.98) x 2 8.6 (0.52) 5.1 (0.31)
Delivery flow L/min (gal/min) 38.4 (10.1) x 2 20.6 (5.44) 12.2 (3.22)
Control system Total power shift control by tilting angle (power shift)
Rated revolution min-1(rpm) 2400
Weight kg (lb) 27.5(60.6)
6-81050 NA Issued 01-2006 Bur 24-3

24.1.1.2 CONSTRUCTION FUNCTION
FIG. 24-2
1. Piston pump
The pump is a variable displacement double
piston pump which delivers two equal flows
with one cylinder block and has only one inlet
port. The flow is separated into two flows by
the control plate on the cover and is supplied
to two delivery ports on the cover.
The hydraulic pressure produced by the
delivery oil acts on the hanger, resists the
spring force, and tilts the hanger. As the
piston stroke is changed by the tilting of the
hanger, the flow rate varies.
The 3rd pump, pilot pump, is installed on the
same shaft with a coupling.
24-4 Issued 01-2006 Bur 6-81050 NA

A. The cylinder block is splined and rotates F. The oil sucked from the inside port of the
with the drive shaft. cylinder block is supplied through the
B. The pistons in the cylinder block follow the inside port of the control valve.
sliding surface of the hanger and move to G. The oil sucked from the outside port of the
and fro. cylinder block is supplied through the
C. The piston moves to increase the capacity outside port of the control plate.
from the bottom dead point to the top
dead point, the oil flows from the inlet port
into cylinder block through the control
plate. (Suction stroke)
D. As the piston moves to decrease the
capacity from the top dead point to the
bottom dead point, the oil is pressurized
and sent out to the delivery port. (Delivery
stroke)
E. By changing the tilting angle of the hanger
(sliding surface), the displacement varies.
6-81050 NA Issued 01-2006 Bur 24-5

2. Control D. When the hydraulic pressure on the
A. The piston sliding on the surface of the hanger exceeds the load setting of the
hanger acts on the hanger through the spring, the hanger is tilted and held at the
hydraulic pressure due to oil pressure at position where the hydraulic pressure
ports P1 and P2. balances the spring pressure. (Control
line, Area A)
B. The spring is located in a position which
opposes the oil pressure. E. The control line is shifted after the
hydraulic pressure P3 acts on the piston.
C. When the hydraulic pressure acting on the
hanger goes below the load setting of the
s p r i ng , th e h a n g e r i s a u to m a t i c a l l y
adjusted to the maximum tilt angle.
24-6 Issued 01-2006 Bur 6-81050 NA

3. Adjusting procedure of set torque
A. Loosen the hexagon nut.
B. Set the power line by tightening or
loosening the adjusting screw.
6-81050 NA Issued 01-2006 Bur 24-7

24.1.1.3 INNER CONSTRUCTION

Refer to Fig. 24-2 regarding the whole pump
24.1.1.3.1 DRIVE SHAFT
No. Name Qty No. Name Qty No. Name Qty

1. Shaft 1 5. Not used 9. O-ring 1
2. Seal case 1 6. Snap ring for shaft 1 10. Snap ring 1
3. Bearing 1 7. Snap ring for shaft 1 11. Key 1
4. Not used 8. Oil seal 1
24.1.1.3.2 SWASH PLATE (HANGER)

1 Hanger 1 3 Distance Piece 1 5 Capscrew 4
2 Plate 1 4 Bearing 2 6 O-ring 1
24-8 Issued 01-2006 Bur 6-81050 NA

24.1.1.3.3 ROTARY GROUP

1 Piston 10 4 Retainer 1 7 Spring 1
2 Cylinder block 1 5 Plate 1 8 Parallel pin 3
3 Not used 6 Guide 1 9 Spring seat 2
10 Snap ring 1
24.1.1.3.4 CONTROL SPRING

1 Spring seat 1 6 Spring 1 34 Shim 2
2 Spring seat 1 7 O-ring 1 44 Shim 2
3 Cover 1 8 Capscrew 2 54 Shim 2
4 Setscrew 1 9 Nut 1 64 Shim 2
5 Spring 1
6-81050 NA Issued 01-2006 Bur 24-9

24.1.1.3.5 COVER

1 Cover 1 6 O-ring 4 12 Not used
2 Control plate 1 7 Plug 4 13 Capscrew 1
3 Parallel pin 2 8 Not used 16 Plug: M8 2
4 Capscrew 3 9 Orifice 3 17 Plug: M5 1
5 O-ring 1 10 Bearing 1
24-10 Issued 01-2006 Bur 6-81050 NA

24.1.1.3.6 GEAR PUMP

3 Housing 1 10 Plate 2 16 Square ring 1
4 Cover 1 11 Guide 2 17 Square ring 2
5 Gear 1 12 Coupling 1 18 O-ring (1B P6) 1
6 Gear 1 14 O-ring 2 19 Capscrew (M12 x 25) 2
7 Side plate assy 2 15 O-ring 1
6-81050 NA Issued 01-2006 Bur 24-11

24.1.1.3.7 HOUSING

1 Cylinder 1 4 Parallel pin 1 7 Disk spring 3
2 Piston 1 5 Spring seat 1 8 O-ring 1
3 Piston 2 6 Capscrew 2 9 O-ring 1
24.1.1.3.8 TROCHOID PUMP

1 Gear 1 4 O-ring 1 7 Side plate (B) 1
2 Casing 1 5 Spring pin 1 8 Spring pin 1
3 Side plate (A) 1 6 Capscrew 3 9 Plate 1
24-12 Issued 01-2006 Bur 6-81050 NA

24.1.2 PILOT VALVE (ATT)

24.1.2.1 SUMMARY
24.1.2.1.1 GENERAL VIEW
6-81050 NA Issued 01-2006 Bur 24-13

24.1.2.1.2 CONSTRUCTION
FIG. 24-3 PILOT VALVE-SECTIONAL VIEW

101 Casing 1 213 Seal 4 241–1 Spring 2
151 Plate 1 214 O-ring; 1B P20 4 241–2 Spring 2
201 Spool 4 216–1 Spring seat 2 301 Joint; M14 1
211 Plug 4 216–2 Spring seat 2 302 Disk 1
212–1 Push rod 2 217 Washer 2 4 312 Adjusting nut; M14 1
212–2 Push rod 2 221 Spring 4 501 Bellows 1
24-14 Issued 01-2006 Bur 6-81050 NA

24.1.2.2 OPERATION 3. The Lever being held (See Fig. 24-6)

1. Lever in neutral position (See Fig. 24-4) When the lever is tilted until the pressure of the
The force of the secondary pressure setting port 2, 4 rises to an oil pressure corresponding to
spring (241) centers the pilot valve. The spool the set spring force, the hydraulic pressure is
(201) is pushed up by the return spring (221) balanced with the spring (241) force. When the
against spring seat (216) connecting the output pressure of the por t 2, 4 rises above a set
ports 2, 4 to the tank port T. This makes the pressure, port P is closed and port T is opened.
output pressure equal to the tank pressure. When the pressure of the port 2, 4 falls below a
set pressure, then port P is opened and port T is
closed holding the second pressure constant.
FIG. 24-4 LEVER IN NEUTRAL POSITION
2. When the Lever is tilted (See Fig. 24-5)
FIG. 24-6 LEVER BEING HELD
The push rod (212) strokes when the lever is
tilted. The spool (201) and spring seat (216)
moves downward making port P connect with the
port 2, 4. Now oil from the pilot pump can flow to
port 2, 4, to produce pressure at the control
valve.
FIG. 24-5 WHEN LEVER IS TILTED
6-81050 NA Issued 01-2006 Bur 24-15

24.1.3 PILOT VALVE (TRAVEL)

24.1.3.1 SUMMARY
ITEM SPECIFICATIONS
Model (Type) PVD6P4001
Max. primary pressure 6.9MPa (1000 psi)
Rated flow 10 L/min (2.6 gal/min)
Weight 3.9 kg (8.6 lb)
24.1.3.1.3 PERFORMANCE CHARACTERISTICS
24-16 Issued 01-2006 Bur 6-81050 NA

FIG. 24-7 PILOT VALVE-SECTIONAL VIEW
Torque Nm (lbf ft) No. NAME Qty Torque Nm (lbf ft) No. NAME Qty
101 Casing 1 6.9 (5.1) 252 Plug 2
102 Casing (Damper) 1 261 O-ring 3
201 Cover 2 8.8 (6.5) 271 Capscrew 4
202 Plug 4 301 Spool 4
203 Grease cup 4 311 Spring seat 4
210 Packing 4 313 Washer 4
211 O-ring 4 324 Spring 4
214 Push rod 4 413 Cam shaft 2
217 Shim 4 414 Bushing 4
218 Spring seat 4 420 Cam 2
224 Piston 4 471 Steel ball 4
225 Steel ball 12 6.9 (5.1) 472 Set screw 2
29.4 (21.7) 251 RO Plug 3 501 Boots (Bellows) 2
6-81050 NA Issued 01-2006 Bur 24-17

24.1.3.2 OPERATION
24.1.3.2.1 REDUCING VALVE 2. Lever is tilted, (See Fig. 24-9)
1. When the lever is in neutral position By rotating cam (420), push rod (214) on the
(See Fig. 24-8) port 1 side is pushed down, and the spool is
The spool is pushed up by the return spring moved down, spring (324) sets the secondary
(335) to the spring seat (311), and is in the pressure, shim (217) and washer (313) are
neutral position and por ts 1 and 2 are moved and port P is connected to the port 1.
connected to the tank. The supplied oil from the pilot pump flows into
port 1 and generates pressure.
When the pressure at port 1 rises to the
pressure equivalent to the spring pressure for
the secondary pressure setting set by tilting
the control section, the hydraulic pressure
applied to the spool equals the spring force
and maintains port 1 at a constant delivery
pressure.
The spool on the port 2 side is held at neutral
position, and the return oil from the control
valve is discharged through port T.
FIG. 24-8
FIG. 24-9
24-18 Issued 01-2006 Bur 6-81050 NA

24.1.4 CONTROL VALVE

24.1.4.1 SUMMARY
24.1.4.1.1 GENERAL VIEW AND HYDRAULIC PORTS NO.
MODEL (TYPE) BCV65–AR11

Manual None
Valve operation Travel left, Travel right, Boom, Arm, Bucket, Slewing, Swing, Dozer,
Pilot
Service, Travel straight and conflux
Flow rate P1, P2 – 57.1 L/min(15.1gal/min), P3 – 33.8 L/min(8.9gal/min)
P1, P2: 23.0 +0.5 MPa (3340 +72 psi) at 57.1 L/min (15.1 gal/min)
Setting pressure at main relief valve (MRV1)
P1, P2, P3 P3:23.0 +0.5 MPa (3340 +72 psi) at 5 L/min (1.3 gal/min)
at 33.8 L/min (8.9 gal/min) (MRV2)
B1, A3, B3, A4, B4, B9 port (OR9, OR7, OR8, OR11, OR10, OR1)
Setting pressure at over load relief valve 25.5 +0.5 MPa (3700 +72 psi) at 5 L/min (1.3 gal/min)
A8, B8 port (OR4, OR3) 27.5 +0.5 MPa (4000 +72 psi) at 5 L/min (1.3 gal/min)
6-81050 NA Issued 01-2006 Bur 24-19

SPJ24000003E01
Figure 25

1 Dozer section 1 8 P1, P2 inlet straight 1 15 Over load relief valve 6
2 Slewing section 1 9 Travel (left) section 1 16 Over load relief valve 2
P3 inlet, independent travel
3 1 10 Boom section 1 17 Anti cavitation valve 1
and conflux section
4 Arm section 1 11 Bucket section 1 18 Tie bolt (L=303) 4
5 Service section 1 12 End cover 1 19 Tie bolt (L=143) 4
6 Swing section 1 13 P1, P2 Main relief valve 1 20 Nut 8
7 Travel (right) section 1 14 P3 Main relief valve 1
1. Component Parts
The control valve is roughly classified into the • Accessory section (valve)
following three sections. P1, P2, P3 main relief, overload relief, anti
• Pilot operation section cavitation, boom lock
Travel right and left, boom, arm, bucket, slewing,
swing, independent travel and conflux, dozer
blade, service (nibbler and breaker)
• Accessory section
P1 and P2 inlets, and P3 inlet (common with
independent travel and conflux)
24-20 Issued 01-2006 Bur 6-81050 NA

24.1.4.1.4 PILOT OPERATION: SWING (NO.6)
24.1.4.1.5 PILOT OPERATION: SLEWING (NO.2)
24.1.4.1.6 ANTI CAVITATION VALVE
6-81050 NA Issued 01-2006 Bur 24-21

24.1.4.1.7 MAIN RELIEF VALVE (P1, P2, P3) AND OVERLOAD RELIEF VALVE
24.1.4.1.8 MAIN RELIEF VALVE (P3)
SPH24000025E01.TIF Figure 30
24.1.4.1.9 OVERLOAD RELIEF VALVE.
24-22 Issued 01-2006 Bur 6-81050 NA

24.1.4.1.10 HYDRAULIC CIRCUIT
6-81050 NA Issued 01-2006 Bur 24-23

24.1.4.2 EXPLANATION OF OPERATION

WARNING: As the flow from the pump is fed
1. Neutral position
into each line (P1, P2, P3), the switching
P1: sections of respective line shown below are
The oil delivered from the hydraulic pump flows in operable condition.
from the P1 port of the control valve (C/V) into • P1 line: Left travel, Boom, Bucket
the left travel spool section through the passage • P2 line: Right travel, Boom Swing, Service
of the supply section. and Arm
In the spool neutral position, the oil passes • P3 line: Dozer, slewing [Service and Arm]
through the by-pass of the spool leading from the
left travel to the boom because the spool does Pp1:
not cut off the by-pass and flows out to the tank The oil from the pump flows from the (C/V) Pp1
circuit through the by-pass of the spool for the por t into the pilot circuit through the orifice
bucket and the by-pass leading to the tank. provided on P3 supply section. (Two systems for
P2: shifting independent travel and for shifting arm
and service flow conflux)
The oil delivered from the hydraulic pump flows
from the P2 port of (C/V) into the right travel In the neutral spool position, the oil of the
spool section through the passage of the supply independent travel shifting side flows out to the
section. tank passage through the passages provided to
the right and left travel spool and the swing
In the spool neutral position, the oil passes spool.
through the by-pass of the spools for the right
travel, boom swing and service, and flows out to Therefore the pilot circuit pressure becomes
the tank circuit through the by-pass circuit equal to the tank pressure, the pressure of the
leading from the by-pass of the spool for service. independent travel valve is equal to the tank
pressure, and consequently the independent
P3:
travel spool does not switch.
The oil delivered from the hydraulic pump flows Moreover, the oil of the flow conflux shifting side
from the (C/V) P3 port into the parallel circuit of flows out to the tank passage through the
swing and dozer operation. passage provided to the service spool. Since the
Since the spool is in the neutral position, the oil pilot passage pressure is equal to the tank
flows out to the tank passage through the by- pressure and the receiving pressure of the flow
pass passages of the spools for the dozer and conflux piston is equal to the tank pressure, the
slewing. flow conflux spool is not shifted.
24-24 Issued 01-2006 Bur 6-81050 NA

FIG. 24-12 OPERATION AT NEUTRAL POSITION
6-81050 NA Issued 01-2006 Bur 24-25

2. Pilot operating section The return oil from the boom cylinder rod
1. Operating boom raise side flows into the A8 port, and with the
movement of the spool the oil flows out
In the boom raise operation, the pilot into the tank circuit that is connected by
secondary pressure enters into the Pa8 the notch in the spool. Consequently, the
port, and moves the spool for the boom boom cylinder extends and raises the
operation. And with the movement of the boom.
spool, as the by-pass circuit is cut at the
boom switching section, the oil received The oil from the Pp1 port passes through
through the P1 port flows from the parallel the orifice on the P3 supply section and
circuit through the check valve installed on flows into the pilot circuit.
the upper part of the spool by-pass circuit The oil in the pilot circuit flows from the
for the travel operation into the parallel travel switching section to the tank circuit,
circuit on the boom switching section. and the pilot circuit pressure becomes
With the movement of the spool, as the equal to the tank pressure, consequently
circuit from the passage leading to the th e i n d ep e n d en t travel s p o ol i s n o t
boom lock section to the bridge passage switched.
is opened, the oil entered in the parallel
circuit passes through the load check
valve on the boom switching section and
flows into the boom lock section through
the bridge passage. The oil entering the
boom section opens the lock valve and is
fed into the boom cylinder head side.
FIG. 24-13 OPERATION AT BOOM RAISING
24-26 Issued 01-2006 Bur 6-81050 NA

3. Flow conflux function Since the spool shifting results in shutoff of the
This valve actuates the arm and service using pilot and tank passages for flow conflux, the
joined flow amount of P2 and P3 pumps. pressure in the flow conflux pilot passage
equalizes to the Pp1 port supply pressure, which
The flow conflux circuit is used only for actuating actuates the flow conflux valve.
the arm and service as explained below. (The
explanation shown below for the service shifting Once the spool is shifted, the oil supplied from
is also applicable to the arm.) P3 flows into the second by-pass passage of P2
side. Therefore the flow of oil supplied from P3
The operation for the service shifts the spool for joins in the parallel passage of the P2 side in
the service by the secondary pressure from the proportion to an operating amount of the arm or
remote control valve. the service.
(The drawing below shows service operation.)
FIG. 24-14 ACTUATION OF FLOW CONFLUX CIRCUIT IN SERVICE OPERATION
6-81050 NA Issued 01-2006 Bur 24-27

4. travel function The pressure of the pilot passage equalizes to

When both right and left travel is shifted, and the pressure of Pp1 port, the spools in the P1/P2
boom, bucket, boom swing and service is shifted, supply section are shifted. Thereby P2 parallel
the oil flow from the Pp1 is cut off from the tank passage is connected with P1 parallel passage
passage. After shifting, the oil supplied to P1 and P2
Then the Pp1 port supply pressure acts on the actuates the right and left travel, and the oil
travel straight spool shifting the spool. supplied to P3 actuates the other attachments.
Once the spool is shifted, the oil supplied from Therefore even if the travel and other attachment
P3 passes through the parallel and by-pass are simultaneously operated, the travel is
passages of the slewing and dozer shifting correctly performed without deviating.
sections, and passes through the spool of the P3 The arm or service operated in the flow conflux
supply section and flows into the parallel position without relating to the independent travel
passage of the P2 side. function can be simultaneously performed with
t h e t rave l i n t h e s a m e o p e ra b i l i t y a s t h e
independent travel function.
FIG. 24-15 INDEPENDENT TRAVEL ACTUATION
24-28 Issued 01-2006 Bur 6-81050 NA

5. Function of Lock Valve Piston (C) is held at the position shown in the
1. Piston Holding figure.
When the boom spool is at neutral position, The hydraulic pressure to hold the boom
the pilot piston chamber (a) is connected to cylinder is applied to the lock valve chamber
the drain passage through the pilot port (Pb8) as shown in the figure, pressing the needle
for releasing lock valve. And the piston valve and lock valve to their seats
chamber (b) is also connected to the drain respectively. This prevents leakage on the
passage through the drain port (Dr1). head side of boom cylinder, and also prevents
the ar m cylinder from movement due to
leakage.
FIG. 24-16 FUNCTION OF LOCK VALVE (PISTON HOLDING)
6-81050 NA Issued 01-2006 Bur 24-29

2. Release The opening of the needle valve results in the

When the pilot pressure is applied to the pilot pressure drop in the lock valve chamber. The return
port (Pb8) for releasing lock valve, piston (C) is oil from the boom cylinder opens the lock valve, and
moved opening the needle valve in piston (A). flows into the tank passage through the notch
(groove) of the boom spool and the throttle (drilled
The retur n oil from boom cylinder passes hole).
through the lock valve, the lock valve chamber,
pilot piston chamber, drilled hole in needle valve,
pushing up the steel ball.
FIG. 24-17 FUNCTION OF LOCK VALVE (RELEASE)
24-30 Issued 01-2006 Bur 6-81050 NA

6. Operation of relief valve A. The oil passes through the inside of the
1. Operation at relief condition piston in the pressure regulating valve
(main valve) and fills in “A” chamber inside
of the piston through the orifice “B” to
securely seat the pressure regulating
valve, the socket, and the body seat.
FIG. 24-18
B. When the pressure of the oil in the P port Then, the oil passes through the inside of
reaches the set pressure of the spring, the the piston, orifice B, A chamber, ring
oil acts on the needle seat and opens the orifice, and drilled hole D in order, and
adjust valve. flows out to the tank circuit around the
socket.
C. The pressure in “A” chamber drops
because the needle seat valve is open,
consequently the oil in the P port flows out
to the tank circuit through the drilled hole
“E”.
D. When the pressure on the P port drops the pressure in the P port, consequently
lower than the spring set pressure of the the adjust valve is also pushed against the
needle valve, the needle valve is pushed seat and returns to the former condition
against the seat by the spring force and (Fig. 24-18).
the pressure in “A” chamber is equal to
6-81050 NA Issued 01-2006 Bur 24-31
2. Suction operation When the pressure of the return circuit is

When the negative pressure is generated in greater than the P circuit, the socket is
the P port, the oil is supplied from the return pushed up.
circuit. Consequently, the space between the body
seat and the socket opens, and the oil flows
from the return passage into the P port and
the space fills with the oil stopping cavitation.
7. Operation of anti-cavitation valve Consequently, the space between the body
When the negative pressure is generated in the seat and the socket opens, and the oil flows
P port, the oil is supplied through the return from the return circuit into the P port and the
circuit. When the pressure from the P port rises, space fills with oil.
the valve is pushed up.
24-32 Issued 01-2006 Bur 6-81050 NA

24.1.5 SLEWING MOTOR

24.1.5.1 GENERAL VIEW
24.1.5.2 HYDRAULIC CIRCUIT
24.1.5.3 SPECIFICATIONS
Slewing motor unit PLC-120–18B-1FS2–8284A
Part No. Type PY15V00012F1
Slewing motor PM-1B-22B-FS2–4572A
Displacement cm3/rev (cu in/rev) 22.1 (1.35)
Hydraulic motor
Rated flow L/min (gal/min) 33.8 (8.93)
Static friction torque Nm (lb ft) 73.0 (54)
Parking brake
Release pressure MPa (psi) Min. 2.5 (363) Max. 4. 9 (710)
Set pressure MPa (psi) 21.0 (3045) at 34l/min (9.0 gal/min)
Relief valve
Cracking pressure MPa (psi) 16.5 (2393) at 1l/min (0.26 gal/min)
Reduction unit Reduction ratio 17.7
Weight kg (lb) Approx. 40 (88)
6-81050 NA Issued 01-2006 Bur 24-33

24.1.5.4 CONSTRUCTION
24-34 Issued 01-2006 Bur 6-81050 NA


(Reduction assy) 204 Cylinder 1 302 Check valve 2
101 Casing 1 205 Valve plate 1 303 Plug 2
102 Carrier 1 1 206 Piston 9 304 Spring 2
103 Carrier 2 1 207 Shoe 9 305 O-ring; 1B P11 2
104 Pinion shaft 1 208 Shoe holder 1 306 O-ring; 1B P18 2
105 Internal gear A 1 209 Cylinder holder 1 (Relief valve assy)
106 Spur gear 1 4 210 Swash plate 1 401 Seat 2
107 Spur gear 2 3 212 Retainer 2 402 Retainer 2
108 Sun gear 1 1 213 Pin 3 403 Poppet 2
109 Sun gear 2 1 214 Filter 2 404 Piston 2
110 Pin 1 4 215 Spring 1 405 Cap 2
111 Pin 2 3 216 Ball bearing 1 406 Spring 2
112 Seal ring 1 217 Ball bearing 1 407 Spacer *
113 Thrust collar 1 218 O-ring; 1B G120 1 408 O-ring; 1B P14 2
114 Pre-load collar (semi-circular) 2 221 Snap ring 1 409 O-ring; 1B P18 2
115 Taper roller bearing 1 223 Socket bolt; M12× 35 5 410 O-ring; 1B P22 2
116 Taper roller bearing 1 224 Spring pin 1 411 O-ring; 1B P28 2
117 Roller 68 225 Parallel pin; ø6× 14 1 412 Backup ring 4
118 Roller 69 226 Parallel pin 1 (Timer assy)
119 Thrust washer 14 231 Piston 1 501 Valve block 1
123 Snap ring (for shaft 30) 1 232 Spring B 12 502 Spool 1
124 Snap ring (for shaft 20) 7 233 Friction plate 2 503 Piston 1
125 Spring pin 7 234 Separator plate 2 504 Stopper 1
127 Pin 4 235 O-ring; 1B G100 1 505 Spring (1) 1
128 Oil seal 1 236 O-ring; 1B G110 1 506 Spring (2) 1
129 O-ring 1 237 Backup ring 1 507 Spring seat 1
130 Socket bolt; M8× 25 5 238 Backup ring 1 508 Plug; PF1/4 4
136 Ring 1 242 Socket bolt; M6× 15 4 509 O-ring; 1B P11 4
201 Body 1 244 Socket bolt; M8× 50 4 510 O-ring; 1B P7 2
202 Housing 1 245 O-ring; 1B P18 2 511 Plug 2
203 Shaft 1 301 Cover 1 512 Plug 1
6-81050 NA Issued 01-2006 Bur 24-35

24.1.5.5
1. Operating slewing motor:
The axial piston (swash plate) type motor
converts hydraulic energy delivered by the pump
into rotary motion.
FIG. 24-19 OPERATION OF HYDRAULIC MOTOR
Oil supplied through the control valve from
FIG. 24-20 OPERATION OF PARKING BRAKE
hydraulic pump is directed to the valve plate (1).
This oil enters port A of the valve plate and the oil • When the brake release pressure is blocked:
flows into the cylinder bore in the cylinder (2) and Brake piston (1) is pressed in the direction of
pushes on piston (3). The force on the piston is the arrow by the pressure of spring (2). The
converted by the swash plate (4) into rotary t wo f r i c t i o n p l a t e s ( 4 ) s e c u r e d by t h e
motion, which is transmitted to the shaft (5) crescent-shaped groove of cylinder (3) are
splined to the cylinder (2). sandwiched between three separator plates
Return oil from the cylinder bore flows out port B (6) secured to housing (5). Cylinder (3) is
of the valve plate (1). then unable to turn because of the frictional
fo r c e b e t w e e n f r i c t i o n p l a t e s ( 4 ) a n d
Reverse rotation the oil flows into port B and the separator plates (6).
return oil flows out of port A. • When the brake release pressure is applied:
2. Operation of parking brake: When the brake release pressure is supplied
The parking brake operates to hold the output to chamber (7), the pressure overcomes the
shaft of the slewing motor when the slewing spring (2) and moves brake piston (1) which
motor stops. releases the brake.
24-36 Issued 01-2006 Bur 6-81050 NA

3. Operation of hydraulic valve 1. 1st Stage:

As pressure P1 flowing into the hydraulic
motor increases, pressure corresponding
to the spring action F1 causes the poppet
open.
2. 2nd Stage:
The pressure P1 flows into “secondary
chamber” through the “orifice” which
causes the piston to push to the stroke
end. The pressure P1 rises to a set value
Ps.
The above-mentioned 2-step action
absorbs shocks which occurs when the
hydraulic motor starts and stops.
B. Check Valve:
After accelerating slewing of the upper
structure, when the speed is reduced by half,
the supply rate from pump to por t A is
lowered. If the upper structure is slewing at a
comparatively high speed, the pressure in the
SPH24000045E01 Figure 49 (C) section is lowered to a negative pressure
FIG. 24-21 OPERATION OF SHOCKLESS RELIEF VALVE making lubrication necessary. When the
A. Shockless relief valve: pressure of port B is equal to or lower than
the working pressure of cushion relief valve
The shockless valve is made up of a poppet, the oil of (C) section supplied through port A
spring and the piston that changes in a two is discharged to the control valve through port
step stroke. B. As a result, the flow rate from the control
The IN and OUT ports of the hydraulic motor valve is not enough to lubricate the motor. To
are closed when the hydraulic motor stops. prevent this, the make-up check valve is
The motor attempts to keep slewing by inertia installed to supply necessary oil into the (C)
o f t h e u p p e r s t r u c t u r e. T h i s p r o d u c e s section.
pressure (braking pressure) on the OUT port
side by the pumping action of the motor. The
shockless relief valve relieves the braking
pressure by the following two step actions.
NOTE: The shockless relief valve also operates
to absorb shock in the same way when the motor
starts up.
6-81050 NA Issued 01-2006 Bur 24-37

C. Action of hydraulic parking brake (P/B) timer: 2. When the parking brake acts:
If the pilot pressure is released from the
secondary pilot pressure port (PP), the
brake release pressure at the brake
releasing pressure port (PB) is blocked by
spool (502). The pressure of the parking
brake piston chamber is pushed out
through port DR by the force of the spring
in the parking brake. The oil that is flowing
out is regulated by an orifice (503) and
delays the applying action of the parking
brake for a certain time length.
SPH24000046E01.TIF Figure 51
FIG. 24-23 OPERATION OF PARKING BRAKE TIMER
1. When the parking brake is released:
When the pressure is supplied to the
brake release command secondary pilot
pressure por t (PP), brake releasing
pressure then passes through port (PB)
into the chamber of the parking brake
piston and releases the parking brake.
24-38 Issued 01-2006 Bur 6-81050 NA

4. Reduction Unit (Planetary 2 stage):
FIG. 24-24 OPERATION OF SLEWING REDUCTION UNIT
This slewing reduction unit for the slewing motor The gear ratio of the two-stage planetary gear
is made up of two stage planetary gear sets. It can generally expressed by:
conver ts high-speed rotary motion from the
slewing motor into low speed and high-torque
motion to rotate the pinion shaft.
Refer to the Fig. 24-24, sun gear 2 (S2) is splined
on the output shaft of the slewing motor and the
rotation of sun gear 2 (S2) performs primary
reduction through gears (S2), (b2), and (a2).
After primary reduction, a secondary reduction is
performed through gears (S1) (splined to carrier
2), (b1), and (a1).
After secondary reduction, rotation is transmitted SPH24000050E01 Figure 53
to the pinion shaft splined to carrier 1 creating
slewing force.
6-81050 NA Issued 01-2006 Bur 24-39

24.1.6 TRAVEL MOTOR

24.1.6.1 SPECIFICATIONS
24-40 Issued 01-2006 Bur 6-81050 NA

Model (Type) GM06VA

Rated output revolution (1st / 2nd) min-1 (rpm) 30.9 / 52.2
Reduction unit Output torque (1st / 2nd) Nm (lbf ft) 5710 / 3280 (4211 / 1033)
Reduction ratio 1 / 68.6
Displacement (1st / 2nd) cm3/rev (cu in/rev) 26.4 / 15.3 (1.61 / 0.93)
Rated operating pressure MPa (psi) 23.0 (3340)
Rated output revolution (1st / 2nd) min-1(rpm) 2119 / 3583
Hydraulic motor
Rated flow L/min (gal/min) 57.1 (15.1)
2-Speed shifting pressure MPa (psi) 3.5 (507)
Automatic 2-speed shifting pressure MPa (psi) 18.5 (2680)
Static friction torque Nm (lbf ft) 64.7 (47.7)
Parking brake
Releasing pressure MPa (psi) 0.89 (129)
Weight kg (lb) 65 (143)
6-81050 NA Issued 01-2006 Bur 24-41

24-42 Issued 01-2006 Bur 6-81050 NA

24.1.6.1.4 SECTIONAL VIEW
6-81050 NA Issued 01-2006 Bur 24-43

No. Name Qty No. Name Qty

1 Hub 1 102 Shaft 1
2 Spindle 1 103 Swash plate 1
3 Carrier 1 107 Retainer plate 1
4 Sun gear (1) 1 108 Thrust ball 1
5 Planetary gear (1) 3 109 Timing plate 1
6 Sun gear (2) 1 110 Washer 2
7 Planetary gear (2) 4 112 Piston 1
9 Thrust washer (1) 2 113 Spring 8
11 Thrust collar (4) 4 114 Spring 1
12 Thrust washer (3) 7 115 Friction plate 2
13 Cover 1 116 Separator plate 3
14 Coupling 1 132 Oil seal 1
22 Ring nut 1 135 O-ring 1
24 Ball bearing 2 139 O-ring 1
27 Needle roller bearing with retainer 3 145 Snap ring 1
28 Needle roller bearing with retainer 4 149 Ball bearing 1
29 Inner race 3 150 Ball bearing 1
30 Inner race 4 151 Roller 3
167 Pivot 2
Floating seal kit 1 177 Parallel pin 2
31 Floating seal 2 190 Spring 1
33 Plug with flange 1 Rear flange assembly 1

35 O-ring 1 •Rear flange kit 1
37 O-ring 3 201 ••Rear flange 1
39 Plug 2 223 ••Spool 1
40 Hexagon head screw 7 •Spool kit 1
41 Steel ball 1 263 ••Spool 1
42 Parallel pin 2 264 ••Oil stopper 1
43 O-ring 2 221 •Plug 2
44 O-ring 1 224 •Plug 2
45 Ring 1 225 •Stopper 2
47 Hexagon socket set screw 2 226 •Plug 2
227 •Valve 2
228 •Spring 2
Cylinder and piston kit 1 230 •Spring 2
104 •Cylinder block 1 236 •O-ring 2
•Piston kit 1 237 •O-ring 2
••Piston assembly 9 252 •Hexagon socket plug 4
105 •••Piston 1 254 •Hexagon socket plug 6
106 •••Shoe 1 266 •Spring 1
268 •Steel ball 1
Piston kit 1 273 •O-ring 2
•Piston assembly 1 275 •Orifice 5
161 ••Piston 1 276 •Orifice 1
162 ••Shoe 1 279 •Filter 1
163 •Seal ring 1 280 •Plug with flange 1
299 •Name plate 1
241 Parallel pin 2
243 Capscrew 6
24-44 Issued 01-2006 Bur 6-81050 NA

24.1.6.2 FUNCTION
24.1.6.2.1 REDUCTION UNIT Sun gear (4) is meshed with three planetary
1. Function gears (5), and three planetary gears (5) mesh
with hub (1) while rotating on their axis.
This reduction gear unit is composed of two
stage planetary gear mechanism. At that time, the hub is rotated by the rotation of
the planetary gears (5).
The reduction gear reduces the high speed of a
hydraulic motor and converts it low–speed, high– The hub rotation is transmitted to carrier (3)
torque rotation. which connected to planetary gears (5), and that
causes sun gear (6) rotation of the second stage.
2. Operating Description
The rotation of sun gear (6) is transmitted to the
T h e r o t a t i o n o f hy d r a u l i c m o t o r s h a f t i s hub via four planetary gears (7) of the second
transmitted to sun gear (4) of the first stage stage.
which is linked with shaft (102).
The generated rotation of reduction gear is
output rotation.
24.1.6.2.2 HYDRAULIC MOTOR SECTION 3. Parking brake
(Brake valve, parking brake, high and low speed The parking brake is used to the prevent
change mechanism) machine from running away or slipping while
1. Function parking on a slope using the friction plate
type brake mechanism, and is installed on the
1. Hydraulic motor hydraulic motor.
Hydraulic motor is referred to as a swash 4. High / Low 2-speed shifting mechanism
plate type axial piston motor which converts
the pressure oil power supplied by pump into By means of changing the tilt angle of the
rotary motion. swash plate to change the stroke volume of
piston with help of the function on the shifting
2. Brake valve valve and control piston, the speed is shifted
A. Travel motor controls the force of to high speed with low torque or low speed
rotational inertia of the body to brake and with high torque.
stop the rotation smoothly.
B. Check valve function to prevent hydraulic
motor from cavitation.
C. Open the port to release the parking
brake force at travel motor operation, and
close the port at a standstill.
6-81050 NA Issued 01-2006 Bur 24-45

2. Operation Then the force of spring (228) slides the

1. Hydraulic motor spool placed on the neutral position
leftward.
Hydraulic oil supplied by the pump enters the The sliding of spool forms the space
rear flange (201) of travel motor, it is returned (passage) between spool and rear flange
from timing plate (109) to cylinder block (104) w i t h s p o o l gr o ove. T h i s p a s s a g e i s
t h r o u g h b r a ke va l ve m e c h a n i s m . T h e connected to port (D) and port (B) of the
pressure supplied to one side of cylinder return circuit of the hydraulic motor, and
block pushes 4 or 5 pistons (105), generating the return oil returns to tank side, enabling
the power {F (N) = 100 × P (MPa) × A (cm2)}. hydraulic motor to rotate.
This power enters on swash plate (103), but
swash plate (103) is fixed having an angle (α) Then, the sliding of spool (223) routes oil
against axis of drive shaft (102), and divided to port (P). The pressure oil supplied to
into component of force (F 2 , F 3 ). And the port (P) moves piston (112) of parking
radial component of force (F 3 ) generated brake, and releases the parking braking.
various torque (T = F3 x ri) against line Y1 - (For details, refer to item “Parking brake”.)
Y 2 . The total torque [T = Σ (F 3 x r i)] is If pressurized oil is supplied from port (B)
connected to turning effor t, and rotates the movements of spool (223) and valve
cylinder block (104) through piston (105). (227) are reversed so that the hydraulic
This cylinder block (104) is connected with motor is rotated reversely.
drive shaft (102) with spline, and rotates drive
shaft (102) to transmit torque.
2. Brake valve
A. Operation (Brake released)
The pressure oil is supplied to through
port (A), opens valve (227), and supplied
to port (C) on the section side of hydraulic
motor to rotate hydraulic motor. At the
s a m e t i m e, t h e p r e s s u r e o i l e n t e r s
chamber (b) through passage (a) from the
small hole of spool (223).
24-46 Issued 01-2006 Bur 6-81050 NA

B. Stop / Stall (braking action) When the spool entirely returns to the
If pressurized oil supply through the port neutral position, the passage on the
(A) is suspended while travelling, the hydraulic motor of the oil return side is
hydraulic force to push the spool is lost, completely closed by the spool, and the
and the spool (223) returns to the neutral hydraulic motor ceases its rotation. While
position due to the spring (228) force. At the is machine working, the brake valve
that time, though the oil in the chamber (b) smoothly stops rotation of the hydraulic
tr ies to flow out to the por t (A) side motor which tries to rotate with its inertia
through the passage (a) in the spool, its force, by means of throttling the return
flow is restricted and some back pressure side passage of the hydraulic motor,
is generated by the throttle effect in the generating back pressure due to shape of
passage (a) controlling the return speed the spool groove and controlling the return
of the sp oo l. At th e s am e t ime, t he speed of the spool.
hydraulic motor tries to rotate with its When the brake is engaged, the hydraulic
inertia force even though the pressurized motor tries to rotate with its inertia force
oil is suspended, and the return oil from and to intake oil with its pumping action.
the hydraulic motor tries to return to the Because its passage is closed with the
port (B) side from the port (D) through the spool, the oil supply is suspended. This
passages on spool groove and rear causes cavitation in the hydraulic motor.
flange. To prevent the cavitation, the valve (227)
i s o p e ra t e d by ve r y s l i g h t n e g a t i ve
pressure to open the passages of port (A)
side and intake port (C) of the hydraulic
motor.
When pressurized oil is supplied through
the port (B), each motion of the above
mentioned parts becomes symmetrical
right and left to stop the hydraulic motor.
6-81050 NA Issued 01-2006 Bur 24-47

C. Self-traveling
While machine is being operated and the
travel speed is increased due to steep
slope, the oil flow rate of the hydraulic
motor is higher than the supply flow rate of
the hydraulic oil pump. The rotation of the
hydraulic motor in this case is called a
self-traveling (Overrun).
While self-traveling, the oil pressure is
lowered similar to the stopping condition.
The brake valve is moved similar to the
stopping condition, throttles passage in
the return side of hydraulic motor, and
generate back pressure.
As the force of iner tia decreases the
revolution of hydraulic motor to revolution
having a balance with the supply flow rate
of pump.
24-48 Issued 01-2006 Bur 6-81050 NA

3. Parking brake The force of the spring pushes mating

A. Traveling plate (116) and friction plate (115) against
spindle (2) on the reduction gear section.
The pressure oil supplied trough brake The frictional force produced by the push
valve actuates on spool (223) of brake power stops the rotation of cylinder block
valve on the hydraulic motor section, (104), and transmits braking torque
opens passage to parking brake, and is 32.4Nm (23.9 lbf ft) to hydraulic motor
supplied to cylinder chamber piston (112) shaft. The oil is controlled through an
on the reduction gear section. orifice which results in smooth operation.
Pressure which is 0.89MPa(129 psi) or
higher exceeds the force of spring moving
piston (112) toward rear flange (201) side.
This movement of piston (112) reduces
the push power to separator plate (116)
and friction plate (115), and releases the
brake.
B. Stopping
If pressure oil from brake valve is cut, and
the pressure in cylinder chamber (a)
lowers 0.89MPa(129 psi) or less, the
piston (112) moves by the force of spring
(113).
6-81050 NA Issued 01-2006 Bur 24-49

4. High / Low 2-speed shifting mechanism The pressurized oil is cut off at port (C), and oil in the
A. Low speed chamber (P) is released into the drain (motor case)
through the valve (263). The tilt angle of the swash
When pilot pressure is not supplied plate (103) becomes the maximum θ 1 resulting the
through the port (D), the valve (263) is maximum stroke volume and low speed rotation of
pushed up to the upper position due to the hydraulic motor.
spring (266) force and pressurized oil
through the port (A) or (B).
B. High speed The pressurized oil at the port (C) is supplied to the
When 3.5MPa (507 psi) of pilot pressure chamber (P) through the valve (263), and piston
is supplied through port (D), it defeats the (161) pushes the swash plate (103) up to plane X
spring (263) force and pressurized oil and maintains it in this position. The tilt angle of the
through the port (A) or (B) to push down swash plate becomes the minimum θ 2 resulting the
the valve (263) to lower position. minimum stroke volume and high speed rotation of
the hydraulic motor.
24-50 Issued 01-2006 Bur 6-81050 NA

C. Automatic shifting to low speed during Oil in the chamber (P) is released into the drain
high speed operation (motor case) through the valve (263). Then the tilt
If the load is increased while high speed angle of swash plate becomes the maximum θ 1 and
operation, the oil pressure at the port (A) is maintained at its position resulting low speed
or (B) is also increased. When the oil rotation.
pressure reaches to 18.5MPa (2680 psi),
i t ex c e e d s t h e p i l o t p r e s s u r e o f
3.5MPa(507 psi), and the valve (263) is
pushed up to upper position.
6-81050 NA Issued 01-2006 Bur 24-51

24.1.7 SWIVEL JOINT

24.1.7.1 SUMMARY
FIG. 24-25 GENERAL VIEW
Part Number 24100J12703F1

Port No. A, B, C, D E, F P G (Drain)
Rated working pressure MPa (psi) 20.6 (2990) 20.6 (2990) 3.4 (500) 0.5 (73)
Pressure test MPa (psi) 30.9 (4480) 30.9 (4480) 30.9 (4480) 1.0 (145)
Rated flow L/min (gal/min) 70 (18.5) 40 (10.6) 10 (2.6) 10 (2.6)
Port size PF1/2 PF3/8 PF1/4 PF3/8
Revolution rpm Less than 15
Weight kg (lb) Approx 22 (49)
24-52 Issued 01-2006 Bur 6-81050 NA

FIG. 24-26 CONSTRUCTION

1 STEM 1 7 NAME PLATE 1 13 BOLT (M10× 30) 4
2 BODY 1 8 O-RING 1 14 PLUG (PF1/4) 3
3 FLANGE 1 9 O-RING 1 15 SPRING WASHER 4
4 SPACER 1 10 DUST SEAL 1 16 BACK-UP RING 1
5 PIN 1 11 DUST SEAL 1 17 CLEVIS 2
6 SLIPPER SEAL 7 12 SNAP RING 1
24.1.7.1.4 FUNCTION
The swivel joint is installed at the slewing center of the machine, and maintains the connection of hydraulic oil
circuits regardless to the slewing angle on the upper frame. The body (2) and shaft (1) which are able to
independently rotate, the necessary number of ports (3) are provided corresponding to the number of circuits. The
necessary number of grooves is machined on both of the body (2) at its inner periphery and the shaft (1) at its outer
periphery, and these grooves are sealed at upper and lower portions with the seal (4)
6-81050 NA Issued 01-2006 Bur 24-53

24.1.8 CYLINDER
24.1.8.1 SUMMARY
FIG. 24-27 GENERAL VIEW OF CYLINDER
Center distance of mounting pins Dry weight

Cylinder Cylinder Bore / Rod Dia. Stroke Cushion
Full extend B / Full retract A kg (lb)
Boom (Canopy) ø100 / ø55 (3.94" / 2.17") 699 (2’3.5”) 1768/ 1069 (5’9.6” / 3’6.1”) Rod side 57 (127)
Boom (Cab) ø100 / ø55 (3.94" / 2.17") 666 (2’2.2”) 1753 / 1069 (5’9.0” / 3’6.1”) Rod side 56 (123)
Arm ø90 / ø50 (3.54" / 1.97") 716 (2’4.2”) 1836 / 1120 (6’0.3” / 3’8.1”) Rod & Head 49 (108)
Bucket ø75 / ø45 (2.95" / 1.77") 546 (1’9.5”) 1378 / 832 (4’6.3” / 2’8.8”) None 27 (60)
Swing ø90 / ø50 (3.54" / 1.97") 567 (1’10.3”) 1510 / 943 (4’11.4” / 3’1.1”) None 39 (86)
Dozer ø95 / ø55 (3.74" / 2.17") 200 (7.87") 700 / 500 (2’3.6” / 1’7.7”) None 27 (60)
24-54 Issued 01-2006 Bur 6-81050 NA

24.1.8.2 CONSTRUCTION AND FUNCTION

24.1.8.2.1 BOOM CYLINDER
FIG. 24-28 CONSTRUCTION OF BOOM CYLINDER

1 TUBE ASSY 1 8 NOT USED 15 SEAL RING 1
2 ROD ASSY 1 9 LOCK NUT 1 16 BACK-UP RING 1
3 BUSHING 2 10 WEAR RING 2 17 DUST SEAL 1
4 HEAD 1 11 SEAL RING 1 18 O RING 1
5 CUSHION BEARING 1 12 SEAL RING 1 19 BACK-UP RING 2
6 PISTON 1 13 RING 1 20 O RING 3
7 NOT USED 14 ROD BUSHING 1 21 DUST SEAL 1
6-81050 NA Issued 01-2006 Bur 24-55

24.1.8.2.2 ARM CYLINDER
FIG. 24-29 CONSTRUCTION OF ARM CYLINDER

1 TUBE ASSY 1 9 LOCK NUT 1 17 DUST SEAL 1
2 ROD ASSY 1 10 WEAR RING 2 18 O RING 2
3 BUSHING 2 11 SEAL RING 1 19 BACK-UP RING 3
4 HEAD 1 12 SEAL RING 1 20 O RING 1
5 CUSHION BEARING 1 13 RING 1 21 DUST SEAL 4
6 PISTON 1 14 ROD BUSHING 1 23 CUSHION BEARING 1
7 NOT USED 15 SEAL RING 1 24 PLATE RING 1
8 NOT USED 16 BACK-UP RING 1 25 RING 1
24-56 Issued 01-2006 Bur 6-81050 NA

24.1.8.2.3 BUCKET CYLINDER
FIG. 24-30 CONSTRUCTION OF BUCKET CYLINDER

1 TUBE ASSY 1 10 WEAR RING 1 17 DUST SEAL 1
2 ROD ASSY 1 11 SEAL RING 2 18 O RING 1
3 BUSHING 2 13 RING 1 19 BACK-UP RING 1
4 HEAD 1 14 ROD BUSHING 1 20 O RING 1
6 PISTON 1 15 SEAL RING 1 21 DUST SEAL 4
9 LOCK NUT 1 16 BACK-UP RING 1
6-81050 NA Issued 01-2006 Bur 24-57

24.1.8.2.4 SWING CYLINDER
FIG. 24-31 CONSTRUCTION OF SWING CYLINDER

24-58 Issued 01-2006 Bur 6-81050 NA

24.1.8.2.5 DOZER CYLINDER
FIG. 24-32 CONSTRUCTION OF DOZER CYLINDER

6-81050 NA Issued 01-2006 Bur 24-59

24.1.8.2.6 FUNCTION (EXAMPLE FOR BOOM 2. Function of each Part

CYLINDER) The following description is based on a cylinder
1. Fundamental Function with a typical structure (Boom cylinder).
This is a kind of hydraulic actuator that converts 1. Cylinder Head Assy
the energy in pressurized oil supplied by the The cylinder head assy also works as a
hydraulic pump to a large force linear direction by bearing by the means of a pressed bushing
m e a n s o f t h e p i s t o n . C h a n g i n g ove r t h e (14) in the cylinder head (4). Oil leakage is
operating direction for either extension or prevented by insertion of a seal (15) into the
retraction by means of actuating the valve lever bore of cylinder head. The dust invasion is
to change over the direction of pressurized oil protected by pressing a dust seal (17) into the
flow. Such conversion of energy force and bore of cylinder head.
change over the operating direction are of the
fundamental function of this cylinder.
FIG. 24-33 CYLINDER HEAD ASSY
A. Bushing (14) B. Dust Seal (17)
The bushing (14) is pressed into the bore The dust seal (17) is located at the
on cylinder head to support the piston rod. entrance where the piston rod comes in
T h e bu s h i n g ( 1 4 ) b e a r s ra d i a l l o a d and out. Its function is to protect invasion
imposed on the cylinder, and performs of dust and water into the cylinder to
linear movement against the piston rod at secure good sealing effect of the seal
high facial pressure, and minimized the (15), as well as to remove dust and mud
eccentricity of piston rod that badly affects adhered on the piston rod.
to the sealing effect by supporting its one
end.
24-60 Issued 01-2006 Bur 6-81050 NA

FIG. 24-37 PISTON ASSY
2. Piston Assy C. Cushion Bearing (5)
The piston assy has the seal ring (11) which The cushion bearing (5) is located
is inserted at the center portion of the piston between the piston and the stepped
(6), to prevent leakage of pressurized oil from portion of piston rod. This cushion ring
either chamber of left or right to the other has the inner seal ring (12), this causes
chamber. The wear rings (10) are inserted in the seal ring to float. This has the function
both sides of the seal ring (11) to bear radial to form a circular gap adjacent to the fully
load imposed on the cylinder, and also to extended position, and to throttle the oil to
catch contaminations. and soften the shock prior to the fully
A. Seal Ring (11) extended position.
The location of seal ring (11) is the center D. Cushion Bearing (23)
of piston. The seal ring (11) is to seal the The cushion bearing (23) is located at the
circular gap between the piston and the end of piston rod. At the full retracting of
cylinder tube utilizing a tension of the O- cylinder rod, cushion bearing (23) plunges
r ing, to for m both chambers of high into hole of cylinder bottom, and forms a
pressure side and low pressure side circular gap and throttles the oil flow.
isolating from each other making the Consequently the collision speed of rod
piston as the border. slows down and the shock of collision is
B. Wear Ring (19) absorbed.
Two wear rings are provided at both sides

of the seal ring (11) directly getting in
touch with the cylinder tube. Along with
the rod bushing (14), the wear rings (10)
bear radial load imposed on the cylinder,
perform linear movement against inside
face of cylinder at high facial pressure,
and minimize the eccentricity of piston rod
that badly affects to the sealing effect by
supporting it at one end. And the slide ring
has another function of bur ying and
catching contaminations between the
cylinder tube and the slide rings.
6-81050 NA Issued 01-2006 Bur 24-61

24.2 ELECTRICAL EQUIPMENT

24.2.1 ELECTRICAL EQUIPMENT LIST
Group Code Part Name Part No.

D-1 DIODE
D-2 DIODE
D-3 DIODE
Diode D-4 DIODE YN02D01001P1
D-12 DIODE
D-13 DIODE
D-14 DIODE
E-1 FUSE BOX PW73E00001F1
E-2 GENERATOR (ALTERNATOR) E/G accessory (119626–77210)
E-3 HORN PY53S00002P1
E-4 FUSIBLE LINK PH73S00001P1
E-6 GAUGE CLUSTER PH59S00005F1
E-8 AIR HEATER E/G accessory (129100–77501)
Electrical
E-10 RADIO (OPT) Cab accessory (PY54S00001P1)
Fittings
E-12 HEATER (OPT) PM21M00005F1
E-13 BATTERY YJ72S00001P1
E-14 SEQUENCE BOX PA24S00002P3
E-15 FUSE BOX (OPT) (FOR COOLER) PH73E00004F1
E-20 TRAVEL ALARM PW53S00002F1
E-26 HOUR METER YT58S00006P1
L-1 ROOM LAMP Cab accessory (PM80S00006P1)
Light L-2 BOOM WORKING LIGHT PM80S00007F1
L-5 CAB / CANOPY WORKING LIGHT PW80S00003F1
M-1 STARTER MOTOR E/G accessory (129136-77011)
M-2 WIPER MOTOR (CAB) Cab accessory (PM76S00001F1)
Motor M-3 WASHER MOTOR (CAB) Cab accessory (PE54C00002S002)
M-4 DECELERATION MOTOR PH20S00008F1
M-6 FUEL PUMP PW22P00001P1
R-1 BATTERY RELAY PH24S00001P1
R-2 SAFETY RELAY PX24S00001P1
R-3 DECELERATION RELAY (EU NA Aust) PA24E01001P1
R-6 TIMER UNIT PH25S00002P1
R-7 E/G STOP RELAY PH24S00001P1
R-8 CHARGE INDICATOR RELAY
Relay
R-9 CAB / CANOPY WORKING LIGHT
R-14 SLEW/SWING SELECT RELAY
R-22 SW. SELECT RELAY PA24E01001P1
R-23 SLEW/SWING PRESER VATION RELAY
R-24 NIBBLER OPEN RELAY
R-25 NIBBLER CLOSE RELAY
SE-1 FUEL SENSOR PX52S00006F1
Sensor
SE-2 ENGINE THERMO SENSOR PA24S00003P1
SV-1 LEVER LOCK SOL.
PX35V00003F1
SV-2 2-SPEED SELECT SOL.
SV-3 E/G STOP SOL. E/G accessory (119233–77932)
Solenoid SV-5 POWER SHIFT SOL. (Cooler Spec) YJ35V00004F2
SV-9 NIBBLER OPEN SOL. (NA)
PY35V00005F1
SV-10 NIBBLER CLOSE SOL. (NA)
SV-12 SLEW/SWING SELECT SOL. (NA) PE35V00001F2
NOTE: The part number may be changed owing to modification, use them only for reference.
NOTE: NA: North America, Aust: Australia
24-62 Issued 01-2006 Bur 6-81050 NA

Group Code Part Name Part No.

SW-1 KEY SWITCH PH50S00008S002
SW-2 WORKING LIGHT SW. PV24E01001P1
SW-3 2-SPEED SELECT SW. YN03M01286S002
SW-4 WIPER WASHER SW. PY50S00004P2
SW-5 E/G COOLANT TEMP. SW. PM50S00006P1
SW-6 E/G OIL PRESSURE SW. E/G accessory (114250–39450)
SW-7 HORN SW. YN50E01001P1
SW-9 LEVER LOCK SW. PA50S00001P1
SW-10 HEATER SW. (OPT) PY50S00003P2
SW-11 DECELERATION SW. (OPT) PM50S00005P1
Switch SW-14 AIR FILTER RESTRICTION SW. (NA) PW11P00010S004
SW-23 TRAVEL ALARM SELCT SW. (OPT.) 2479U1190F16
SW-24 TRAVEL RIGHT (FORWARD) PRESSURE SW. (OPT) (NA)
SW-25 TRAVEL RIGHT (REVERSE) PRESSURE SW. (OPT) (NA)
GB50S00049F2
SW-26 TRAVEL LEFT (FORWARD) PRESSURE SW. (OPT) (NA)
SW-27 TRAVEL LEFT (REVERSE) PRESSURE SW. (OPT) (NA)
SW-28 SLEW/SWING SELECT SW. (NA) LF03M01005F3
SW-30 SLEW/SWING LEVER PRESS. SW.(LEFT) (NA)
GB50S00049F2
SW-31 SLEW/SWING LEVER PRESS. SW.(RIGHT) (NA)
SW-33 NIBBLER OPEN SW. (NA)
LF03M01005F3
SW-34 NIBBLER CLOSE SW. (NA)
NOTE: The part number may be changed owing to modification, use them only for reference.
NOTE: NA: North America, Aust: Australia
6-81050 NA Issued 01-2006 Bur 24-63

24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT

24.2.2.1 DIODE
Specifications and Description
Code No. ..................................................................................................................................... D-1, 2, 3, 4, 12~14
Parts Name ...................................................................................................................................................... Diode
Parts No. .......................................................................................................................................... YN02D01001P1
Use .. Horn, E/G stop solenoid, E/G stop relay, Travel 1, 2 speed sol., Battery relay, Slew/Swing, Select relay, E/G
stop solenoid
Applicable Machines .... PW10-22001~, PX11-08901~, PW11-30001~, PX12-11001~,PH05-03501~,PJ04-03001~
24.2.2.2 FUSE BLOCK
Code No. ............................................................................................................................................................. E-1
Parts Name ................................................................................................................................................. Fuse box
Parts No. ......................................................................................................................................... PW73E00001F1
Use ................................................................................................................................................. Circuit protection
Applicable Machines ..................................................... PW11-30001~, PX12-11001~,PH05-03501~,PJ04-03001~
24-64 Issued 01-2006 Bur 6-81050 NA

24.2.2.3 ALTERNATOR
Code No. .............................................................................................................................................................. E-2
Parts Name ............................................................................................................................. Generator (Alternator)
Parts No. ............................................................................................................................................. 119626-77210
Use ............................................................................................................................................................ Generator
6-81050 NA Issued 01-2006 Bur 24-65

24.2.2.4 HORN
Code No. ............................................................................................................................................................. E-3
Parts Name ........................................................................................................................................................ Horn
Parts No. .......................................................................................................................................... PY53S00002P1
Use .................................................................................................................................................... Warning sound
24.2.2.5 FUSIBLE LINK
Code No. ............................................................................................................................................................. E-4
Parts Name .............................................................................................................................................. Fusible link
Parts No. .......................................................................................................................................... PH73S00001P1
Use .................................................................................................................................................................... Fuse
Applicable Machines ........................ PW08-20001~, PX09-08001~, PW10-22001~, PX11-08901~, PW11-30001~,
PX12-110 01~,PH05-03501~,PJ04-03001~
24-66 Issued 01-2006 Bur 6-81050 NA

24.2.2.6 INSTRUMENT CLUSTER
Code No. .............................................................................................................................................................. E-6
Parts Name ......................................................................................................................................... Gauge Cluster
Parts No. .......................................................................................................................................... PH59S00005F1
Use ...................................................................................................................................................... Monitor Panel
24.2.2.7 INTAKE AIR HEATER (GRID HEATER)
Code No. .............................................................................................................................................................. E-8
Parts Name ................................................................................................................................................ Air heater
Parts No. ............................................................................................................................................. 129100-77501
Use .......................................................................................................................................................... E/G starter
Applicable Machines ...................................................................................................... PH05-03501~,PJ04-03001~
6-81050 NA Issued 01-2006 Bur 24-67

24.2.2.8 RADIO (OPTIONAL)
Code No. ........................................................................................................................................................... E-10
Parts Name ....................................................................................................................................................... Tuner
Parts No. .......................................................................................................................................... PY54S00001P1
Use ........................................................................................................................................................ Radio (OPT)
Applicable Machines .......................... PW08-20001~, PX09-08001~, PW10-22001~, PX11-08901~,PX11-08901~,
PW11-30001~,PX12-11001~,PH05-03501~,PJ04-03001~
24.2.2.9 HEATER (OPTIONAL)
Code No. ........................................................................................................................................................... E-12
Parts Name ..................................................................................................................................................... Heater
Parts No. ......................................................................................................................................... PM21M00005F1
Use ..................................................................................................................................................... Heating (OPT)
Applicable Machines .....PW10-22001~, PX11-08901~, PW11-30001~, PX12-11001~,PH05-03501~,PJ04-03001~
24-68 Issued 01-2006 Bur 6-81050 NA

24.2.2.10 BATTERY
Code No. ............................................................................................................................................................ E-13
Parts Name .................................................................................................................................................... Battery
Parts No. ............................................................................................................................................. YJ2S00001P1
Use ...................................................................................................................................................... Power source
24.2.2.11 RELAY
Code No. ............................................................................................................................................................ E-14
Parts Name ....................................................................................................................................................... Relay
Parts No. .......................................................................................................................................... PA24S00002P3
Use .................................................................................................................................. Sequence (Holding circuit)
6-81050 NA Issued 01-2006 Bur 24-69

24.2.2.12 FUSE (OPTIONAL EQUIPMENT)
Code No. ........................................................................................................................................................... E-15
Parts Name ............................................................................................................................. Fuse box (For cooler)
Parts No. .......................................................................................................................................... PH73E00004F1
Use ......................................................................................................................................................... Fuse (OPT)
Applicable Machines ..... PW10-22001~, PX11-08901~, PW11-30001~, PX12-11001~,PH05-03501~,PJ04-03001~
24.2.2.13 TRAVEL ALARM
Code No. ........................................................................................................................................................... E-20
Parts Name ............................................................................................................... Travel alarm (Australia, China)
Parts No. ......................................................................................................................................... PW53S00002F1
Use .................................................................................................................................................... Warning sound
Applicable Machines .................................................................................................... PH05-03501~, PJ04-03001~
24-70 Issued 01-2006 Bur 6-81050 NA

24.2.2.14 HOUR METER
Code No. ............................................................................................................................................................ E-26
Parts Name .............................................................................................................................................. Hour meter
Parts No. .......................................................................................................................................... YT58S00006P1
Use ...................................................................................................................................................... Service meter
24.2.2.15 DOME LIGHT
Code No. ............................................................................................................................................................... L-1
Parts Name ........................................................................................................................................................ Light
Parts No. .......................................................................................................................................... PM80S00006P1
Use ....................................................................................................................................... Dome light (Cab Spec.)
6-81050 NA Issued 01-2006 Bur 24-71

24.2.2.16 BOOM WORKING LIGHT
Code No. .............................................................................................................................................................. L-2
Parts Name ........................................................................................................................................................ Light
Parts No. .......................................................................................................................................... PM80S00007F1
Use ................................................................................................................................... Boom working light (L.H.)
Applicable Machines ..... PW10-22001~,PX11-08901~, PW11-30001~, PX12-11001~,PH05-03501~,PJ04-03001~
24.2.2.17 CANOPY WORKING LIGHT
Code No. .............................................................................................................................................................. L-5
Parts Name ........................................................................................................................................................ Light
Parts No. ......................................................................................................................................... PW80S00003F1
Use .......................................................................................................................................... Canopy working light
24-72 Issued 01-2006 Bur 6-81050 NA

24.2.2.18 STARTER
Code No. .............................................................................................................................................................. M-1
Parts Name ....................................................................................................................................................... Motor
Parts No. ............................................................................................................................................. 129136-77011
Use .......................................................................................................................................................... E/G starter
6-81050 NA Issued 01-2006 Bur 24-73

24.2.2.19 WIPER MOTOR
Code No. ............................................................................................................................................................. M-2
Parts Name ....................................................................................................................................................... Motor
Parts No. .......................................................................................................................................... PM76S00001F1
Use .............................................................................................................................................. Wiper (Cab Spec.)
Applicable Machines ............. PM06-05601~, PV09-22001~, PW10-22001~, PX11-08901~, PW11-30001~, PX12-
11001~,PH05-03501~,PJ04-03001~
24.2.2.20 WINDSHIELD WASHER MOTOR
Code No. ............................................................................................................................................................. M-3
Parts Name ....................................................................................................................................................... Motor
Parts No. ...................................................................................................................................... PE54C00002S002
Use .............................................................................................................................. Window washer (Cab Spec.)
24-74 Issued 01-2006 Bur 6-81050 NA

24.2.2.21 DECELERATOR
Code No. .............................................................................................................................................................. M-4
Parts Name ....................................................................................................................................................... Motor
Parts No. .......................................................................................................................................... PH20S00008F1
Use ............................................................................................................................ Deceleration (EU NA Aust.)
Applicable Machines ..................................................................................................... PH05-03501~,PJ04-03001~
6-81050 NA Issued 01-2006 Bur 24-75

24.2.2.22 FUEL PUMP
Code No. ............................................................................................................................................................. M-6
Parts Name ............................................................................................................................................... Fuel pump
Parts No. ......................................................................................................................................... PW22P00001P1
Use ...................................................................................................................................................... Auto air bleed
24.2.2.23 BATTERY RELAY
Code No. .......................................................................................................................................................... R-1,7
Parts Name ....................................................................................................................................................... Relay
Parts No. .......................................................................................................................................... PH24S00001P1
Use ............................................................................................................................... Battery relay, E/G stop relay
24-76 Issued 01-2006 Bur 6-81050 NA

24.2.2.24 SAFETY RELAY

Code No. .............................................................................................................................................................. R-2
Parts Name ............................................................................................................................................. Safety relay
Parts No. .......................................................................................................................................... PX24S00001P1
Use ............................................................................................................................................ Protection of starter
24.2.2.25 DECELERATION RELAY, CHARGE INDICATOR RELAY, SLEW/SWING RELAY, ETC.

Code No. ....................................................................................................................................... R3, 8, 9,14,22~25
Parts Name ....................................................................................................................................................... Relay
Parts No. .......................................................................................................................................... PA24E01001P1
Use ...................................................................... Deceleration relay, Charge indicator relay, Slew/swing relay, etc.
6-81050 NA Issued 01-2006 Bur 24-77

24.2.2.26 DELAY TIMER RELAY

Code No. ............................................................................................................................................................. R-6
Parts Name ....................................................................................................................................................... Relay
Parts No. .......................................................................................................................................... PH25S00002P1
Use ........................................................................................................................................................... Timer Unit
PX12-11001~,PH05-03501~,PJ04-03001~
24.2.2.27 FUEL LEVEL SENDER

Code No. ........................................................................................................................................................... SE-1
Parts Name .................................................................................................................................................... Sensor
Parts No. .......................................................................................................................................... PX52S00006F1
Use ......................................................................................................................................................... Fuel sensor
24-78 Issued 01-2006 Bur 6-81050 NA
24.2.2.28 ENGINE TEMPERATURE SENDER

Code No. ............................................................................................................................................................ SE-2
Parts Name .................................................................................................................................................... Sensor
Parts No. .......................................................................................................................................... PA24S00003P1
Use .............................................................................................................................................. E/G thermo sensor
PX12-11001~,PH05-03501~,PJ04-03001~
24.2.2.29 SAFETY LEVER LOCK TRAVEL 2-SPEED SELECT SOLENOID

Code No. ......................................................................................................................................................... SV-1,2
Parts Name .................................................................................................................................................. Solenoid
Parts No. .......................................................................................................................................... PX35V00003F1
Use .............................................................................................................. Safety lever lock Travel 2-speed select
6-81050 NA Issued 01-2006 Bur 24-79

24.2.2.30 ENGINE STOP SOLENOID

Code No. ........................................................................................................................................................... SV-3
Parts No. ............................................................................................................................................. 119233-77932
Use .............................................................................................................................................................. E/G stop
24.2.2.31 POWER SHIFT SOLENOID

Code No. ........................................................................................................................................................... SV-5
Parts No. ........................................................................................................................................... YJ35V00004F2
Use .................................................................................................................................. Power shift (Air-con spec.)
24-80 Issued 01-2006 Bur 6-81050 NA

24.2.2.32 NIBBLER SOLENOID

Code No. ....................................................................................................................................................... SV-9,10
Parts No. .......................................................................................................................................... PY35V00005F1
Use .................................................................................... Nibbler open SOL., Nibbler close SOL. (North America)
Applicable Machines ..................................................... PW11–30001~, PX12-11001~,PH05-03501~,PJ04-03001~
24.2.2.33 SLEW/SWING SELECT SOLENOID

Code No. .......................................................................................................................................................... SV-12
Parts No. .......................................................................................................................................... PE35V00001F2
Use .................................................................................................................... Slew/Swing select (North America)
6-81050 NA Issued 01-2006 Bur 24-81

24.2.2.34 IGNITION SWITCH

Code No. .......................................................................................................................................................... SW-1
Parts Name ..................................................................................................................................................... Switch
Parts No. ...................................................................................................................................... PH50S00008S002
Use ........................................................................................................................................................... Key switch
24.2.2.35 LIGHT SWITCH

Code No. .......................................................................................................................................................... SW-2
Parts No. .......................................................................................................................................... PV24E01001P1
Use ....................................................................................................................................................... Working light
24-82 Issued 01-2006 Bur 6-81050 NA

24.2.2.36 TRAVEL 1 2 SPEED SWITCH

Code No. ........................................................................................................................................................... SW-3
Parts No. ....................................................................................................... YN03M01286S002 (Right travel lever)
Use ................................................................................................................................................ Travel 1, 2 speed
24.2.2.37 WINDSHIELD WASHER SWITCH

Code No. ........................................................................................................................................................... SW-4
Parts No. .......................................................................................................................................... PY50S00004P2
Use .................................................................................................................................... Wiper washer (Cab only)
6-81050 NA Issued 01-2006 Bur 24-83

24.2.2.38 ENGINE TEMPERATURE SWITCH

Code No. .......................................................................................................................................................... SW-5
Parts No. .......................................................................................................................................... PM50S00006P1
Use ....................................................................................................................................... E/G water temperature
Applicable Machines..... PW10-22001~, PX11-08901~, PW11-30001~, PX12-11001~,PH05-03501~,PJ04-03001~
24.2.2.39 ENGINE OIL PRESSURE SWITCH

Code No. .......................................................................................................................................................... SW-6
Parts No. ............................................................................................................................................. 114250-39450
Use .................................................................................................................................................. E/G oil pressure
24-84 Issued 01-2006 Bur 6-81050 NA

24.2.2.40 HORN SWITCH

Code No. ........................................................................................................................................................... SW-7
Parts No. .......................................................................................................................................... YN50E01001P1
Use ......................................................................................................................................................... Horn switch
24.2.2.41 LEVER LOCK SWITCH

Code No. ........................................................................................................................................................... SW-9
Parts No. .......................................................................................................................................... PA50S00001P1
Use .................................................................................................................................................... Lever lock SW.
6-81050 NA Issued 01-2006 Bur 24-85

24.2.2.42 HEATER SWITCH (OPTIONAL)

Code No. ........................................................................................................................................................ SW-10
Parts No. .......................................................................................................................................... PY50S00003P2
Use ........................................................................................................................................... Heater switch (OPT)
24.2.2.43 DECELERATION SWITCH

Code No. ......................................................................................................................................................... SW-11
Parts Name ...................................................................................................................................................... Switch
Parts No. ...........................................................................................................................................PM50S00005P1
Use ..............................................................................................................................................Deceleration switch
24-86 Issued 01-2006 Bur 6-81050 NA

24.2.2.44 TRAVEL ALARM SWITCH (OPT)

Code No. .......................................................................................................................................................... SW-23
Parts No. ............................................................................................................................................ 2479U1190F16
Use ...............................................................................................................................................Travel alarm (OPT)
Applicable Machines ..... PW10-22001~, PX11-08901~, PW11-30001~, PX12-11001~,PH05-03501~,PJ04-03001~
24.2.2.45 TRAVEL ALARM (AUSTRALIA) SLEW/SWING LEVER (NORTH AMERICA) SWITCH

Code No. .............................................................................................................................. SW-24, 25, 26, 27,30,31
Parts No. ........................................................................................................................................... GB50S00049F2
Use ................................................................................. Travel alarm (Australia) Slew/Swing lever (North America)
Applicable Machines ......................................................PW11-30001~, PX12-11001~,PH05-03501~,PJ04-03001~
6-81050 NA Issued 01-2006 Bur 24-87

24.2.2.46 NIBBLER OPEN SW., NIBBLER CLOSE SW.,

SLEW/SWING SELECT SW. (NORTH AMERICA) GRIP AND SWITCH

Code No. .............................................................................................................................................. SW-28, 33, 34
Parts Name........................................................................................................................................ Grip and Switch
Parts No............................................................................................................................................. LF03M01005F3
Use ................................................... Nibbler open SW., Nibbler close SW., Slew/Swing select SW. (North America)
Applicable Machines....................................................... PW11-30001~, PX12-11001~,PH05-03501~,PJ04-03001~
24-88 Issued 01-2006 Bur 6-81050 NA

E50
GENERAL DISASSEMBLY AND

ASSEMBLY
Issued January 2006

SECTION 3 - GENERAL DISASSEMBLY AND ASSEMBLY
Revision History
SECTION 3 - GENERAL DISASSEMBLY AND ASSEMBLY
SECTION 3
TABLE OF CONTENTS
CHAPTER 31
31.1 GENERAL DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-3
CHAPTER 32
ATTACHMENTS
32.1 REMOVING AND INSTALLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-3
32.2 DISASSEMBLING AND ASSEMBLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-13
CHAPTER 33
33.1 REMOVING AND INSTALLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-5
CHAPTER 34
TRAVEL SYSTEM
34.1 REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-3
6-81060 NA Issued 01-2006 Bur 0-I

NOTES
SECTION 3 - DISASSEMBLY AND ASSEMBLY
CHAPTER 31
E50
GENERAL DISASSEMBLY AND

ASSEMBLY
Issued January 2006

CHAPTER 31 - GENERAL DISASSEMBLY AND ASSEMBLY
Revision History
31-II Issued 01-2006 Bur 6-81070 NA

CHAPTER 31
TABLE OF CONTENTS
31.1 GENERAL DISASSEMBLY AND ASSEMBLY

31.1.1 Contents of General Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-3
31.1.2 Specification of Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-3
6-81070 NA Issued 01-2006 Bur 31-1

NOTES
31-2 Issued 01-2006 Bur 6-81070 NA

31.1 GENERAL DISASSEMBLY AND ASSEMBLY

31.1.1 CONTENTS OF GENERAL DISASSEMBLY AND ASSEMBLY
This chapter is consist of three sections as follows. 31.1.2 SPECIFICATION OF TIGHTENING
TORQUE
1. ATTACHMENT.......................Index No.: 32
Tightening torque is indicated as follows, for
Part I: Removing and Installing Assembly
example;
Pa r t I I : D i s a s s e m b l i n g a n d A s s e m b l i n g T=100Nm (73.8 lb. ft.)
Components
Tolerance is ± 10% unless otherwise specified.
1. Hydraulic cylinder • Refer Index No. 11 TOOLS for standard
2. Upper Slewing Structure tightening torque.
Index No.: 33
Pa r t I I : D i s a s s e m b l i n g a n d A s s e m b l i n g
Components
1. Hydraulic pump
2. Control Valve
3. Pilot Valve (ATT)
4. Pilot Valve (Travel)
5. Slewing Motor
6. Swivel Joint
2. TRAVEL SYSTEM..........................Index No.: 34
Pa r t I I : D i s a s s e m b l i n g a n d A s s e m b l i n g
Components
1. Travel Motor
6-81070 NA Issued 01-2006 Bur 31-3

NOTES
31-4 Issued 01-2006 Bur 6-81070 NA

CHAPTER 32
E50
ATTACHMENTS
Issued January 2006

CHAPTER 32 - ATTACHMENTS
Revision History
32-2 Issued 01-2006 Bur 6-81080 NA

CHAPTER 32
ATTACHMENTS
TABLE OF CONTENTS
32.1 REMOVING AND INSTALLING

32.1.1 Attachment Assembly and Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-3
32.1.2 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-4
32.1.2.1 Removal of Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-4
32.1.2.2 Installation of Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-5
32.1.3 Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-5
32.1.3.1 Removal of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-5
32.1.3.2 Installation of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-7
32.1.4 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-8
32.1.4.1 Removal of Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-8
32.1.4.2 Installation of Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-9
32.1.5 Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10
32.1.5.1 Preparation for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10
32.1.5.2 Removal of Swing Bracket and Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10
32.1.5.3 Installation of Swing Bracket and Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-11
32.1.6 Dozer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-12
32.1.6.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-12
32.1.6.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-12
32.2 DISASSEMBLING AND ASSEMBLING
32.2.1 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-13
32.2.1.1 Necessary Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-13
32.2.1.2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-13
32.2.1.3 Cylinder Construction (Example of Boom Cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-14
32.2.1.4 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-15
32.2.1.5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-18
32.2.1.6 Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-23
32.2.1.7 Jig List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-26
32.2.1.8 Possible Causes for Trouble and Remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-30
6-81080 NA Issued 01-2006 Bur 32-1

NOTES
32-2 Issued 01-2006 Bur 6-81080 NA


32.1.1 ATTACHMENT ASSEMBLY AND NAME
FIG. 32-1 ATTACHMENT NAME AND POSITION
6-81080 NA Issued 01-2006 Bur 32-3

32.1.2 BUCKET
32.1.2.1 REMOVAL OF BUCKET
1. Place the bucket on the ground so that the
bucket and arm connecting pins do not have
pressure on them.
2. Move the O-rings (3) toward the bucket bosses.
3. In order to remove pin (K) which links the arm
and bucket, remove the ring (2) and the pin (1)
with a punch and drive out pin (K).
• If the pin does not come off easily, the pin
has pressure on it.
• Do not damage the dust seal between the
arm and the bucket bosses.
4. Adjust the bucket so that pin (J) between the
bucket link and the bucket does not have
pressure on it.
5. Remove the ring (2) and pin (1) then drive out pin
(J).
6. Remove bucket assembly
Weight:
112 kg (247 lbs)
FIG. 32-3 ASSEMBLY OF PIN (SECTION A-A)
FIG. 32-2 TO PLACE BUCKET ON GROUND
32-4 Issued 01-2006 Bur 6-81080 NA

32.1.2.2 INSTALLATION OF BUCKET 32.1.3 ARM

Installation is performed in the reverse order of 32.1.3.1 REMOVAL OF ARM
removal, including the following: 1. Retract the bucket and arm cylinders, lower the
CAUTION: When aligning the pin position, boom to the ground.
do not put your finger in the pin holes in any 2. Shut off the engine and operate the control
circumstances, align them visually. levers several times to release the pressure in
circuits.
1. Clean the welded part of the structures, and
3.
check that there are no cracks on the parts.
4. Put the safety lock lever in the “Locked” position,
2. Check that the dust seal is not damaged, replace
depress the air breather on the hydraulic oil tank
as needed.
to release the pressure in the tank.
3. Inspect pins and bushings according to the
5. Disconnect the hoses connected to the bucket
Section “ATTACHMENT DIMENSIONS” and
cylinder. Plug the openings.
“SPECIFICATIONS”.
4. When inserting the pin, coat the shaft with : 27mm
grease.
6. Lift up the arm cylinder with a sling in order to
• The bucket can be mounted easily if the
release any load to the pin (E).
bucket link is installed first.
7. Remove the capscrew and nuts securing pin (E).
Remove the pin (E) and shims.
: 19mm
8. Placing a wooden block under the arm cylinder,
let the cylinder down.
9. Install the pin (E) and capscrew and nuts that
secure pin (E). Attach lifting equipment to pin (E)
and the arm tip, slightly lift up in order to relieve
any load to the pin (F).
FIG. 32-4 INSTALLATION OF BUCKET
FIG. 32-5 ARM REMOVING POSTURE
6-81080 NA Issued 01-2006 Bur 32-5

12. Removal of Bucket Cylinder

1. Remove the capscrew from pin (H), remove
pin (H).
: 24mm
2. Remove the capscrew and nuts from pin (G),
remove pin (G).
: 17mm
3. Attach suitable lifting equipment to the bucket
cylinder, and remove the cylinder.
Weight; approx. 27kg (60 lbs)
FIG. 32-6 SECTIONAL VIEW OF INSTALLING PIN
10. Remove the capscrew from pin (F), remove pin
(F).
: 36mm SPW32000008E01 Figure 8

11. Remove the arm assembly. FIG. 32-8 SECTIONAL VIEW OF INSTALLING PIN
Weight of arm assembly: approx.
180kg (397 lbs)
FIG. 32-7 REMOVAL OF ARM ASSEMBLY
32-6 Issued 01-2006 Bur 6-81080 NA

32.1.3.2 INSTALLATION OF ARM

Installation is performed in the reverse order of 6. Refer to Fig. 32-10 for capscrew nut installation,
removal, including the following. also see procedures for checking for bushing
clearance.
CAUTION: When aligning the pin position,
do not put your finger in the pin holes in any 7. For the adjustment of clearance, insert plastic
circumstances, align them visually. shim first, then adjust the clearance with steel
shims.
2. Check the dust seal for damages, replace as
needed (referring to Fig. 32-9 for the installing
procedures).
4. Before installing the pin, apply grease to the
shaft area.
5. Referring to Fig. 32-10, install the capscrew and
nuts to secure the pin.
: 19mm, 24mm, 36mm FIG. 32-9 DUST SEAL INSTALLATION
6-81080 NA Issued 01-2006 Bur 32-7

32.1.4 BOOM 5. Removal of Boom assembly

32.1.4.1 REMOVAL OF BOOM 1. Attach lifting equipment to the boom.
1. Lower the boom and support the boom end with 2. Lift the boom assembly in order to relieve any
a suitable stand. load on the boom foot pin (A).
2. Disconnect all hoses from the bucket cylinder, Weight of boom assembly: approx
arm cylinder and boom cylinder, install plugs in 240 kg (529 lbs)
all the openings.
3. Removing the capscrew that secures pin (A),
: 27mm remove the pin (A).
3. Disconnect the wiring for working light at the 4. Remove the boom assembly.
connector.
4. Removal of Boom Cylinder
1. Lift up the boom cylinder with a nylon sling to
prevent the boom cylinder from falling.
2. Removing the capscrew and nuts that secure
pin (C), remove pin (C).
: 19mm
FIG. 32-13 REMOVAL OF BOOM ASSEMBLY
6. Removal the Arm Cylinder
1. Removing the capscrew and nuts that secure
pin (D), remove pin (D).
: 19mm
2. Attach a sling to the tube of the arm cylinder,
SPW32000011J01 Figure 11 remove the arm cylinder.
FIG. 32-11 REMOVAL OF BOOM CYLINDER Weight:
3. Retract the rod, then put the cylinder on a 49 kg (108 lbs)
stable stand.
4. Removing the capscrew that secures pin (B),
remove the pin (B).
5. Remove the boom cylinder.
Weight:
57 kg (126 lbs)
32-8 Issued 01-2006 Bur 6-81080 NA

32.1.4.2 INSTALLATION OF BOOM

Installation is performed in the reverse order of 6. Refer to Fig. 32-16 for capscrew nut installation,
removal, including the following. also see procedures for checking for bushing
clearance.
CAUTION: When aligning the pin position,
do not put your finger in the pin holes in any 7. For the adjustment of clearance, insert plastic
circumstances, align them visually. shim first, then adjust the clearance with steel
shims.
2. Check the dust seals for damage, replace as
needed (referring to Fig. 32-15 for installing
procedures).
4. Before inserting the pin, apply grease to the
shaft.
5. Referring to Fig. 32-16, install the capscrew and
nuts that secure the pin.
: 19mm FIG. 32-15 DUST SEAL INSTALLATION
6-81080 NA Issued 01-2006 Bur 32-9

32.1.5 SWING 3. Removing two capscrews (B8) (B9) securing

32.1.5.1 PREPARATION FOR REMOVAL pins (L1) (L2), remove pins (L1) (L2).
1. To make the removal easier, swing the boom : 19mm

around 30 degrees to the left.
2. Disconnect the hoses of bucket cylinder, arm
cylinder and boom cylinder, and install plugs in
all the openings.
: 27mm
32.1.5.2 REMOVAL OF SWING BRACKET AND
CYLINDER
1. Removal of swing bracket (A9)
1. Remove the capscrew (C4) securing pin (M)
in swing cylinder (C11), remove the pin.
: 19mm
FIG. 32-17 SWING PORTION
4. Remove the swing bracket (A9).
Weight of Swing Bracket:
112 kg (247 lbs).
2. Removal of Swing Cylinder (C11)
1. Disconnect hoses for the swing cylinder,
install plugs in the openings.
: 22mm
2. Attach lifting equipment to the swing cylinder.
3. Removing the capscrew (C5) securing pin
(N), remove pin.
: 19mm
4. Remove the swing cylinder (C11) from the
2. Install the boom foot pin (A) in the swing
front side.
bracket (A9), then lift it up.
Weight of Swing Cylinder:
39 kg (86 lbs)
32-10 Issued 01-2006 Bur 6-81080 NA

32.1.5.3 INSTALLATION OF SWING BRACKET AND CYLINDER

Installation is performed in the reverse order of 3. Before inserting the pin, apply grease to the
removal, including the following. shaft.
1. Check the dust seal for damages, and replace as 4. Refer to Fig. 32-18 for capscrew nut installation,
needed. also see procedures for checking for bushing
2. Inspect pins and bushings according to the clearance.
FIG. 32-18 SECTIONAL VIEW OF PIN INSTALLING
6-81080 NA Issued 01-2006 Bur 32-11

32.1.6 DOZER
32.1.6.1 REMOVAL
1. Put a support under the mounting side of dozer 32.1.6.2 INSTALLATION
and stabilize to relieve any load to the pin (P). Installation is the reverse of removal, paying
attention to the following.
2. Before installing pins (P), (Q) and (R), apply
grease to their shaft areas.
3. Referring to Fig. 32-20 for installation of the nuts
for the capscrews that secure the pins.
: 19mm
FIG. 32-19 REMOVING/INSTALLING DOZER
2. Disconnect the hydraulic hoses and install plugs
in the openings.
: 22mm
3. Attach a nylon sling to the dozer cylinder (C1), lift
it up slightly to relieve any load on pin (Q).
4. Support the cylinder (C1) with a wood block.
5. Remove the capscrew (C3) and nuts (C4)
securing pin (Q), remove the pin. SPW32000022E01 Figure 22
FIG. 32-20 TIGHTENING PROCEDURES FOR NUTS
: 19mm
6. Remove the capscrew (B2) and nuts (B3)
securing both pins (P), remove the both pins.
7. Gradually move the machine to backward away
from the dozer.
Weight of dozer assembly:
175 kg (386 lbs)
8. If necessary, remove the dozer cylinder by
removing pin (R).
Weight of dozer cylinder:
27 kg (60 lbs)
32-12 Issued 01-2006 Bur 6-81080 NA


32.2.1 CYLINDER
32.2.1.1 NECESSARY TOOLS
Though the required tools and jigs differ for 32.2.1.2 GENERAL PRECAUTIONS
different types of cylinders, as a guideline, tools • During disassembly and assembly keep work
and jigs to be prepared are shown in Table 32-1. area clean, and always keep disassembled
Table 32-1 List of Tools and Jigs parts clean.
• Prior to disassembly, thoroughly clean the
Tool/Jig Remarks cylinder externally.
1.Steel hammer • Use caution not to damage parts during
Hammer
2.Wooden or plastic hammer disassembly / assembly.
Screwdriver Several kinds of small and large sizes • Apply a thin layer of grease or hydraulic oil to
Chisel Flat chisel
seals prior to installation.
• After the installation of O-ring, make sure they
Capable to hold outer dia. of cylinder
Vise are not twisted.
head and tube installing pin portion.
• Apply clean hydraulic oil to each sliding portion
1.Special wrench before installation.
Wrench
2.Extension pipe for wrench • Make sure each sliding part is free of burrs and
A sharp-point tool may be used in place of defects and operates smoothly.
Gimlet
gimlet • This manual describes the boom cylinder as a
1.For installing seal ring typical example.
2.For pushing seal ring into groove Refer to 24.1.8 of COMPONENT SYSTEM
Jig for the sectional view of hydraulic cylinders
3.For reforming seal ring
4.For pressing bushing
when disassembling and reassembling the
cylinders.
1.Slide calipers
Measuring 2.Micrometer
Device 3.Cylinder gauge
4.V-block
• For the details of special jigs, refer to 32.2.1.7 of

this section.
6-81080 NA Issued 01-2006 Bur 32-13

32.2.1.3 CYLINDER CONSTRUCTION (EXAMPLE OF BOOM CYLINDER)

NOTE: See 24.1.8 for other cylinders.
FIG. 32-21 CONSTRUCTION OF BOOM CYLINDER
No. NAME Q’TY No. NAME Q’TY No. NAME Q’TY

1 Tube assembly 1 9 Lock nut 1 17 Dust seal 1
2 Rod assembly 2 10 Wear ring 1 18 O-ring 2
3 Bushing 1 11 Seal ring 1 19 Back-up ring 3
4 Cylinder Head 1 12 Seal ring 1 20 O-ring 1
5 Cushion bearing 1 13 Ring 1 21 Dust seal 4
6 Piston 1 14 Rod bushing 1 22 Bolt 2
7 Pipe 1 15 Seal ring 1
8 Pipe 2 16 Back-up ring 1
32-14 Issued 01-2006 Bur 6-81080 NA

32.2.1.4 DISASSEMBLY 4. Loosen the cylinder head (4).

• Prior to loosening the cylinder head, pull out
NOTE: The numbers in () following each part name
the piston rod (2) by 100 ~ 200 mm (4 ~ 8
are the Items corresponding to those in Fig. 32-21
in).
unless otherwise noted.
1. Disassembly of cylinder
1. Secure the clevis portion of tube in a vice,
support the other end with a wooden stand to
hold the cylinder level.
2. Drain the hydraulic oil from the cylinder.
• Slowly move the piston rod in and out.
FIG. 32-24 DISASSEMBLING CYLINDER HEAD
5. Pull the piston rod assembly from the tube.

• Pull the piston rod straight out to prevent
damage to the sliding surface.
2. Disassembly of piston rod assembly
1. Clamp the piston rod end in a vise, support
SPW32000024J01 Figure 24 the piston end with a wooden block to hold
FIG. 32-22 DISASSEMBLING CYLINDER ASSEMBLY the rod level.
3. Straighten the locking fin for the cylinder head
(4).
• Use caution bending or straightening the
locking fin, the locking fin and cylinder tube
are one piece.
FIG. 32-25 DISASSEMBLING PISTON ROD
FIG. 32-23 DISASSEMBLING CYLINDER ASSEMBLY
6-81080 NA Issued 01-2006 Bur 32-15

2. Disassembly of the piston 4. Remove piston (6).

A. Remove ring (25) using snap ring pliers,
and remove plate ring (24) and cushion
ring (23). (Only for arm cylinder)
5. Remove the cushion bearing (5). (Boom
and Arm cylinder only)
B. Remove cushion bearing before loosening
lock nut (9).
6. Remove the seal ring (12). (Boom and
Arm cylinder only)
• Expand the split on the seal ring to remove.
3. Remove lock nut (9)
32-16 Issued 01-2006 Bur 6-81080 NA

7. Remove the cylinder head (4). 2. Removal of seal ring

Remove the seal ring (15) and back up ring
(16).
3. Disassembly of piston assembly:
1. Remove the slide ring (10) from the piston
FIG. 32-28 DISASSEMBLING CYLINDER HEAD
(6).
• Expand the split on the slide ring (10) just 3. Remove the dust seal (17).
enough to remove it. • Alternately tap the inside of the metal ring of
wiper ring in several different positions, as
shown.
FIG. 32-26 DISASSEMBLING PISTON ASSEMBLY
2. Remove the seal ring assembly (11).
3. Cut off the seal ring (11) or remove it using a SPW32000035J01 Figure 38
screw driver.
FIG. 32-29 REMOVING DUST SEAL
4. Disassembly of cylinder head assembly: 4. Remove the bushing (13) using a removal jig.
1. Remove the O-rings (18) and (20) and back-
up ring (19) from the outer peripher y of
cylinder head (4).
FIG. 32-30 REMOVING BUSHING
FIG. 32-27 DISASSEMBLING CYLINDER HEAD ASSEMBLY
6-81080 NA Issued 01-2006 Bur 32-17

5. Disassembly of clevis portion: 32.2.1.5 ASSEMBLY

1. Remove the dust seal (21) from the clevis 1. Assembling Clevis Portion
portion of tube (1) and piston rod (2). 1. With the installation jig (B), press the
bushings (3) into the piston rod (2) and tube
(1).
• Apply hydraulic oil to the surface of the
parts.
FIG. 32-31 REMOVING DUST SEAL
2. Remove the pin bushing (3).
• Using a metal block, push out the bushing
with a press. SPH32000033J01 Figure 42
FIG. 32-33 INSTALLING PIN BUSHING (2)
2. With the setting tool, install the dust seal (21).
FIG. 32-32 REMOVING PIN BUSHING SPW32000040E01 Figure 43
FIG. 32-34 INSTALLING DUST SEAL
32-18 Issued 01-2006 Bur 6-81080 NA

2. Assembling Cylinder Head 4. Using the setting tool, install the wiper ring
1. With installation jig (A), press in the bushing (17).
(14).
• Apply hydraulic oil on inner periphery of the
cylinder head (4).
• Press fit the bushing (14) into the cylinder
head (4) until the top surfaces are level.
FIG. 32-38 INSTALLING WIPER RING
FIG. 32-35 ASSEMBLING CYLINDER HEAD
2. Install the back-up ring (19) and O-rings (18
and 20).
FIG. 32-36 INSTALLING BACK-UP RING AND O-RING
3. Installing seal
Install the backup ring (19) and seal (15).
FIG. 32-37 INSTALLING U-RING
6-81080 NA Issued 01-2006 Bur 32-19

3. Assembly of piston portion: 4. Piston rod assembly:

1. Install the O-ring for the seal ring assembly 1. Clamp the piston rod end in a vise, support
(11). the piston end with a wooden block to hold
the rod level.
• Apply hydraulic oil to the seal.
2. Install the wear ring (10). SPH32000012E01 Figure 51
• Expand the split on the slide ring (10) as 2. Face the slit of seal ring (12) to the thread,
little as required to install it. and install the seal ring into groove of piston
rod.
3. Since the seal ring is stretched during 3. Install the cushion bearing (5) on the rod from
installation, reform it with jig (D). taper side as shown in the photo.
• Make sure the direction of seal ring and
cushion bearing are correct, if installed
incorrectly the cushion effect will not be
obtained
32-20 Issued 01-2006 Bur 6-81080 NA

4. Install the piston sub-assembly and lock nut 6. Install the cushion (23) on rod retracting side,
(9). plate ring (24) and snap ring (25).
• Insert the piston from the flat side of piston (Arm cylinder only)
bore • Place the flat portion (2 places) of cushion
bearing (23) in the direction shown in the
photo.
• Confirm that the cushion bearing is movable
after installing the snap ring (25).
5. Tighten the lock nut (9) with torque wrench.
• Torque lock nut:
See Table 32-2, page 32-23. SPH32000017E01 Figure 56
5. Assembly of cylinder:
1. Clamp the cylinder tube clevis end in a vise,
support the open end with a wooden block to
hold it level.
• Align the center of piston rod to the center of
tube and install the piston rod in straight, do
not damage seals.
FIG. 32-39 INSERTING PISTON ROD ASSEMBLY
6-81080 NA Issued 01-2006 Bur 32-21

6. Install the cylinder head (4). 2. Bend the locking fin on the tube to lock the
• Apply hydraulic oil on the packings (seals) cylinder head.
prior to installation.
• Tightening torque for cylinder head: See
Table 32-2, page 32-23.
FIG. 32-41 ASSEMBLING CYLINDER ASSEMBLY
FIG. 32-40 INSTALLING CYLINDER HEAD
32-22 Issued 01-2006 Bur 6-81080 NA

32.2.1.6 MAINTENANCE STANDARDS

32.2.1.6.1 INSPECTION AFTER DISASSEMBLY
1. Inspection item
TABLE 32-2
Parts Name Inspecting Portion Inspection Item Remedy

1. Neck of rod Presence of crack Replace
2. Stepped part to which
Presence of crack Replace
piston is attached
3. Threads Presence of seizure, etc. Recondition or replace
4. Bend Measure amount of bend Refer to Rod Bend
Piston rod
1.Wearing off of plating 1.Replace
5. Plated surface 2.Rust on plating 2.Replace
3.Presence of defect 3.Recondition or replace
6. Rod Wear of outside Recondition or replace
7. Bushing at mounting part Wear of inside Replace
1. Welded part of bottom Presence of crack Replace
2. Tube at mounting part Presence of crack Replace
Cylinder tube
3. Tube inside Presence of defect Replace if oil leak is seen
4. Bushing at mounting part Wear of inside Replace
1.Wear of inside
Cylinder head 1.Bushing Replace
2.Defect of inside
2. Repair procedure Replace sliding parts and seal parts according to the
following procedures.
1 Bushing Where 1/4 of circumference is worn in copper color.
2 Seals and slide rings Replace them when cylinder is disassembled.
3 Pin bushing Where severe scuffing is appeared.
4 Piston rod When a bend of 0.5 mm/m (0.02 in/3.3 ft.) or more is apparent.
3. Torque specifications
4. Service limits
Unit: Nm (lb. ft.)
Cylinder Cylinder head A Piston B Service limits represent the limits of wear on the
sliding surfaces of the cylinder tube and the
Boom 650 (480) 1860 (1370)
piston.
Arm 550 (406) 1500 (1110)
1. Clearance between piston rod and rod
Bucket 390 (288) 830 (612)
bushing:
Swing 550 (406) 1520 (1120)
Replace the bushing if the clearance between
Dozer 600 (443) 1520 (1120)
the piston rod and the rod bushing exceeds
0.25 mm (0.01 in).
2. Bend of piston rod:
6-81080 NA Issued 01-2006 Bur 32-23

The allowable bend of the rod is maximum 6. Leakage test

0 . 5 m m / 1 m ( 0 . 0 2 i n / 3 . 3 f t . ) . Fo r • External leakage
measurement, suppor t both ends of the A. Apply test pressure for 3 minutes each to
parallel section of the piston rod with V- the rod retraction side and to the rod
blocks, set a dial indicator in the center extension side of the cylinder.
between the two V-blocks turn the piston rod,
a n d r e a d t h e d i f fe r e n c e b e t w e e n t h e B. Confirm that rod seals, cylinder head and
maximum and minimum values on the dial welds are free from abnormalities, such
indicator. as exter nal leakage and per manent
• Even if the bend is within the allowable limit, deformation.
the cylinder may not operate smoothly • Internal leakage
because of localized bend. Look for this A. Disconnect the hose from the rod
during function test after installation. extension side of the cylinder.
Replace the rod if the cylinder makes a B. Apply test pressure to the rod retraction
squeaking noise or does not operate side of the cylinder for 3 minutes.
smoothly. C. Measure the leakage from the rod
extension side.
• Leakage should be below 1 cc (0.06 cu in) /
3 min.
FIG. 32-52 MEASURING METHOD
5. Inspection after installation
1. Unloaded performance test SPW32000059E01 Figure 63
FIG. 32-54 LEAKAGE TEST
A. Put the cylinder horizontally at unloaded
condition.
B. Apply pressure slowly and alternately
through the ports at both ends to operate
the piston rod 5 or 6 times.
C. Check that the cylinder operates normally.
FIG. 32-53 UNLOADED TEST
32-24 Issued 01-2006 Bur 6-81080 NA

7. Bleeding air from hydraulic cylinder 2. Repeat the step of extending and retracting
Bleed air from the cylinder after removing or the cylinder 4 or 5 times at slow speed of
installing it, or after disconnecting a hydraulic engine.
pipe. • Move the piston rod 100 mm (4 in) short of
its stroke end.
1. Start the engine and let it idle for about 5
minutes. 3. Repeat step 2 procedures at high idle, then
move the piston rod to stroke end at low idle
to open the pressure relief valve.
6-81080 NA Issued 01-2006 Bur 32-25

32.2.1.7 JIG LIST

32.2.1.7.1 INSTALLATION JIG (A) FOR PRESS FITTING ROD BUSHING.
32-26 Issued 01-2006 Bur 6-81080 NA

32.2.1.7.2 INSTALLATION JIG (B) FOR PRESS FITTING PIN BUSHING.
32.2.1.7.3 REFORMING JIG (D) FOR SEAL RING
6-81080 NA Issued 01-2006 Bur 32-27

32.2.1.7.4 INSTALLING JIG (C) FOR PRESS FITTING DUST SEAL RING
32-28 Issued 01-2006 Bur 6-81080 NA

32.2.1.8 POSSIBLE CAUSES FOR TROUBLE AND REMEDY
Trouble Conditions Major Possible Causes Remedy

Foreign matter is caught by U-ring or wiper ring at
Remove foreign matter.
its inside periphery.
Scuffing or fault on U-ring or wiper ring at its inside
Replace each part with new one.
periphery.
Grind sliding face with a fine oil stone. (less
Oil leakage from piston rod
than 1.6S)
seal.
If leakage is not stopped by grinding,
Scuffing on sliding face of piston rod.
replace seals such as U-ring, etc.
If leakage is not stopped by replacing
seals, replace piston rod.
Peeling off of hard chrome plating. Re-plating of hard chrome on piston rod.
Oil leakage from outer Damages on O-ring. Replace.
periphery of cylinder head. Damages on back-up ring. Replace.
Oil leakage from welded
Damages on welded portion on tube. Replace.
portion.
Piston movement due to Foreign matter is caught by sliding face of slide
Remove foreign matter.
leakage. ring.
(A static load that is equivalent Scuffing or faulty condition on sliding face of slide
to max. working pressure, Replace.
ring.
movement of piston is greater Scuffing on sliding face of seal ring assembly. Replace.
than 0.5mm (0.02 in)) per 10
minutes. Damages on O-ring. Replace.
6-81080 NA Issued 01-2006 Bur 32-29

32-30 Issued 01-2006 Bur 6-81080 NA

CHAPTER 33
E50
Issued January 2006

CHAPTER 33 - UPPER SLEWING STRUCTURE
Revision History
33-II Issued 01-2006 Bur 6-81090 NA

CHAPTER 33
TABLE OF CONTENTS

33.1.1 CANOPY / CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-5
33.1.1.1 Canopy Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-5
33.1.1.2 Cab Removal (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-6
33.1.1.2.1 Cab Removal Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-6
33.1.1.2.2 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-6
33.1.2 GUARD (COVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-8
33.1.2.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-8
33.1.2.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-9
33.1.3 FLOOR PLATE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-10
33.1.3.1 Floor Plate Removal Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-10
33.1.3.2 Floor Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-11
33.1.3.3 Installing Floor Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-11
33.1.4 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-12
33.1.4.1 Removal Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-12
33.1.4.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-12
33.1.4.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-12
33.1.5 COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-13
33.1.5.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-13
33.1.5.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-13
33.1.6 PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-14
33.1.6.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-14
33.1.6.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-15
33.1.7 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-16
33.1.7.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-16
33.1.7.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-18
33.1.8 SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-19
33.1.8.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-19
33.1.8.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-19
33.1.9 Pattern Change CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-20
33.1.9.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-20
33.1.9.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-20
33.1.10 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-21
33.1.10.1 Removal Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-21
33.1.10.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-21
33.1.10.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-22
33.1.11 HYDRAULIC Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-22
33.1.11.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-23
33.1.11.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-24
33.1.12 AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-25
33.1.12.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-25
33.1.12.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-25
33.1.13 GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-26
33.1.13.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-26
6-81090 NA Issued 01-2006 Bur 33-1
33.1.13.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-26

33.1.14 MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-27
33.1.14.1 Removal Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-27
33.1.14.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-27
33.1.14.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-27
33.1.15 CONTROL STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-28
33.1.15.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-28
33.1.15.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-33
33.1.16 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-34
33.1.16.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-34
33.1.16.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-34
33.1.17 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-35
33.1.17.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-35
33.1.17.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-36
33.1.18 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-37
33.1.18.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-37
33.1.18.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-37
33.1.19 PILOT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-39
33.1.19.1 Preparation For Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-39
33.1.19.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-39
33.1.19.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-39
33.1.20 SLEWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-40
33.1.20.2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-40
33.1.20.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-41
33.1.21 SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-42
33.1.21.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-42
33.1.21.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-44
33.1.22 UPPER FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-45
33.1.22.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-45
33.1.22.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-46
33.2.1 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-47
33.2.1.1 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-47
33.2.1.2 Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-48
33.2.1.2.1 Tools and Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-48
33.2.1.3 Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-65
33.2.2 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-66
33.2.2.1 Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-66
33.2.2.2 Precautions For Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-69
33.2.2.3 Required Tools and Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-69
33.2.2.4 Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-70
33.2.2.5 Precautions When Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-75
33.2.2.6 Precautions When Installing Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-75
33.2.2.7 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-75
33.2.2.8 Maintenance standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-78
33.2.2.9 Cause of failure and corrective action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-79
33.2.3 PILOT VALVE (Attachment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-81
33.2.3.1 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-81
33.2.3.2 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-82
33-2 Issued 01-2006 Bur 6-81090 NA

33.2.3.3 Disassembling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-82

33.2.3.3.1 General cautions for disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-82
33.2.3.3.2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-82
33.2.3.4 Assembling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-85
33.2.3.4.1 General cautions for assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-85
33.2.3.5 Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-88
33.2.3.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-88
33.2.4 PILOT VALVE (TRAVEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-89
33.2.4.1 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-89
33.2.4.2 Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-90
33.2.4.3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-91
33.2.4.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-92
33.2.5 SLEWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-93
33.2.5.1 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-93
33.2.5.2 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-94
33.2.6 SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-113
33.2.6.1 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-113
33.2.6.2 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-114
33.2.6.2.1 General precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-114
33.2.6.2.2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-114
33.2.6.2.3 Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-115
33.2.6.3 Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-116
33.2.6.3.1 Check Procedures and Remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-116
33.2.6.3.2 Parts Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-116
33.2.6.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-118
6-81090 NA Issued 01-2006 Bur 33-3

NOTES
33-4 Issued 01-2006 Bur 6-81090 NA


33.1.1 CANOPY / CAB
33.1.1.1 CANOPY REMOVAL
4. Removing canopy assembly
1. Disconnect the light harness (B1) that runs
inside the support (A1).
2. Loosen one capscrew M10x40 (A8) and four
capscrews M14x55 (A7) to remove the
canopy.
: 17 mm and 22 mm
3. Canopy weight: 120 kg (265 lbs)
5. Install the canopy in reverse order of the removal.
Tighten the capscrews at the torque specified
SPW33000001J01 Figure 1 below:
FIG. 33-1 FLOOR MAT REMOVAL M10: T=46Nm (34 lb ft)
1. Remove the floor mats (5) and (8).
M14: T=125 Nm (92 lb ft)
M16: T=191 Nm (141 lb ft)
FIG. 33-2 REMOVAL OF CANOPY ASSEMBLY AND HANDRAIL
2. Removing handrail (A3)
3. Loosen the sems-bolt M16x65 (A4) and
M16× 100 (A5) to remove the handrail (A3).
: 24 mm
6-81090 NA Issued 01-2006 Bur 33-5

33.1.1.2 CAB REMOVAL (OPTION)

33.1.1.2.1 CAB REMOVAL PREPARATION 4. Removing cab mounting screws. Loosen six
capscrews for mounting the cab.
Two capscrews (1) M16× 100
One capscrew (2) M16× 50
Two capscrews (3) M12× 50
One capscrew (24) M12× 40
: 19 mm and 24 mm
FIG. 33-3 FLOOR MAT REMOVAL • An extension tool about 1 m (36.4") long is
1. Remove the floor mats (6) and (7). required for removing the capscrew item 1
2. Removing cab harness connector (with mark *).
• Disconnect connectors of cab harness and cab
connecting harness. (See ELECTRICAL
SYSTEM)
33.1.1.2.2 CAB REMOVAL
FIG. 33-5 CAB ASSEMBLY FASTENING POSITIONS
FIG. 33-6 SEAT BELT ASSEMBLY REMOVAL
5. Lifting cab
1. Loosen the sems-bolt M10× 20 (C6) to
remove the seat belt assembly (C2) in
SPH33000152E01 Figure 4 advance to prevent it from interfering with the
FIG. 33-4 OUTSIDE OF CAB
cab during lifting.
1. Remove the fuel filler cap (A2) and rubber cover : 17 mm
(20).
2. Put slings through the lifting eyes on the cab
2. To removing cover installed on rear of cab, top and lift up
loosen three sems-bolt M6× 25 (12)
Cab weight: 250 kg (550 lbs)
3. : Cross tip screwdriver
33-6 Issued 01-2006 Bur 6-81090 NA

33.1.1.2.3 INSTALLING CAB

Install the cab in reverse order of the removal.
• Capscrew (24), it will be necessary to adjust
the clearance with shims as shown in Fig.
33-5.
Tighten screws to the torque specified below.
M6: T=4.4 Nm (3.3 lb ft)
M10: T=46 Nm (34 lb ft)
M12: T=79 Nm (59 lb ft)
M16: T=191 Nm (141 lb ft)
6-81090 NA Issued 01-2006 Bur 33-7

33.1.2 GUARD (COVER)

33.1.2.1 REMOVAL
FIG. 33-9 COVER ASSEMBLY (5) REMOVAL
2. Removing cover assembly (5)
Loosen three M8× 25 sems-bolts (33) to remove
the cover assembly (5).
SPH33000153J01 Figure 7 : 13 mm
FIG. 33-7 COVER REMOVAL
• Fig. 33-7shows the cover of the canopy.
FIG. 33-10 COVER ASSEMBLY (1) REMOVAL
1. Unlock the cover (1-8) to open the cover
assembly (1).
FIG. 33-8 HOOD ASSEMBLY (3) REMOVAL
2. Loosen four capscrews M16x50 (30) to
1. Removing hood assembly (3) remove the cover assembly (1).
Unlock and open the hood assembly (3). Loosen
two capscrews M12× 35 (35) at the hinge section : 24mm
(3-9) to remove the hood (3).
: 19 mm
33-8 Issued 01-2006 Bur 6-81090 NA

33.1.2.2 INSTALLATION
Install the above assemblies in reverse order of the
removal.
Tighten the capscrews to the torque specified
below:
M8: T=24 Nm (18 lb ft)
M10: T=46 Nm (34 lb ft)
M12: T=79 Nm (59 lb ft)
M16: T=191 Nm (141 lb ft)
SPH33000156J01 & SPH33000157J01 Figure 11

FIG. 33-11 COVER ASSEMBLIES (2) AND (4) REMOVAL
the cover assembly (2).
: 17 mm
Loosen two M10× 25 sems-bolts (37) and two
M14x30 (4) to remove the cover assembly (4).
: 17 mm
6. Removing guard assembly (6) (See fig. 33-7)
Loosen two sems-bolts (35) M12x35 and three
sems-bolts (40) M10x20 and remove the guard.
: 17 mm, 19 mm
7. Removing cover assembly (9) (See fig. 33-7)
Loosen one sems-bolts (40) M12x20 and remove
the cover.
: 17 mm
6-81090 NA Issued 01-2006 Bur 33-9

33.1.3 FLOOR PLATE ASSEMBLY

Remove floor plate together with the travel pilot valve
assembly and the swing pedal in one piece.
33.1.3.1 FLOOR PLATE REMOVAL
PREPARATION
NOTE: Disconnect the negative terminal of the
battery to prevent a short circuit.
FIG. 33-13 PILOT PIPING DISCONNECTION
SPW33000332E01 Figure 12 6. Release the pressure in the hydraulic system,
FIG. 33-12 COVER ASSEMBLY (2) REMOVAL removing travel pilot hoses.
1. Remove the floor mats (5) and (8). (See Section Disconnect hoses of the travel pilot valve (A10)
33.1.1.) at the valve side position marked with * and then
2. Remove the canopy or cab. (See Section 33.1.1.) plug the openings.
• Attach a tag recording the valve connecting
3. Remove the covers (2) and (4) as well as the port to each of the disconnected hoses. For
plates (3). installation, tighten the hose fittings at the
following torque:
: 13 mm
4. Remove the cover assembly (5) of the deck
under the floor [See Section 33.1.2.1-(4)].
5. Disconnect wiring for travel 2-speed selector
switch.
If machine is equipped with a travel alarm, SPW33000080E01 Figure 14
disconnect the connectors of the four pressure
switches on travel pilot valve. NOTE: Do not over torque, the pilot valve is made of
aluminum.
33-10 Issued 01-2006 Bur 6-81090 NA

33.1.3.2 FLOOR PLATE REMOVAL
FIG. 33-14 PILOT PIPING REMOVAL SPW33000016E01 Figure 17
7. Release the pressure in the hydraulic system, FIG. 33-15 FLOOR PLATE (1) REMOVAL
remove N&B solenoid hoses. 1. Remove the M8× 20 sems-bolt (6).
Disconnect hoses of the N&B solenoid valve (B5)
and then plug the openings. : 13 mm
• Attach a tag recording the valve connecting 2. Remove the floor plate assembly (1).
port to each of the disconnected hoses. For
installation, tighten the hose fittings to the 33.1.3.3 INSTALLING FLOOR PLATE
following torque: 1. Assemble the floor plate in reverse order of the
removal.
Sems-bolt (6) M8:
: 13 mm
Tightening torque: 23.5 Nm (17 lb ft)
NOTE: Do not over torque, the pilot valve is made of
aluminum.
6-81090 NA Issued 01-2006 Bur 33-11

33.1.4 BATTERY
33.1.4.1 REMOVAL PREPARATION 3. Disconnect the positive terminal of the battery.
: 12 mm
CAUTION: Follow the removal procedure of

battery cables. Disconnect the ground cable
first. Reconnect the ground cable last.
Failure to do so may result in a dangerous
situation due to spark.
4. Loosen the M8 nut (7) to remove the plate (5)

and the rod (4).
: 13 mm
SPW33000017J01 Figure 18 5. Remove the battery (1).
FIG. 33-16 FLOOR SECTION REMOVAL PREPARATION 33.1.4.3 INSTALLATION
1. Remove the floor mats (5) and (8). Install the battery in reverse order of the removal.
2. Remove the cover (4). Nut (A3) M8:
3. Remove the cover assembly (5) of the lower left
: 13 mm
side (See Section 33.1.2.1-(4)).
Tightening torque: 3.5 Nm (2.6 lb ft)
33.1.4.2 REMOVAL
FIG. 33-17 BATTERY REMOVAL
1. Unclip and remove cover (A5).
2. Disconnect the negative terminal of the battery.
33-12 Issued 01-2006 Bur 6-81090 NA

33.1.5 COUNTERWEIGHT
33.1.5.1 REMOVAL PREPARATION Counterweight weight:
580 kg (1,285 lbs)
3. Loosen three M20× 70 capscrew (B1).
: 30 mm
4. Remove the shims (B3), (B4) and (B5).
5. Remove counterweight (A1).
1. Remove the cover assemblies (1), (2), (4), (5),
(9) and guard assembly (6) as well as the hood
assembly (3) (See 33.1.2 (page 33-8)).
2. Lifting tools preparation
• Lifting jigs for counterweight (see Tool list)
• Two M20× 35 screws (A)
• Wire rope (Nylon sling)
33.1.5.2 REMOVAL SPH33000161E01 Figure 22
FIG. 33-19 COUNTERWEIGHT INSTALLATION
1. Install the counterweight in reverse order of the
removal.
2. Reinstall the shims (B3), (B4), and (B5).
3. Lifting counterweight
Make sure that all the three mounting bolts can
be hand started.
4. Apply Loctite #262 on the capscrews (B1) and
tighten them together with the washer (B2).
: 30 mm
Tightening torque: 373 Nm (275 lb ft)
5. Remove lifting jigs.
FIG. 33-18 COUNTERWEIGHT REMOVAL
1. Remove the plate (B7) and attach the lifting jigs
for counterweight.
2. Put a rope through the lifting lugs and take up the
slack.
6-81090 NA Issued 01-2006 Bur 33-13

33.1.6 PUMP 33.1.6.2 REMOVAL

33.1.6.1 REMOVAL PREPARATION
FIG. 33-20 FILLER NECK REMOVAL
1. Remove the cover assembly (4) and (5) (See
Section 33.1.2 (page 33-8)).
2. Remove the counterweight (See Section
33.1.5 (page 33-13)).
3. Depressurize the hydraulic oil reservoir and drain
the hydraulic oil (See Section 33.1.11 (page 33-
22)).
• Spread a vinyl sheet under the pump to
prevent contamination due to oil leakage.
4. Remove the filler neck (C1) of the fuel supply
port for ease of access.
Two capscrews M10x20 (C7)
: 17 mm SPH33000163E01 Figure 24
Tightening torque: 46 Nm (4.7 lb ft) FIG. 33-21 PUMP REMOVAL
1. Disconnecting hoses and fittings connected to
the pump
• Attach a tag to each hose for identification.
1. Loosen four M12× 35 capscrews (19) to
remove the tube (14).
: 10 mm
2. Remove the pilot delivery hose (B23).
: 22 mm
3. Remove the main pump delivery hoses (8),
(9) and (10).
: 27 mm
2. Loosen two M12× 30 capscrews (C4) to remove
the pump.
: Ball joint type 10 mm

Pump weight: 35 kg (78 lbs)
33-14 Issued 01-2006 Bur 6-81090 NA

33.1.6.3 INSTALLATION 4. Install the main pump delivery hoses (8), (9), and
Install the pump in reverse order of the removal (10), and the pilot delivery hose (B25) (See Fig.
according to the tightening torque and sealant 33-21).
instructions.
5. Tighten the capscrew (19) to install the suction
tube (14).
: 10 mm
6. When the suction hose (12) is removed, apply
sealant on the inserted portion of the hose and
fix the tube with the clip (20).
: Flat tip screwdriver

T=5.4 Nm (4.0 lb ft)
7. Fill the reservoir with hydraulic oil (approx. 42
liters (11 gal)).
FIG. 33-22 PUMP INSTALLATION
8. Loosen the air bleed valve on the pump to
1. Apply grease to the spline part of the pump input remove air from the pump, (See Fig. 33-22).
shaft.
Grease: Shell Retinax AM Grease or equivalent : 10 mm
(M olybdenum disulfide extreme pres sure 9. Reinstall each component removed during
multipurpose grease) removal preparation.
2. Insert the pump spline part to the coupling. 10. After starting the engine, release air (See
3. Fix the pump by the capscrew (C4). Section 33.1.11.3 (page 33-24)).
: Ball joint type 10 mm
6-81090 NA Issued 01-2006 Bur 33-15


33.1.7.1 REMOVAL PREPARATION 33.1.7.2 REMOVAL
1. Unlock and open the right upper cover (1). 1. Disconnecting hoses
2. Remove the right lower cover (2) (See Section Tag and disconnect all the hoses connected to
33.1.2.1 (page 33-8)). the control valve, install plugs and caps on all
• Spread a vinyl sheet under the control valve to open lines and fittings.
prevent contamination due to oil leakage. • Remove the return hose to the hydraulic
3. Release the residual pressure in the circuit and reservoir for ease of access.
the pressure in the hydraulic reservoir.
FIG. 33-23 MAIN HYDRAULIC HOSE DISCONNECTION
33-16 Issued 01-2006 Bur 6-81090 NA

FIG. 33-24 PILOT HYDRAULIC HOSE DISCONNECTION
6-81090 NA Issued 01-2006 Bur 33-17

FIG. 33-26 CONTROL VALVE REMOVAL
FIG. 33-25 CONTROL VALVE REMOVAL
1. Install the control valve in reverse order of the
2. Removing control valve removal.
1. Loosen one M10× 50 capscrew (2) and two 2. Attach two capscrews (4) and one (11).
M12x40 capscrews (13) to remove the control
valve (A1) with the bracket (1). CAUTION: Clean the mounting surface and
tighten the valve down evenly to prevent
: 17 mm, 19 mm deformation of the valve.
Weight of removed parts:
Approx. 46 kg (102 lbs) : 13 mm, 17 mm
2. Loosen two M10× 25 capscrews (4) and one Tightening torque: M8 24 Nm (18 lb ft)
M8x80 capscrew (11) to remove the control M10 65.7 Nm (48 lb ft)
valve (A1). 3. Attach the capscrew (2).
: 13 mm, 17 mm : 17 mm, 19 mm
Weight: Approx. 35 kg (77 lbs) Tightening torque: M10 65.7 Nm (48 lb ft)
M12 79 Nm (58 lb ft)
4. Tighten the hose fittings to the following torque:
5. Operate the attachment to check for correct
function.
6. Check for leaks and fill the reservoir as needed.
33-18 Issued 01-2006 Bur 6-81090 NA
33.1.8 SOLENOID VALVE

33.1.8.1 REMOVAL PREPARATION 3. Removing solenoid valve
1. Unlock and open the right upper cover (1) (See Loosen two M8× 20 capscrews (B5) to remove
33.1.2.1 (page 33-8)). the solenoid valve (B1).
2. Remove the right lower cover (2) (See
33.1.2.1 (page 33-8)). : 13 mm
33.1.8.2 REMOVAL 33.1.8.3 INSTALLATION

1. Install the solenoid valve in reverse order of the
removal.
Tighten the fittings at the following torque:
FIG. 33-27 SOLENOID VALVE REMOVAL
1. Disconnecting hoses
Tag and disconnect all the hoses connected to
the solenoid valve (B1). Plug and cap all lines
and fittings.
NOTE: Item (B32) is a drain hose for the
hydraulic reservoir, attach a vacuum pump to the
reservoir to prevent oil loss.
2. Disconnecting connector
Disconnect two connectors connected to the
main harness.
6-81090 NA Issued 01-2006 Bur 33-19

33.1.9 PATTERN CHANGE CONTROL VALVE

33.1.9.1 REMOVAL PREPARATION 2. Removing pattern change valve
1. Unlock and open the right upper cover (1) (See Loosen four M8x25 capscrews (9) to remove
33.1.2.1 (page 33-8)). pattern change valve (5).
2. Remove the right lower cover (2). (See
33.1.2.1 (page 33-8)) : 13 mm
3. Release the pressure in the hydraulic system

and the reservoir.
33.1.9.2 REMOVAL
Tag and disconnect all the hoses connected to
the pattern change valve. Plug and cap all lines
and fittings.
FIG. 33-29 PATTERN CHANGE VALVE REMOVAL
1. Install the pattern change valve in reverse order
of the removal.
Tighten the fittings to the following torque:
FIG. 33-28 CONNECTION BETWEEN P/V AND PATTERN
CHANGE VALVE
33-20 Issued 01-2006 Bur 6-81090 NA

33.1.10 FUEL TANK

FIG. 33-30 FUEL DRAIN
1. Remove the floor mats (5) and (6), the floor
covers (2) and (4), and the floor plate (1)
(See 33.1.3.1 (page 33-10)).
2. Remove the cover assembly (4) on the left lower
side
(See 33.1.2.1 (page 33-8)).
3. Remove the battery
(See 33.1.4.2 (page 33-12)).
FIG. 33-31 FUEL TANK REMOVAL
1. Open the fuel filler cap (B2) and loosen the drain
plug (B10) to drain fuel.
Tank capacity: 52 liters (14 gal)
2. Disconnect the hoses (2) and (3) for the fuel inlet
and outlet, the hose (B4) for the fuel supply port,
and two air bleed hoses.
3. Loosen the M10× 20 sems-bolt (B9) to remove
the boss (B11) together with the drain hose
(B12).
: 17 mm
4. Disconnect connector (A13) for the level sensor.
5. Remove two M10× 20 capscrews (B7).
: 17 mm
6. Remove the fuel tank (A1) together with the
bracket assembly (B14).
6-81090 NA Issued 01-2006 Bur 33-21

33.1.10.3 INSTALLATION 33.1.11 HYDRAULIC RESERVOIR

Assemble the fuel tank in reverse order of the 33.1.11.1 REMOVAL PREPARATION
removal and tighten the screws to the specified
torque shown in the following table:
1. Swing boom 90 degrees to the right for ease of
removal of the reservoir.
2. Unlock and open the right upper cover (1) (See
33.1.2.1 (page 33-8)).
3. Remove the right lower cover (2) (See
33.1.2.1 (page 33-8))).
4. Remove the floor cover (2) (See 33.1.2.1 (page
33-8)).
5. Remove the inspection cover (1-3) of the control
stand.
Six M8× 20 sems-bolts (1-5)
: 13 mm
33-22 Issued 01-2006 Bur 6-81090 NA

33.1.11.2 REMOVAL
FIG. 33-33 DRAINING HYDRAULIC OIL
6. After releasing internal pressure of the hydraulic
FIG. 33-34 SUCTION HOSE REMOVAL
reservoir, remove the plug (B14) below the
solenoid valve to drain hydraulic oil. 1. Disconnecting suction hose
1. Remove the clip (20).
: 22 mm
Reservoir capacity: 41 liters (11 gal) : Flat tip screwdriver
• Spread a vinyl sheet under the solenoid 2. Remove the hose (11).
valve to prevent contamination around the
valve due to oil leakage. : Flat tip screwdriver
• Releasing reservoir pressure
Press the cap boot of breather assembly (A14) to
release the internal pressure (See Fig. 33-34).
CAUTION: Press and hold the boot until air-

relieving sound stops.
7. Remove the control valve (See 33.1.7.2 (page

33-16)).
8. Remove the solenoid valve (See 33.1.8.2 (page
33-19)).
9. Remove the harness and hose clamped on the
reservoir.
NOTE: Remove the pattern change valve
(option) if equipped.
FIG. 33-35 RETURN OIL HOSE REMOVAL
2. Removing return oil hose and drain oil hose
Disconnect each hose from the position marked
with *.
: 19, 22, and 36 mm
: Flat tip screwdriver
6-81090 NA Issued 01-2006 Bur 33-23

1. Clean hydraulic oil reservoir, hoses, and
components.
2. Install the reservoir in reverse order of the
removal.
The specified torque is shown in the following
table:
• Apply Loctite #262 to B1.
NOTE: Disconnect nibbler and breaker if equipped.
3. After Installing, fill the reservoir with the specified
hydraulic oil and check the oil level with the level
gauge (A1-11) (See Fig. 33-36).
SPH33000178J01 Figure 45 Oil quantity: about 41 liters (11 gal)
FIG. 33-36 HYDRAULIC OIL RESEVOIR REMOVAL
4. Air bleeding
3. Removing hydraulic oil reservoir
1. Start the engine.
Loosen four M10× 30 capscrews (B1) to remove
the hydraulic oil reservoir (A1) and shim (B3). 2. Run the engine at low idle for two or three
minutes, extend and retract each cylinder
: 17 mm several times to bleed air in the circuit.
Weight: about 37 kg (82 lbs)
FIG. 33-37 BOOM POSITION FOR CHECKING OIL LEVEL
5. Rechecking oil level
33-24 Issued 01-2006 Bur 6-81090 NA

Stop the engine with boom in the position shown 33.1.12 AIR CLEANER
in Fig. 33-37 to recheck oil level. Check for oil 33.1.12.1 REMOVAL PREPARATION
leakage on each part.
Open the rear hood assembly.
33.1.12.2 REMOVAL
FIG. 33-38 AIR CLEANER REMOVAL
1. Disconnect connectors from the indicator on the
air-cleaner (1), if equipped.
2. Loosen the clamps (9 and 10) to remove the air
hoses (2 and 3)
. : Flat tip screwdriver

3. Loosen a M20x25 sems-bolt (12) and a M10x30
sems-bolt (16), then remove the air cleaner
assembly (1) with bracket (6).
4. Loosen four M8× 20 (11) sems-bolts to remove
the air cleaner assembly (1).
: 13 mm
Assemble the air cleaner in reverse order of the
removal.
• Tightening torque
Sems-bolts (11): 23.5 Nm (17 lb ft)
Sems-bolts (12 and 16): 46.1 Nm (34 lb ft)
6-81090 NA Issued 01-2006 Bur 33-25

33.1.13 GENERATOR 33.1.13.3 INSTALLATION

1. Remove the cover at the lower right of the seat
(See 33.1.11.1 (page 33-22)).
2. Disconnect the negative battery terminal.
3. Remove guard assembly (6) (See
33.1.2.1 (page 33-8)).
33.1.13.2 REMOVAL
FIG. 33-40 GENERATOR TERMINAL
1. Install the generator in reverse order of the
removal.
2. V-belt tension
Press the middle of the V-belt with a thumb to
adjust the deflection within the following range:
Deflection: 10 to 15 mm (0.39 to 0.59 inch)
FIG. 33-39 GENERATOR REMOVAL
1. Disconnect the connector and remove the nut
(M6) for the terminal B.
2. Remove the capscrews (1), (2), and (3).
: 13mm
3. Remove the V-belt and the generator.
33-26 Issued 01-2006 Bur 6-81090 NA

33.1.14 MUFFLER 33.1.14.3 INSTALLATION

33.1.14.1 REMOVAL PREPARATION Install the muffler in reverse order of the removal and
1. Remove the hood assembly (3) (See tighten the screws and nuts to the specified torque
33.1.2.1 (page 33-8)). shown in the following table:
2. Remove the cover assembly (5) (See

33.1.2.1 (page 33-8)).
33.1.14.2 REMOVAL
FIG. 33-41 MUFFLER REMOVAL
1. Loosen three M8× 20 sems-bolts (8) to remove
the cover (16).
: 13 mm
2. Remove M8 nut (19) to loosen the clamp (4), and
loosen four M8 nuts (9-1) to remove U bolt (27)
then disconnect the exhaust tube (3).
: 17 mm
3. Loosen four M8 nuts (9-2) fastening the exhaust
manifold for the engine to remove the muffler.
: 13 mm
4. Loosen four M8× 20 capscrews (14) to remove
the muffler (1).
6-81090 NA Issued 01-2006 Bur 33-27

33.1.15 CONTROL STAND

1. Remove the canopy and the handrail (See
33.1.1 (page 33-5)).
2. Remove the floor covers (2 and 4), and the
plates (3) (See 33.1.3.1 (page 33-10)).
3. Remove the covers (1), (2), (4), (5), (6) and (9)
fo r t h e g u a r d s , a n d t h e h o o d ( 2 ) ( S e e
33.1.2 (page 33-8)).
4. Remove the counterweight (See 33.1.5 (page
33-13)).
5. Disconnect the ground cable from the battery. SPH33000162E01 Figure 54
33.1.15.2 REMOVAL FIG. 33-43 FILLER NECK REMOVAL

4. Removing filler neck (fuel supply port)
1. Pull out the hose (B4) connected to the fuel
tank.
2. Loosen two M8× 20 capscrews (B34) to
remove the filler neck (B1).
: 13 mm
FIG. 33-42 CONTROL CABLE REMOVAL
1. Remove the air cleaner (See 33.1.12 (page 33-
25)).
2. Removing throttle cable (15)
1. Pull out the pin (10) and remove the pin (6).
2. Loosen the adjusting nut (M8) to remove the
cable. SPH33000185E01 Figure 55
FIG. 33-44 AIR BLEED HOSE DISCONNECTION
3. Removing deceleration motor (option)
5. Disconnect the air bleed hose for the fuel tank.
1. Disconnect the connector.
2. Loosen the adjusting nut (M8) to remove the
cable.
3. Loosen three M8× 20 sems-bolts (12) to
remove the deceleration motor (8).
: 13 mm
33-28 Issued 01-2006 Bur 6-81090 NA

FIG. 33-45 PILOT VALVE REMOVAL FOR DOZER
6. Pilot valve removal for dozer
Tag and disconnect all the hoses connected
to the pilot valve. Plug and cap all lines and
fittings.
2. Removing pilot valve
Loosen two M8× 20 capscrews (11) to remove
the pilot valve.
6-81090 NA Issued 01-2006 Bur 33-29

FIG. 33-46 SEAT AND COVER REMOVAL
7. Removing seat and front stand cover
Loosen four M8× 20 sems-bolts (6) to remove the
seat assembly (7) and the front stand cover (1) in SPH33000189E01 Figure 59
one piece. FIG. 33-48 PILOT HOSE DISCONNECTION
9. Disconnecting pilot hose
: 17 mm
1. Disconnect the hose of the right pilot valve
(R) under the pilot valve
(See Section 33.1.19.2 page 33-39).
2. Disconnect the hose of the left pilot valve (L)
from the control valve and solenoid valve
sections (See 33.1.7.2 (page 33-16) and
33.1.8.2 (page 33-19)).
• If equipped with a pattern change valve
(option), disconnect hose at the pattern
change valve.
8. Removing heat insulation cover
Loosen two M6× 12 sems-bolts (11) to remove
the cover (4).
: 10 mm
the cover (3).
: 13 mm
33-30 Issued 01-2006 Bur 6-81090 NA

10. Removing heater hose (option)

Loosen four sems-bolts (15) M8¥20 to remove
the cover (14).
: 13 mm
Loosen five sems-bolts (15) M8x20 to remove
the cover (20).
: 13 mm
Remove the engine side clips (5), and disconnect
the hose (1) and (6)
Loosen four sems-bolts (12) M8x16 to remove
the heater (2).
: 13 mm
11. Disconnecting harness
See below drawing to disconnect the harness
connected to the instrument harness and main
FIG. 33-49 HEATER HOSE DISCONNECTION
harness.
6-81090 NA Issued 01-2006 Bur 33-31

FIG. 33-50 CONTROL STAND REMOVAL
12. Removing control stand
Remove M8 (A12), M10 (A14) and M12 (A15)
sems-bolts for fastening the stand in addition to
the sems-bolts already removed to disassemble
the canopy and floor covers.
: 13 mm, 17 mm and 19 mm
Weight of removed stand: approx. 55 kg (120 lbs)
• Before lifting the control stand, ensure that
harnesses and hoses have been disconnected.
FIG. 33-51 SUPPORT REMOVAL
13. Removing support
1. Loosen four M8× 25 sems-bolts (B6).
: 13 mm
2. Loosen four M16× 50 (30) capscrews to
remove the support (11).
: 24 mm
Weight: approx. 45 kg (99 lbs)
33-32 Issued 01-2006 Bur 6-81090 NA

1. Install the control stand in reverse order of the
removal.
Tighten the capscrews and sems-bolts at the
torque specified below:
6-81090 NA Issued 01-2006 Bur 33-33

33.1.16 STARTER
FIG. 33-52 SEAT AND COVER REMOVAL
1. Remove the floor cover (See Section 33.1.3.1
page 33-10).
2. Remove the seat and the front stand cover,
loosen four M8× 20 sems-bolts (6), and remove
the seat assembly (7) and the front stand cover
(1) in one piece.
: 17 mm
3. Disconnect the negative cable from the battery.
33.1.16.2 REMOVAL
1. Remove the M8 nut for the terminal B of the
starter. SPH33000195E01 Figure 66
FIG. 33-53 STARTER REMOVAL
: 13 mm 33.1.16.3 INSTALLATION
2. Disconnect connector on the terminal S of the Install starter in reverse order of the removal.
starter.
3. Loosen two fastening bolts (1) to remove the
starter.
: 19 mm
33-34 Issued 01-2006 Bur 6-81090 NA

33.1.17 RADIATOR
FIG. 33-54 DUCT REMOVAL
1. Remove the right side cover assemblies (1), (2),
(6), and (9), and the hood assembly (3) (See
33.1.2 (page 33-8)). SPH33000197E01 Figure 68
2. Remove the counterweight (See 33.1.5 (page FIG. 33-55 RADIATOR REMOVAL
33-13)). 1. Draining water form radiator
3. Remove the duct (13) for the radiator. 1. Remove the radiator cap.
Three M8× 20 sems-bolts (20) 2. Loosen the clamp (A8), then remove the plug
4. Remove the fan guard (A15). (A14) to drain water.
Two M8x20 capscrews (A19) • Volume: Approx. 2.6 litters (0.69 gal)
5. Remove the support (11) See fig. 33-51, (page

33-32)
• In order to facilitate the work, remove the related
covers and components if necessary.
FIG. 33-56 DRAINING HYDRAULIC OIL IN OIL COOLER
2. Draining hydraulic oil in oil cooler
1. Release the pressure in the hydraulic circuit.
2. Remove the oil cooler hoses (18) and (19),
and then plug the inlet/outlet ports of the oil
cooler and the openings of the hoses.
6-81090 NA Issued 01-2006 Bur 33-35

3. Disconnect the hose (A4) of reservoir (A5) by 33.1.17.3 INSTALLATION

removing the clamp (A8).
4. Remove the radiator hoses (A1) and (A2) by
loosening clamp (A7).
Tools: Cutting pliers and flat tip screwdriver
5. Removing radiator
Loosen three M10× 30 (B3) and four M8x25 (B6)
capscrews to remove the radiator assembly.
: 13 mm and 17 mm
Weight: 23 kg (51 lbs)
FIG. 33-57 RADIATOR INSTALLATION
1. Install the radiator in reverse order of the
removal.
2. Apply Loctite #262 on the capscrews (B3).
3. Apply Permatex #98D to the fittings of radiator
hoses (A1) and (A2) prior to the connection.
4. Install the fan and shroud, adjusting their
positions according to Fig. 33-57.
Tightening torque for related parts
5. Fill the cooling system (LLC: Long Life Coolant)
See Maintenance section of the OPERATION &
MAINTENANCE MANUAL for the mixing ratio of
LLC.
33-36 Issued 01-2006 Bur 6-81090 NA

33.1.18 ENGINE 2. Disconnect the ground cable from the engine.

33.1.18.1 REMOVAL PREPARATION 3. Removing engine
1. Remove the side cover and the hood (See 1. Loosen four M12× 120 capscrews (12) fixing
33.1.2 (page 33-8)). the engine on the rubber mount (6 and 7) to
2. Remove the canopy (See 33.1.1 (page 33-5)). remove the engine.
3. Remove the ground cable from the battery. : 19 mm

4. Remove the counterweight (See 33.1.5 (page 2. Lifting engine
33-13)).
Attach lifting equipment to the two lifting eyes
5. Remove the control stand (See 33.1.15 (page at the top of the engine and lift the engine.
33-28)).
Weight: Approx. 170 kg (370 lbs)
6. Remove the air cleaner (See 33.1.12 (page 33-
25)). 3. Place the engine on an engine stand.
7. Remove the muffler (See 33.1.14 (page 33-27)). 33.1.18.3 INSTALLATION

8. Remove the radiator (See 33.1.17 (page 33- 1. Install the engine in reverse order of the removal.
35)). See the following table for torque:
9. Remove the pump or disconnect the hose
connected to the pump (See 33.1.6 (page 33-
14)).
33.1.18.2 REMOVAL
• Use the mount rubber (6) with identification color
of “blue” (three mounts).
• Use the mount rubber (7) with identification color
of “black” (one mount). Part A.
• Use the mount cover (24) with identification
SPH33000199E01 Figure 72 color of “black” (three mounts).
FIG. 33-58 FUEL HOSE REMOVAL • Use the mount cover (26) with identification
1. Disconnecting fuel hose color of “plating” (one mount). Part A. (See fig.
33-59)
Disconnect each hose marked with .
2. Disconnecting cable connector
(for details, see ELECTRICAL SYSTEM)
1. Disconnect the terminal B of the starter motor
(M-1) on the positive cable of the battery (See
33.1.16.2 (page 33-34)).
6-81090 NA Issued 01-2006 Bur 33-37

FIG. 33-59 ENGINE REMOVAL
33-38 Issued 01-2006 Bur 6-81090 NA

33.1.19 PILOT VALVE

33.1.19.1 PREPARATION FOR REMOVAL 33.1.19.3 INSTALLATION
FIG. 33-60 COVER REMOVAL (RIGHT CONTROL BOX)
NOTE: Since the same method applies to the right-hand
and the left-hand pilot valve, only the method for the right-
hand is described.
1. Disconnect negative cable from the battery.
2. Release the residual pressure in the circuit and FIG. 33-62 PILOT VALVE PORT LOCATION
1. Install the pilot valve in reverse order of the
3. Remove the right and left control boxes and the removal to the following tightening torque:
monitor panel.
1. Attaching sems-bolts (10).
4. Loosen sems-bolts (10) to remove the cover
assembly (A3) and (A4) (See Fig. 33-60). : Torx driver
T=0.27 Nm (0.2 lb ft)
: Torx driver
2. Installing hoses, etc.
33.1.19.2 REMOVAL
NOTE: Use cation when tightening the fittings to the pilot
valve because it is made of aluminum.
2. Pressurize the hydraulic reservoir (See
33.1.11.3 (page 33-24)).
3. Operate the attachment to check the for correct
function.
4. Check for oil leaks and oil level.
FIG. 33-61 HOSE REMOVAL
1. Tag and disconnect each hose at the position
marked with *, cap and plug all open fittings.
2. Shift the boot and remove four capscrews (A2).
: 10 mm
3. Remove the pilot valve (A1).
6-81090 NA Issued 01-2006 Bur 33-39


1. Remove the floor mat, the floor plate and the
cover (See 33.1.3.1 (page 33-10)).
2. Release the residual pressure in the circuit and
33.1.20.2 REMOVAL
FIG. 33-65 PILOT HOSE REMOVAL
2. Remove pilot hoses (B31) and (B37) connected
to the slewing motor.
SPH33000201J01 Figure 79 : 19 mm
FIG. 33-63 MAIN HOSE DISCONNECTION
FIG. 33-66 SLEWING MOTOR REMOVAL
3. Loosen ten M16× 40 capscrews (3) to remove the
slewing motor.
FIG. 33-64 MAIN HOSE DISCONNECTION : 24 mm [approx. 300 mm (11.8") in length
1. Disconnect six hoses (A17), (A20), (20), (21), extension is required].
(22) and (23) connected to the slewing motor Weight: about 40 kg (88 lbs)
(See Fig. 33-63 and Fig. 33-64).
: 22 and 27 mm
33-40 Issued 01-2006 Bur 6-81090 NA

33.1.20.3 INSTALLATION 3. Connect the hoses

1. Install the motor in reverse order of the removal • Fill the casing with hydraulic oil through the
according to the tightening torque shown below. motor drain port prior to connecting drain
piping.
1. Apply Loctite #515 on the entire
circumference surface for mounting the
slewing motor (1).
2. Install the capscrews (3).
: 24 mm
T=216.6 Nm (160 lb ft)
Apply Loctite #262 to the capscrew.
2. Check the oil level in the reservoir.
3. Start and run the engine at low idle, slew the
machine for a few minutes and check for oil
leakage and abnormal noise.
6-81090 NA Issued 01-2006 Bur 33-41

33.1.21 SWIVEL JOINT

FIG. 33-67 LIFTING MACHINE
FIG. 33-69 DRAIN HOSE DISCONNECTION
1. Remove the upper-side drain hoses (A22) and
the connector (1) and elbow (2).
: 19 mm
FIG. 33-68 UNDERCOVER REMOVAL
1. Lift the machine by approx. 30 cm (1 foot) and
insert support blocks at four places under the
tra ck t o s e c u re wo r k i n g s p a c e u n d e r th e
machine.
2. Remove the cover (2) of the floor plate (See
33.1.3.1 (page 33-10)).
3. Loosen four M10× 25 capscrews (A5) to remove
the cover (A4). FIG. 33-70 UPPER SIDE HOSE DISCONNECTION
: 17 mm
4. Release the residual pressure in the circuit and
the hydraulic reservoir.
5. Disconnect the hose of the slewing motor (See
33.1.20 (page 33-40)).
• Remove the canopy to facilitate the removal of
the swivel joint.
33-42 Issued 01-2006 Bur 6-81090 NA

FIG. 33-73 SWIVEL JOINT REMOVAL
4. Removing swivel joint
Loosen four M12× 40 capscrews (C2) to remove
FIG. 33-71 LOWER SIDE HOSE DISCONNECTION
the swivel joint (C1) through the bottom.
2. Tag and disconnect all of the hoses connected to
the swivel joint, plug and cap all fittings and lines. : 19 mm
Weight: 22 kg (49 lbs)
FIG. 33-72 LINK REMOVAL
3. Remove the link
Loosen two M12× 40 capscrews (A6) to remove
the link (A3).
: 19 mm [an extension approx. 300 mm

(11.8") in length required].
6-81090 NA Issued 01-2006 Bur 33-43

33.1.21.3 INSTALLATION 3. Connect the hoses.
2. Reinstall all the removed parts.
3. Pressurize the hydraulic reservoir.
4. Check the for correct function of components.
FIG. 33-74 CONNECTING PORT RELATION
1. Install the swivel joint in reverse order of the
removal to the tightening torque shown below.
1. Install the capscrews (C2).
: 22 mm
T=181 Nm (133 lb ft)
• Apply Loctite #262 on the capscrews.
2. Install the capscrews (A6).
: 19 mm
T=115 Nm (85 lb ft)
• Apply Loctite #262 on the capscrews.
33-44 Issued 01-2006 Bur 6-81090 NA

33.1.22 UPPER FRAME

1. Remove the floor plate and the floor cover (See
33.1.3 (page 33-10)).
2. Remove the canopy (See 33.1.1 (page 33-5)).
3. Remove the guards (See 33.1.2 (page 33-8)).
4. Remove the counterweight (See 33.1.5 (page
33-13)).
5. Drain hydraulic oil from the hydraulic reservoir
(See 33.1.11.1 (page 33-22)).
6. Disconnect the upper-side hoses for the swivel
joint (See 33.1.21.2 (page 33-42)).
7. Remove the link for the swivel joint (See Fig. 33-
72).
8. Remove the attachment (See the “BOOM”
section of the Chapter of ATTACHMENT).
9. Needed Tools
• Lifting device for upper frame. See section
“Tools”.
• Two bolts M20× 110
• Two nuts M20
• Two washers M20
FIG. 33-76 LIFTING UPPER FRAME
1. Mark the slewing bearing
Mark the upper frame and the outer race of
slewing bearing.
2. Lifting upper frame temporarily
1. Attach the upper frame lifting jigs to the rear
end of upper frame using the counterweight
mounting holes.
2. Lift the upper frame at three points, put wire
rope in the swing-bracket mounting hole for
the boom, in two places in the lifting jigs at the
rear of the upper frame.
6-81090 NA Issued 01-2006 Bur 33-45

3. Slowly lower the upper frame while aligning

the marks and watching the engagement of
the slewing pinion gear and the internal gear
of the inner race of slewing bearing.
FIG. 33-75 SLEWING BEARING AND UPPER FRAME
3. Removing bolts that mount upper frame
Loosen one reamer bolt (5) and fifteen
capscrews (4) from the outer race of the slew
bearing to the upper frame.
: 22 mm
4. Removing upper frame
Lift the upper frame a little to ensure safety. Then
remove it and place on stands capable of SPH33000211E01 Figure 96
supporting the frame.
FIG. 33-78 REAMER BOLT POSITION
Weight: Approx. 1,450 kg (3,200 lbs) 4. Installing slewing bearing and upper frame
33.1.22.3 INSTALLATION 1. Apply Loctite #262 on a reamer bolt (5) and
1. Install the upper frame in reverse order of the fifteen capscrews (4) and hand tighten them.
removal. 2. Tighten according to the pattern in fig. 33-78.
: 22 mm, T=181 Nm (135 lb ft)

Apply Loctite #262 to the bolt and capscrews.
3. Fill the grease bath portion surrounding the
gear teeth of the slewing bearing with about
4.8 kg (10.6 lbs) of “Lithium grease.”
5. Install the components removed during
preparation.
FIG. 33-77 SLEWING BEARING INSTALLATION
2. Cleaning contact surface
Clean the bottom surface of the upper frame and
the top surface of the slewing bearing.
Fig. 33-77
• Apply Loctite #515 over the entire circumference
of the outer race inside of the capscrew.
3. Lifting method
1. Attach wire ropes to the upper frame as in
removal and lift up horizontally.
2. Align the match marks made during removal.
33-46 Issued 01-2006 Bur 6-81090 NA


33.2.1 HYDRAULIC PUMP
1. SHAFT ASSEMBLY 4. COVER ASSEMBLY 7. GEAR PUMP ASSEMBLY

2. SWASH PLATE ASSEMBLY (HANGER ASSEMBLY) 5. SPRING ASSEMBLY 8. HOUSING ASSEMBLY
3. ROTARY GROUP 6. NOT USED 9. TROCHOID PUMP ASSEMBLY
6-81090 NA Issued 01-2006 Bur 33-47

33.2.1.2 DISASSEMBLY AND ASSEMBLY 33.2.1.2.2 CAUTIONS DURING DISASSEMBLY

AND ASSEMBLY
33.2.1.2.1 TOOLS AND JIG 1. Cautions for disassembly
1. Tools 1. Never turn the adjusting screw unless
absolutely necessary.
2. Do not drop parts.
2. Cautions for assembly
1. Wash each part thoroughly.
2. During assembly, do not damage parts or
allow foreign materials to enter.
3. As a rule, the O-ring and oil seal should not
be reused.
4. Be sure to torque components when
specified.
2. Jig
1. Work pedestal
Plate which is used to place the pump facing
down.
2. Bearing assembling jig.
33-48 Issued 01-2006 Bur 6-81090 NA

33.2.1.2.3 DISASSEMBLY

SPH33000002J01 Figure 100 3. Remove the case by using two M5× 50
1. Removing gear pump screws.
First remove two capscrews (M10× 25).
: 8 mm

4. Take the gear out of the casing.

2. Remove the coupling.

5. Remove the side plate (A) from the casing.

3. To removing the trochoid pump, remove three
M5× 12 capscrews.
: 4 mm
6-81090 NA Issued 01-2006 Bur 33-49

SPH33000008J01 Figure 106 SPH33000011J01 Figure 109

6. Remove the side plate (B) from the cover. 8. Removing cover. Remove cover slowly
keeping it horizontal. Do not to drop the
control plate attached on the back side.

7. Remove the key from the shaft
9. Removing control spring section. Remove
two springs (inside and outside) and the
guide.

4. To disassembling main pump, remove the cover
NOTE: Since the control spring is strong, remove
three (M12× 30) and one (M12× 55) capscrew. SPH33000013J01 Figure 111
10. Remove the spring seat.
: 10 mm
33-50 Issued 01-2006 Bur 6-81090 NA


11. Lay the pump on the side and take out the
14. Remove seal.
rotary group from the shaft.

15. Remove the O-ring.
12. Remove the plate.

16. Tap the shaft with a plastic hammer and
13. Remove the shaft, the remove the snap ring
remove it.
with snap ring plier.
6-81090 NA Issued 01-2006 Bur 33-51


17. Remove four socket bolts (M6x16) and 20. Remove the hanger.
hanger plate.
: 5 mm

21. Remove the control plate.

18. Remove spacer.

22. Remove two socket bolts (M8x25).
SPH33000022J01 Figure 120 : 5 mm

19. Remove the bearing.
NOTE: Remove only if required.
33-52 Issued 01-2006 Bur 6-81090 NA


23. Remove cylinder and parallel pin. 26. Remove three disk springs and spring seats.

24. If equipped, remove piston for air condition 27. Remove two socket bolts (M8x30) and
mode. remove the cover.
: 6 mm

25. Remove piston. SPH33000031J01 Figure 129
28. Remove spring seat.
6-81090 NA Issued 01-2006 Bur 33-53


29. Remove snap ring from shaft.
31. To disassembling the gear pump (GSP2,
loosen four socket bolts (M10× 20).
: 8 mm

30. Place bearing in a vise, tap shaft with a
plastic hammer and remove the bearing.

32. Remove the cover.

33. Remove the square ring.
33-54 Issued 01-2006 Bur 6-81090 NA

33.2.1.2.4 ASSEMBLY
Assemble the main pump in reverse order of the
disassembly.

34. Remove wear plate, guide and O-ring.

1. When assembling the main pump, install the
hanger assembly.

35. Remove the drive gear and driven gear.

2. Install the bearing.

3. Install spacer.
NOTE: Check preload of bearing, 0.1 ± 0.02 mm
(0.004 ± 0.0008 in) distance.
6-81090 NA Issued 01-2006 Bur 33-55


4. Install the plate with four socket bolts (M6x16) 7. Install the snap ring.
: 5 mm
Torque: 1.35 Nm (11.9 lb in)

SPH33000038J01 Figure 141 8. Install the shaft into the housing.
5. Assembly shaft. NOTE: If needed use a plastic hammer and lightly
tap the shaft into place.

6. Place bearing on shaft, press fit bearing. If a
press is not available, drive the shaft with jig
to protect the splines and use a plastic
hammer. SPH33000042J01 Figure 145
9. Apply grease on the O-ring.
33-56 Issued 01-2006 Bur 6-81090 NA


10. Install seal and seal casing. 13. Apply grease on three parallel pins, place
them in the cylinder block.
NOTE: Apply grease on seal lip prior to installation.

14. Install grease on sphere portion of guide.
11. Install snap ring.

15. Insert pistons into the holes of the cylinder.
12. Install ten pistons in retainer of rotary group.
6-81090 NA Issued 01-2006 Bur 33-57

SPH33000050E01 Figure 152 SPH33000013J01 Figure 155

16. Installing rotary group 19. Apply grease on the sphere portion of the
spring seat and install it into the hanger in the
housing.

17. Install plate in hanger. Apply grease on the
rear surface of the plate to prevent it from SPH33000012J01 Figure 156
dropping out.
20. Install the inner and outer springs.

18. Align rotary group with spline of shaft, install it
into the housing. Apply grease on the sliding
surface of piston shoes and sliding surface of
the control plate of the cylinder block.
33-58 Issued 01-2006 Bur 6-81090 NA


23. If equipped, install piston for air conditioning
mode.

21. Install the spring seat and three disk springs
into the cover assembly.
24. Apply grease on parallel pins and install them
into the cylinder.

22. Install control piston.
25. Install cylinder with two socket bolts (M8x25)
• Apply Loctite #270 to thread portion.
: 6 mm
Torque:
32.5 Nm (23.9 lb ft)
6-81090 NA Issued 01-2006 Bur 33-59


26. Install the cylinder with two socket bolts and 29. Apply grease to rear surface of control plate
tighten (M8× 25). and install it on the cover to align the hole
with parallel pins.
: 6 mm
Torque:
32.5 Nm (23.9 lb ft)

30. Install five O-rings into mating face of cover.
NOTE: There are different sized O-rings.
27. Install spring seat in control spring section.

31. Install cover parallel to the attaching surface
SPH33000059J01 Figure 165 of the housing.
28. Install cover with two socket bolts (M8x30)
: 6 mm
Torque:
32.5 Nm (23.9 lb ft).
33-60 Issued 01-2006 Bur 6-81090 NA


32. Fasten the cover with three M12× 30 and one 35. Install the side plate (B) in the cover.
M12× 55 socket bolts.
: 10 mm

36. Install the side plate (A) into the casing.

33. To install the trochoid pump, insert the key in
the shaft.

37. Place the gear (inner rotor) on the shaft.

34. Insert the key directing the round side to the
trochoid pump side.
6-81090 NA Issued 01-2006 Bur 33-61


38. Install aligning the matchmark to the side
5. To assemble gear pump, insert the square ring
plate (B) side.
onto the plate of the gear side (GSP2).

39. Install the casing into the cover.

41. Install the drive gear and driven gear into the
40. Tighten three M5× 12 capscrews. side plate.
: 4 mm
33-62 Issued 01-2006 Bur 6-81090 NA

SPW33000181J01 Figure 181 SPW33000184J01 Figure 184

42. Install the drive gear, driven gear and side 44. Install the plate, guide and O-ring into the
plate into the housing. housing.
NOTE: Make sure the suction and delivery
direction are correct during installation.

43. Insert O-ring into the guide, and install it to
the plate. SPW33000188E01 Figure 185
SPW33000187E01 Figure 183 SPW33000185J01 Figure 186

45. Install the square ring.
6-81090 NA Issued 01-2006 Bur 33-63

SPW33000186J01 Figure 187 SPH33000003J01 Figure 190

46. Install the cover to the housing. 49. Install the gear pump to the main pump.

47. Mount the cover with four M10× 20 50. Mount the gear pump with two socket bolts
capscrews. (M10× 25).
: 8 mm : 8 mm
Tightening torque: 55~69 Nm (41~51 lb ft) Tightening torque: 62 Nm (46 lb ft)

48. Install O-ring on attaching surface of gear
pump.
33-64 Issued 01-2006 Bur 6-81090 NA

33.2.1.3 MAINTENANCE STANDARD
Item Replacement criterion Remedy
Visual inspection
To be free from flaw, galling and wear.
(Especially the sliding section)
Piston assembly and
Check clearance between the piston Replace.
cylinder block
outer diameter and inner diameter of
the cylinder block.
D-d 0.06 mm (0.0024 in)
Piston shoe and piston

Piston shoe and Check the play in the axial direction of
Replace.
piston the piston and shoe shaft.
0.2 mm (0.0079 in)
Shaft
Check the wear of the oil seal.
Shaft Replace.
Wear amount 0.025 mm
(0.0010 in)
Replace it when the

Control plate Check the sliding surface for flaw.
flaw is severe.

Replace it in a set if it
Check if it is free form galling and step
is impossible to
wear.
repair.
Guide and retainer After repairing with

Check if it is free from slight galling and lapping, clean it to
flaw. remove the lapping
compound.
6-81090 NA Issued 01-2006 Bur 33-65


33.2.2.1 ASSEMBLY DRAWING
1. Assembly Drawing

FIG. 33-79
TABLE 33-1
Item Name Q’TY Item Name Q’TY

1 Dozer section 1 11 Bucket section 1
2 Slewing section 1 12 End cover 1
3 P3 inlet and travel straight conflux section 1 13 P1, P2 Main relief valve 1
4 Arm section 1 14 P3 Main relief valve 1
5 Service section 1 15 Over load relief valve 6
6 Swing section 1 16 Over load relief valve 2
7 Travel (right) section 1 17 Anti cavitation valve 1
8 P1 and P2 inlet section 1 18 Tie bolt (L=303) 4
9 Travel (left) section 1 19 Tie bolt (L=143) 4
10 Boom section 1 20 Nut 8
33-66 Issued 01-2006 Bur 6-81090 NA

2. Cross section
The control valve is roughly classified into the following three sections.
Travel right and left, boom, arm, bucket, slewing, swing, travel straight conflux,
Pilot operation section
dozer and service (Nibbler & breaker)
Accessory section P1 and P2 inlets, and P3 inlet (common with travel straight and conflux)
Accessory section (valve) P1, P2, P3 main relief, overload relief, anti cavitation, boom lock
• For each section a typical example is described.

1. Pilot operation: Swing (Item 6)

FIG. 33-80
2. Pilot operation: Slewing (Item 2)

FIG. 33-81
6-81090 NA Issued 01-2006 Bur 33-67

3. Main relief valve (P1, P2)

FIG. 33-82
4. Anti cavitation valve

FIG. 33-83
33-68 Issued 01-2006 Bur 6-81090 NA

33.2.2.2 PRECAUTIONS FOR DISASSEMBLY 33.2.2.3 REQUIRED TOOLS AND OTHERS
The disassembly and assembly is fundamentally to The following tools are required for the disassembly
be carried out at the manufacturer’s plant, but when it and the assembly of the control valve.
is unavoidably necessary, observe the following
precautions.
Tools Q’TY Remarks
1. All hydraulic equipment is machined with
precision and consequently the clearance of Allen wrench One each 4, 5, 8, 10 mm
each part is very small. When disassembling and Wrench One each 13, 19, 21, 22, 30 mm
assembling, place the machine in the clean area Socket One each 13, 19, 22 mm
to prevent the entry of dust, dirt and sand. 1.96 ~ 19.6 Nm (1.4 ~
Torque wrench 1
2. Before disassembly, review the valve drawing to 14 lb ft)
understand it’s construction clearly. 19.6 ~ 117.7 Nm (14 ~
Torque wrench 1
3. When removing the control valve from the 87 lb ft)
machine, cap every port to prevent dust, etc. Magnet 1
from entering. Before disassembly, recheck that Pliers 1
every fitting is capped, clean the outer surface of Screw driver (–) 1
the assembly. The work should be done on an Tweezer 1
appropriate work bench which is covered by
clean paper or rubber mat. Prepare cleaning solvent, hydraulic oil, grease,
4. If it is necessary to leave hydraulic equipment in L o c t i t e # 2 4 2 , t a g a n d m a r ke r ( fe l t - t i p p e n )
a disassembled state, apply rust preventives beforehand.
and/or seal equipment to protect it from dust and
rusting.
5. The control valve should be transported or
moved holding the main body. After removing the
pilot cover, do not to touch the exposed surfaces
with your bare hands.
6. Even when the movement is not smooth, never
strike it.
7. In addition, after assembly of equipment, various
tests {relief setting, leak test, flow resistance
(pressure loss) test} are required.
6-81090 NA Issued 01-2006 Bur 33-69

33.2.2.4 DISASSEMBLING
1. Spool removal
Place the control valve on work bench directing the actuator port upward.
1. Pilot type,
(See Fig. 33-81 and Fig. 33-84.)
A. Loosen and remove 2 bolts (6) with a 5 mm Allen wrench. Remove the pilot cover (4).
B. The spring of the slewing spool is exposed, grasp the spring and put the spool straight out of the valve
section. Other pilot spools can be removed using the same procedure. Remove O-ring (3) from the flange
bottom.

FIG. 33-84 HYDRAULIC PILOT SWITCHING TYPE
33-70 Issued 01-2006 Bur 6-81090 NA

2. Independent travel spool (See Fig. 33-85).

A. Loosen and remove two sems-bolts (5) with a 5 mm Allen wrench. Remove the pilot cover (4). Grasp the
exposed spring, remove the spool assembly.
B. Remove O-ring (3) from the bottom of the flange.
C. Loosen three socket bolts (17) with an Allen wrench, remove the body assemblies (13-16) and the piston
(10).
D. Remove O-rings (11 and 12).

FIG. 33-85 P3 SUPPLY AND TRAVEL STRAIGHT SECTIONS
3. Relief valve (Code: RV)
A. Remove overload relief valve (Code: ORV)
Place the valve section in a soft jawed vise. Loosen and remove the ORV.
NOTE: The set pressure of the RV and ORV differs in different sections of the valve body, tag every valve with
respective position. Do not disassemble the RV and ORV because they are very difficult to adjust. When there is a
failure, replace the assembly.
6-81090 NA Issued 01-2006 Bur 33-71

4. Disassembly of the load check valve

A. Put the valve section in a soft jawed vise. Loosen plug (9) at the center of the valve with a 8 mm allen
wrench.
B. It may be difficult to loosen the plug because the O-ring gets caught in the threads. Do not force it, tighten
the plug again and loosen it again. Take out spring (8), load check valve (7) with tweezers or magnet.
C. The item numbers in Fig. 33-86 correspond to a swing section. The travel switching, boom lock valve and
service switching sections have different item numbers and can be disassembled in the same manner.

FIG. 33-86 LOAD CHECK VALVE
5. Disassembling lock valve
If the lock valve failed, replace it with a new valve.
NOTE: The disassembling procedures described below are for reference only and used to check the cause for
failure.

FIG. 33-87
A. Loosen the three bolts (27) with a 5 mm Allen wrench. Then remove the lock valve cover (14).
NOTE: Remove the lock valve (6 - 10) and needle valve (11). Remove and store the needle valve first. Do not
disassemble the lock valve, store it as an assembly (6 - 10).
33-72 Issued 01-2006 Bur 6-81090 NA

SPH33000075J01.TIF Figure 206

FIG. 33-88
B. Put the lock valve in a soft jawed vise, loosen and remove the plug (18) with a 8 mm allen wrench.
C. Remove the pistons C (17), A (15) and lock valve spring (16) with a pair of tweezers or a magnet through the
plug bore.
D. Mark on the pistons (C) and (A) to identify the assembled direction.
E. Do not disassemble the piston guide (12), leave it in the lock valve.
F. Loosen the ball retainer (21) with a 4 mm Allen wrench.
G. Remove the ø7steel ball (20) with a magnet.
6. Disassemble other parts
NOTE: Disassembly of parts not described in par. (1) through (5).

FIG. 33-89 SERVICE SECTION
A. Service section
B. Plug for actuator (See Fig. 33-89.)
C. Put the valve in a soft jawed vise with the actuator port facing up.
D. Loosen and remove plug (11) with a 21 mm socket or wrench.
E. Pilot cover (See Fig. 33-84.)
F. Loosen and remove two socket bolts (6) with a 5 mm Allen wrench.
G. Remove the pilot cover (5).
7. Disassembling main frame of switching section
The figures in parentheses following the part names in the description are the item numbers used in Fig. 33-79.
A. Loosen and remove four M8 nuts (20) with a 13 mm wrench or socket.
B. Pull four tie-bolts (18), (19) from the side and remove each section of the valve body.
C. Do not remove plugs screwed in the holes for valve manufacturing unless required.
6-81090 NA Issued 01-2006 Bur 33-73

8. Disassembling anticavitation valve

NOTE: The anticavitation valve is essential for performance, when a fault is detected replace it as an assembly.
A. The figures in parentheses following the part names in the description are the item numbers in the cross-
sectional drawing (Fig. 33-83).
B. Mount the valve in a soft jawed vise.
C. Loosen and remove the plug (3) with a 8 mm Allen wrench.
D. Remove the spring (4). Push in the anti-cavitation valve (1) from the seat side, do not to damage the seat
section.
E. Pull out the O-ring (6) and back-up ring (5) from the side from which the plug (3) was removed.
9. Relief valve (Code: RV)
Disassembling overload relief valve (Code: ORV)
NOTE: The overload relief valve is essential for performance and safety, replace it as an assembly when a fault is
detected.
A. The figures in parentheses following the part names in the description are the item numbers in the cross-
sectional drawing (Fig. 33-82).
B. Mount the valve in a soft jawed vise.
C. Loosen and remove adjusting screw (7) with a 4 mm Allen wrench.
D. Take out spring (9), poppet (6) and spring guide (16).
E. Loosen and remove plug (4) with a 19 mm wrench or socket.
F. Remove socket (1), piston (3), spring (10) and pressure regulating valve (2).
33-74 Issued 01-2006 Bur 6-81090 NA

33.2.2.5 PRECAUTIONS WHEN ASSEMBLING 33.2.2.7 ASSEMBLY

1. The unevenness of torque and contamination 1. Perform assembly referring to the drawings in
during assembly may cause a failure. Observe “Disassembly” Section.
the torque specified in the description. 2. Assembly procedure
2. When assembling, use valve drawings, identify 1. Assembling the valve body of the switching
the part, and ensure that there is no installation section (See Fig. 33-79, page 33-66.)
error and omission of part. Put all sections of valve body in order as
3. After cleaning the parts with cleaning solvent, shown in Table 33-2 directing the ports down.
immerse them in hydraulic oil as required and Table 33-2
reassemble them.
SECTION MARK
4. Before applying Loctite, clean and decrease the
surface and apply Loctite to two threads. (Block) AR11
(Over application may cause a malfunction.) Dozer SD
33.2.2.6 PRECAUTIONS WHEN INSTALLING Slewing AN
SEALS P3 inlet ND
1. Replace seals when assembling. Arm bB
2. Ensure that seals are not deformation or flawed. Service bC

B/Swing bE
3. Apply grease or hydraulic oil to the seals and
seal fitting section to make installation easier, Travel RH DG
unless otherwise specified. P1, P2 inlet FE
4. Do not stretch the seals, they may become Travel LH OC

permanently deformed. Boom QA
5. Do not roll an O-ring when installing, this may Boom lock AT

cause oil leakage. Bucket HD
NOTE: The symbols are engraved on the upper

surface of the valve body section (Port face)
A. Make sure that the mating surfaces of
section is free from dust, etc. and that the
O-rings are in their groove.
B. Insert eight tie bolts (18 and 19) through
the valve body.
C. Tighten eight M8 lock nuts to the specified
torque with a 13 mm socket.
T=19.6 Nm (14.5 lb ft)
NOTE: Observe the specified torque. When the
nut is not tightened to the specified torque, it may
cause a distortion and oil leakage of the valve
body.
D. Do not tighten the nuts in a single torque,
but torque the nuts several times. Tighten
the nuts in a staggered pattern, tap the
valve body with a plastic hammer so the
sections will pull up uniformly.
2. Assembling load check valve
Put the valve body on the work bench with the
actuator ports up.
NOTE: Make sure the correct types of the load
check valves are installed.
6-81090 NA Issued 01-2006 Bur 33-75

A. Sections other than travel, P3 supply, H. P3 supply and independent travel spools
boom lock valve and service (See Fig. 33- (See Fig. 33-85 page 33-71)
86 page 33-72). Use new O-rings (3) and install the flange
B. Install load check valve (7) and spring (8) in the P3 supply section (three places in
in the guide of the load check valve. front and back of the section). Install the
piston (10) in the section.
C. Hand tighten the plug so that the guide of
the load check valve can be installed on I. Insert the bolts (17).
the guide of plug (9). J. Tighten the bolts with a 4 mm Allen
wrench of to the specified torque evenly.
NOTE: Check that O-ring (10) is on the plug.
T=9.8~10.8 Nm (7.2~8 lb ft)
D. Tighten to the specified torque with a 19
K. Apply a small amount of hydraulic oil to
mm socket.
the spool and install it in the section, do
T=39.2 Nm (29 lb ft)
not use excessive force to push in the
E. Travel, P3 supply, service, boom lock spool in if it is sticking.
sections (See Fig. 33-86 page 33-72)
L. Install the spring seat and spring.
F. Install the load check valve, apply grease
M. Install the pilot cover (4).
to the spring (8) and install it in the plug
guide. N. Tighten the bolts (6) with a 5 mm Allen
wrench to the specified torque.
G. Use a new O-ring (10) on plug (9).
T=9.8~10.8 Nm (7.2~8 lb ft)
H. Tighten to the specified torque with a 19
5. Assembling lock valve
mm socket.
If the lock valve is faulty, replace it with a new
T=39.2 Nm (29 lb ft).
assembly.
3. Installing RV and ORV.
NOTE: The assembling procedures described
NOTE: Make sure to install the RV and ORV in below are only for reference after disassembling
the ports that they were removed from. to find the cause for the fault. (See Fig. 33-87
A. Tighten the RV and ORV to the specified page 33-72 and Fig. 33-88 page 33-73)
torque A. Place the lock valve cover (14) in a soft
T=39.2 Nm (29 lb ft) jawed vise.
4. Spool assembly B. Insert piston A (15) into the bore of the
A. Hydraulic pilot type, (See Fig. 33-84 page piston guide (12) paying attention to its
33-70) direction. Insert the lock valve spring (16)
and piston C (17) into the bore of the lock
B. Install spools in the sections making sure
va l ve c o ve r m a k i n g s u r e o f p r o p e r
to use the correct spool for the section
orientation. Tighten the plug (18) with a 8
being assembled.
mm Allen wrench to the specified torque.
C. Use new O-rings (3) on the section. T=39.2~49 Nm (29~36 lb ft)
D. Apply hydraulic oil to the spool before C. Install steel ball (20) in the bore of the
installation, do not force the spool, this valve, instal and tighten up the ball
could damage the spool and the section. retainer (21) to the specified torque.
E. Check that the spool moves smoothly by T=7.8~9.8 Nm (5.8~7.0 lb ft)
hand. D. Install a new flat O-ring on the inserting
F. Install pilot cover (4) on the section on the side of lock valve body.
spring side of the spool, torque the bolts E. Aligning the piston guide on the lock valve
(6) with a 5 mm Allen wrench. cover with the lock valve body, slowly
T=9.8~10.8 Nm (7.2~8 lb ft) press the lock valve cover onto the lock
G. Use a new O-ring (7), install cover (5), valve body.
bolts (6) and tighten with a 5 mm Allen F. Tighten the bolts (27) with a 5 mm Allen
wrench to the specified torque. wrench to the specified torque.
T=9.8~10.8 Nm (7.2~8 lb ft) T=9.8~10.8 Nm (7.2~8.0 lb ft)
NOTE: Tighten up the bolts alternatively so that
the lock valve is flat on the section.
33-76 Issued 01-2006 Bur 6-81090 NA

6. Assembling relief valve and overload relief A. Place spring guide (16) in adjusting screw
valve. (7) and then spring (9).
• The relief valve is essential for performance B. Shake the adjusting screw lightly and be
and safety, it is very difficult to reset the sure that the spring guide (16) and spring
pressure, if the valve is faulty, replace it with (9) are seated. Place the poppet (6) in
a new assembly. plug (4) and tighten adjusting screw (7)
NOTE: The assembling procedures described lightly.
below are only for reference only after C. Hand tighten lock nut M14 (8). Place
disassembling to investigate the cause of the spring (10) and piston (3) in poppet (2),
fault. place them in socket (1).
NOTE: The figures in parentheses following the D. Check that piston (3) is inserted in the
part names in the description are the item hole of the top end of plug (4). Tighten
numbers in the cross-sectional drawing (Fig. 33- body (5) and plug (4) to the specified
82 page 33-68). torque
T=58.8 Nm (43 lb ft)
E. Adjust the pressure with adjusting screw
(7) using a 4 mm Allen wrench, tighten
lock nut M14 (8) to the specified torque
T=19.6Nm (14 lb ft)
7. Assembling anticavitation valve.
• The anticavitation valve is essential for
performance and safety, if faulty, replace it
with a new assembly.
NOTE: The assembling procedures described
below are only for reference only after
disassembling to investigate the cause of the
fault.
8. The figures in parentheses following the part
n a m e s i n th e d e s c r i p t i o n a r e th e i te m
numbers in the cross-sectional drawing (Fig.
33-83 page 33-68).
A. Place anti cavitation valve (1) in body (2),
and spring (4). Install and tighten the plug
to the specified torque.
T=58.8 Nm (43 lb ft)
6-81090 NA Issued 01-2006 Bur 33-77


Parts inspection
Parts name Inspection item Criterion and corrective action

Replace it when there is flaw on the following section.
Sliding section against the spool, especially land
section where the hold pressure is applied.
Valve section Existence of scratch, rust and corrosion Seal pocket section where the spool is placed in or
flange section
Seal section of the port in contact with O-ring
Seat section of relief valve and overload relief valve.
Replace it when there is scratch on the peripheral
Existence of scratch, rust and corrosion
sliding surface
Spool
Insert spool in the hole of a valve section, stroke it
In case the spool is not smooth, repair or replace it.
while rotating.
In case there are flaws and scratches on the seat
Damage of load check valve and spring
section, repair or replace it.
Load check valve
Insert load check valve in plug and manually When it moves smoothly, normal, but if it moves
operate it. unsmooth, replace it.
Rust, corrosion, deformation and breakage of Replace it when the movement is unsmooth or there
Around spring
spring, spring seat, plug, and cover is damage.
Hardening, deformation and flaw of O-ring Replace
Deformation and flaw of dust wiper Replace
Around seal of spool
Rust, corrosion and deformation of oil seal
Repair or replace
retainer
Rust on outer surface Replace
Relief valve Contact surface of valve seat Flaw of dent, replace it.
Overload relief valve Spring in abnormal condition Replace
O-ring, back-up ring Replace all parts.
33-78 Issued 01-2006 Bur 6-81090 NA

33.2.2.9 CAUSE OF FAILURE AND CORRECTIVE ACTION

1. When fault is detected, check the control valve, 3. Since dust is very harmful for hydraulic
pump, cylinder, and motor for abnormality or equipment, pay attention to dust proofing.
failure in the circuit. When a par t must be disassembled, before
Measure the pilot pressure, delivery pressure of starting the work take necessary precautions for
the pump, load pressure, etc. dust protection.
2. If a moving part even has a slight flaw, repair it 4. Handle O-rings carefully in order to not damage
with oil stone or replace it. sealing surfaces. These flaws will cause oil
leakage.
1. CONTROL VALVE
Phenomenon Cause Corrective action

Malfunction of relief valve Measure the pressure of relief valve
Dust caught between pressure regulating valve
Replace the assembly. *
and seat. *
Each attachment does not Dust caught between poppet and seat. * Replace the assembly. *
function, the actuation is Pressure regulating valve is stuck. * Replace the assembly. *
slow. Breakage or fatigue of spring. * Replace the assembly. *
(Poor power) Readjust it, and tighten the lock nut to the
Or there is no response. Loose adjusting screw
specified torque.
Disassemble and clean it.
Dust caught between the valve section and spool,
In case of severe flaw, replace the valve section
or spool is stuck
and spool.
The space between the main frame of the valve
Replace spool.
section and the spool is excessive.
The spool is not returning to the neutral position
Measure pilot secondary pressure.
completely.
Dust caught between the valve section and spool, Disassemble and clean, or when stuck, replace
When spool is placed in or spool is stuck the valve section and spool together.
the neutral position, the Breakage or fatigue of spring Replace spring.
cylinder drop is severe. * Malfunction of ORV * Measure the pressure of ORV.
Malfunction of lock valve
Dust caught in the seat section of the lock valve or
Replace with a new lock valve section assembly
needle valve
(including the lock valve main body).
Sticking lock valve or needle valve
Dust caught in the throttle of the lock valve
Malfunction of load check valve Disassembly and clean
When the cylinder is set to In case of the severe damage, replace the main
Dust caught between load check valve and main
the raise position, the frame and load check valve together.
frame.
cylinder moves down prior
Load check valve is stuck. Ditto
to starting to go up.
Breakage or fatigue of spring Replace spring.
NOTE: In case of failure marked with *, replace with the new relief valve assembly.
6-81090 NA Issued 01-2006 Bur 33-79

2. RELIEF VALVE
The relief valve is essential for performance and safety. It is difficult to adjust the pressure, the following is for
reference only, if the relief valve has a fault replace it as an assembly.
The pressure adjusting valve of each relief valve, Check that the valve doesn’t get dirt in it.
Pressure does not rise. poppet and piston are stuck, kept open, or dust Each part slides freely.
got caught in the seat section of the valve. Clean all parts completely.
Replace the damaged part.
Relief pressure is The valve is damaged, or the piston is stuck in the
Clean all parts completely.
unstable. poppet.
Remove flaw on the surface.
Wear due to dust Disassemble and clean
The relief pressure is not
Lock nut and adjusting screw are loose. Adjusting pressure
within the limit of set
Breakage or fatigue of spring Replace spring.
values.
Malfunction of RV and ORV Measure the pressure of RV and ORV.
Replace the worn or damaged part.
Damage on each seat section
Check that respective part moves freely before
O-ring failure
Oil leakage installing.
Check that it is free from scratches, scoring and
foreign matter before installing.
33-80 Issued 01-2006 Bur 6-81090 NA

33.2.3 PILOT VALVE (ATTACHMENT)


FIG. 33-91 PILOT VALVE (ATTACHMENT)
Table 33-3
Tightening Torque Table
Item Thread size
Nm (lb-ft)
301 M14 47.1 (34.7)
302, 312 M14 68.6 (50.6)
Table 33-4
Item NAME Q’TY Item NAME Q’TY Item NAME Q’TY
101 CASING 1 213 SEAL 4 241–1 SPRING 2
151 PLATE 1 214 O-ring; 1B P20 4 241–2 SPRING 2
201 SPOOL 4 216–1 SPRING SEAT 2 301 JOINT; M14 1
211 PLUG 4 216–2 SPRING SEAT 2 302 DISK 1
212–1 PUSH ROD 2 217 WASHER 2 4 312 ADJUSTING NUT; M14 1
212–2 PUSH ROD 2 221 SPRING 4 501 BELLOWS 1
6-81090 NA Issued 01-2006 Bur 33-81

33.2.3.2 DISASSEMBLY AND ASSEMBLY

33.2.3.3 DISASSEMBLING PROCEDURE
33.2.3.3.1 GENERAL CAUTIONS FOR
DISASSEMBLY
NOTE: Refer to figure 33-91 page 33-81 for items in
parentheses.
1. Carefully handle all the parts, they are very
precisely manufactured.
2. Perform the work carefully without hammering or
using excessive force even if the part is sticking.
Burrs may be produced or the part damaged
causing oil leakage or performance deterioration.
3. When leaving the parts in the disassembled
condition, always take rust preventive and dust
protective measures. Otherwise rust may be
produced on the parts due to humidity.

FIG. 33-93 HANDLE LEVER DISASSEMBLY
1. Remove the handle lever assembly and boot
SPW33000210E01 Figure 209 from the casing (101).
FIG. 33-92 SPECIAL JIG
2. Clean the pilot valve with cleaning solvent.
1. Tools • Screw a plug in each open port.
3. Place the pilot valve in a soft jawed vise.

2. Jig
Used for disassembling and assembling the joint
(301) (See Fig. 33-92).
33-82 Issued 01-2006 Bur 6-81090 NA


FIG. 33-94 ADJUSTING NUT (312) REMOVAL FIG. 33-97 SPRING (221) REMOVAL
4. Loosen and remove adjusting nut (312) and disk 7. Use a flat screwdriver to pull out the plug (221).
(302). • Apply the tip of the flat screwdriver to the
external groove of the plug (211) while
preventing damage to the plug due to eccentric
load.
NOTE: Plug (211) may pop up due to the pressure of
spring (221).

FIG. 33-95 JOINT (301) REMOVAL
5. Turn the joint (301) counterclockwise with a jig to
loosen.
NOTE: When pulling off the joint the plate (151),
plug (211) and push rod (212) may pop up due to the
pressure of spring (221). FIG. 33-98 PUSH ROD (212) REMOVAL
8. Remove the push rod (212), plug (211), pressure
reducing valve section assembly, and return
spring (221) from the casing (101).
• Record the relation between the casing hole
positions and these parts.

FIG. 33-96 PLATE (151) REMOVAL
6. Remove the plate (151).
6-81090 NA Issued 01-2006 Bur 33-83


FIG. 33-99 PRESSURE REDUCING VALVE DISASSEMBLY FIG. 33-101 PULLING OUT PLUG (211)
9. In order to disassemble the pressure reducing 11. Pull out the push rod (212) from the plug (211).
valve, shift the spring seat (216) laterally while
pushing in the spring seat (216) to make the
secondary pressure spring (241) deflect, and
remove the valve from the spool (201) through
the larger hole.
• Be careful not to damage the surface of the
spool (201).
• Do not push down the spring seat (216) by more
than 6 mm (0.24").

FIG. 33-102 SEAL (213) REMOVAL
12. Remove the O-ring (214) and seal (213) from the
plug (211).
13. Cleaning parts
1. Clean the parts with cleaning solvent.
2. Immerse the parts in the solvent to remove
dust and oil. The par ts can easily be
damaged from the use of excessive force
FIG. 33-100 PRESSURE REDUCING VALVE DISASSEMBLY during cleaning.
10. Separate the spool (201), spring seat (216), 3. Check the solvent for contamination, the
secondary pressure spring (241), and washer 2 parts may be damaged causing performance
(217). deterioration after reassembling.
4. Do not dry the parts with compressed air.
Otherwise the parts may be damaged by dust
or moisture in air or rust may be produced.
5. Put a part in a finish cleaning container
containing solvent and turn the part slowly to
sufficiently clean the part including its interior.
Dry parts by wiping off solvent with clean rag.
6. Apply rust preventive agent to the parts.
33-84 Issued 01-2006 Bur 6-81090 NA

33.2.3.4 ASSEMBLING PROCEDURES

33.2.3.4.1 GENERAL CAUTIONS FOR ASSEMBLY 33.2.3.4.2 ASSEMBLY
1. General cautions for assembling work are almost
similar to that for disassembling work.
2. Remove metal chips or foreign substances from
all the parts and ensure that the parts have no
burrs or flaw prior to assembly. Remove burrs or
flaw if any, using oil stone.
3. Always replace O-rings and back-up rings with
new parts.
4. Be careful not to damage the O-rings and back-
up rings when installing them. (Apply a small
amount of grease to install them smoothly.)
5. Apply grease to the parts to be installed in order
to prevent them from dropping. SPW33000221J01 Figure 221
FIG. 33-103 ASSEMBLING SPOOL (201)
6. Tighten screws to the torque specified in Table
33-3 page 33-81. 1. Insert the washer (217), secondary pressure
spring (241), and spring seat (216) on spool
7. After finishing the assembly, screw blind plugs in
(201) in this order.
all the ports to prevent dust intrusion.

FIG. 33-104 ASSEMBLING SPOOL (201)
2. Shift the spring seat (216) laterally while pushing
in the spring seat (216) to make the secondary
pressure spring (241) deflect, and install the
valve to the spool (201) through the larger hole.
• Do not push the spring down by more than 6 mm
(0.24").
6-81090 NA Issued 01-2006 Bur 33-85


FIG. 33-105 INSTALLING SPOOL (221) FIG. 33-107 INSTALLING PUSH ROD (212)
3. Install the return spring (211) into the casing 5. Install the push rod (212) into the plug (221).
(101). Install the pressure reducing valve • Apply hydraulic oil to the surface of push rod.
assembly into the casing (101).

SPW33000224J01 Figure 224 FIG. 33-108 INSTALLING PLUG ASSEMBLY
FIG. 33-106 INSTALLING SEAL (213) 6. Install the plug assembly into the casing (101).
4. Insert the O-ring (214) and seal (213) into the • Do not use excessive force with the spool (201),
plug (221). the casing may be damaged.
• Direct the lip of the seal (213) as shown below:

FIG. 33-109 INSTALLING PLUG ASSEMBLY
7. Install the four assemblies at the same time
using the plate (151) and temporarily fasten with
the joint (301).
33-86 Issued 01-2006 Bur 6-81090 NA


FIG. 33-110 INSTALLING JOINT (301) FIG. 33-112 APPLYING GREASE
8. Install the plate (151). Install the joint (301) to the 11. Apply grease to the rotating section of the joint
casing (101) and tighten the joint to the specified (301) and the push rod (212).
torque using a jig. 12. Install the handle lever assembly and boot.
T=47.1 Nm (34.7 lb ft).

FIG. 33-111 INSTALLING JOINT (301)
9. Install the disk (302) onto the joint (301).
NOTE: Screw in the disk until it contacts the four
push rods (212) equally. Carefully adjust the position
of the disk (302) excessive pressure can be
generated at the neutral position of the lever, leading
to malfunction of the pilot valve.
10. Then install and tighten the adjusting nut (312) to
the specified torque while holding the disk (302).
T=68.6 Nm (50.6 lb ft)
NOTE: Hold the disk (302) in position during
tightening.
6-81090 NA Issued 01-2006 Bur 33-87

Maintenance item Standard Remarks

Replace with a new pilot valve when the amount of
leakage reaches more than 1000 cc/min (61 cu in/ Condition:
Amount of leakage min) or 2000 cc/min (122 cu in/min) at the neutral Primary pressure: 2.94MPa (427 psi)
position of the handle or during operation, Oil viscosity: 23 mm2/s
respectively.
Replace with a new pilot valve when an amount of The wear condition to the left is considered
Spool wear at the sliding section is more than 10 µm to correspond to the above amount of
(0.0004") in comparison with the non-sliding section. leakage.
Replace when a wear amount of the tip is more than 1 mm (0.04").
Push rod

Replace when play of more than 2 mm(0.079") due to
Unnecessary play in Play generated by loosening of the disk or
wear is found on the disk (302) or joint section (301)
operation section adjusting nut should be tightened.
of the operation section.
Replace with a new pilot valve when abnormal noise,
hunting or primary pressure drop is generated during
Action stability
operation and the trouble cannot be remedied
according to Section 33.2.3.6 TROUBLESHOOTING.
NOTE: Replace seals and O-rings with new ones after every disassembly.
33.2.3.6 TROUBLESHOOTING
Phenomenon Possible Cause Corrective action
Primary pressure is insufficient.
Secure primary pressure.
Springs (241-1, 241-2) are broken or
Replace with new ones.
fatigued.
Secondary pressure does not rise. Replace assembly.
Clearance between spool (201-1, 201-2)
and valve body (101) is abnormally large. Disassembly and reassembly or replace
handle portion.
Play of handle portion is too much.
Sliding parts are caught. Correct.
Secondary pressure is unstable. Reservoir line pressure varies. Return directly to oil reservoir.
Air in system. Release air.
Reservoir line pressure is high. Return directly to oil reservoir.
Secondary pressure is high.
Sliding parts are caught. Correct.
33-88 Issued 01-2006 Bur 6-81090 NA

33.2.4 PILOT VALVE (TRAVEL)


FIG. 33-113 PILOT VALVE (TRAVEL)
Torque Torque
No. NAME Q’TY No. NAME Q’TY
Nm (lb-ft) Nm (lb-ft)
101 CASING 1 6.9 (5.1) 252 PLUG 2
102 CASING (DAMPER) 1 261 O-ring 3
201 COVER 2 8.8 (6.5) 271 SOCKET BOLT 4
202 PLUG 4 301 SPOOL 4
203 GREASE CUP 4 311 SPRING SEAT 4
210 PACKING 4 313 WASHER 4
211 O-ring 4 324 SPRING 4
214 PUSH ROD 4 413 CAM SHAFT 2
217 SHIM 4 414 BUSHING 4
218 SPRING SEAT 4 420 CAM 2
224 PISTON 4 471 STEEL BALL 4
225 STEEL BALL 12 6.9 (5.1) 472 SET SCREW 2
29.4 (22) 251 RO PLUG 3 501 BOOT 2
6-81090 NA Issued 01-2006 Bur 33-89


14. Take out spring seat (218) from casing (102)
with tweezers.
15. Take out steel ball (225) using magnet.
16. Place the lower casing assembly in a soft
jawed vise, and take out O-rings (211 and
213) from casing (101).
17. Remove reduction unit valve assembly and
return spring (335) from casing (101).
18. Place cover (201) on the flat bench, use
special jig 1, strike it lightly with hammer, and
drive out the bushing (414).
19. For disassembly of the reduction unit valve
SPW33000234E01 Figure 234 assembly first push spring seat (311) in and
FIG. 33-114 SPECIAL JIG 1 shift the spring seat crosswise, remove it from
1. Special jig for removal and installation of the spool (301) passing through the large hole.
bushing.
2. Precautions for disassembly and assembly
1. Disassemble and assemble the pilot valve
preventing rust, dust, dirt, etc. contamination.
2. Handle parts carefully so as not to damage
them.
3. Write down the installing positions of parts
during disassembly.
3. Disassembly
1. Plug ports (P, T, 1, 2, 3, and 4) of the valve
and clean the outer surface.
2. Put the valve in a soft jawed vise. SPW33000235J01 Figure 235
3. Remove boot (501) from cover (201). FIG. 33-115
4. Remove set screw (472). 20. Separate spool (301), spring (324), shim
(217) and washer.
: 6 mm • Keep all parts as an assembly, do not mix
parts from another unit. Some units may
5. Use a punch (ø7 or less) to drive out the cam not have washers installed on them.
shaft (413).
21. Remove grease cup (203) from plug (202).
6. Remove cam (420).
22. Remove O-ring (212) from plug (202).
7. Remove bolt (271).
: 6 mm
8. Remove cover (201).
9. Remove the casing upper assembly and
place the assembly in a soft jawed vise.
10. Pull the push rod (214) out of plug (202).
11. Remove plug (202) with grease cup (203),
packing (210) and O-ring (212).
12. Remove piston (224).
13. Remove damping spring (336) from the
casing.
33-90 Issued 01-2006 Bur 6-81090 NA

33.2.4.3 ASSEMBLY
1. Clean all parts before assembly, dry them with 12. Install packing (210) in plug (202).
compressed air with water separator in line. Do • Pay attention to the direction when installing the
not use rags. packing.
• Repair the parts damaged during disassembly, • Apply a light coat of grease before installing the
clean them, apply oil to the moving parts, install packing.
the same parts in the positions where they were
removed from.
• Replace O-rings and packings.
2. Install washer (313), shim (217), spring (324),
and spring seat on spool (301) in order.
3. Pass spool (301) through the larger hole of
spring seat (311), push the spring seat in and SPW33000237E01 Figure 237
lock into place. FIG. 33-117
4. Place the casing (101) in a soft jawed vise, and 13. Install grease cup (203) in plug (202).
place spring (335) for return in casing (101). 14. Install push rod (214) on plug (202).
5. Place the reduction unit subassembly described 15. Place the push rod subassembly in casing (102).
above par. 2) and 3) in casing (101).
16. Put cover (201) on the flat work bench, press
• Install them in the positions they were removed
bushing (414) with special jig 1, and press fit the
from.
bushing striking lightly.
• When placing the reduction unit subassembly
into position, pay attention to the spool lower 17. Place the lower cover (101) assembly in a soft
end, do not bring it in contact with the corner of jawed vise, place the casing damper (102)
the casing. assembly on it.
18. Install cover (201) on casing (102).
19. Tighten socket bolt (271) to the specified torque.
20. Install cam (420) on cover (201).
21. Insert cam shaft (413) into cam (420).
22. Apply Loctite #241 or equivalent to the thread of
socket bolt.
23. Tighten bolt (472) to the specified torque.
24. Incline cam (420), apply grease to the top end of
push rod (214), and fill grease cup (203) of plug
(202) with grease.
25. Install the top end of boot (501) on cam (402),
SPW33000236E01 Figure 236 install the boot into the lower groove of cover
FIG. 33-116 (201).
6. Place O-rings (211, 213) in casing (101).
7. Place upper casing (102) in a soft jawed vise and
insert the steel ball (225).
8. Place spring seat (218) in casing (102) with
tweezers.
9. Place damping spring (336) in casing (102).
10. Install piston (224).
11. Install O-ring (212) in plug (202).
6-81090 NA Issued 01-2006 Bur 33-91

Phenomenon Causes Corrective action

Insufficient primary pressure Adjust primary pressure.
Permanent fatigue of spring (324) for setting of
Secondary pressure Replace it with new one.
secondary pressure.
does not rise.
The gap between spool and casing is too large. Replace it with complete remote control valve.
The control section is loose. Replace parts of control section.
Sliding part is not smooth. Repair unsmooth section.
Secondary pressure
Variation of pressure of reservoir line Return oil to oil reservoir directly.
is unstable.
Air in hydraulic system. Bleed air by operating several times.
Secondary pressure Pressure of reservoir line is high. Return oil to oil reservoir directly.
is high. Sliding part is not smooth. Repair unsmooth section.
Air is accumulated in piston chamber. Bleed air by operating several times.
Sliding part is not smooth. Repair unsmooth section.
Permanent fatigue of damping spring (336) Replace it with new one.
Damping does not
Gap between damping piston (224) and casing
work. Replace it with complete remote control valve.
(damper) (102) is too large.
Malfunction of check valve Disassemble and check on check valve section.
Orifice of damping piston (224) is too large. Replace damping piston.
Damping torque is Sliding part is not smooth. Repair unsmooth section.
heavy. Orifice of damping piston (224) is clogged. Repair or replace damping piston.
33-92 Issued 01-2006 Bur 6-81090 NA



6-81090 NA Issued 01-2006 Bur 33-93
No. NAME Q’TY No. NAME Q’TY No. NAME Q’TY

(reduction assy) 204 Cylinder 1 302 Check valve 2
101 Casing 1 205 Valve plate 1 303 Plug 2
102 Carrier 1 1 206 Piston 9 304 Spring 2
103 Carrier 2 1 207 Shoe 9 305 O-ring; 1B P11 2
104 Pinion shaft 1 208 Shoe holder 1 306 O-ring; 1B P18 2
105 Internal gear A 1 209 Cylinder holder 1 (Relief valve assy)
106 Spur gear 1 4 210 Swash plate 1 401 Seat 2
107 Spur gear 2 3 212 Retainer 2 402 Retainer 2
108 Sun gear 1 1 213 Pin 3 403 Poppet 2
109 Sun gear 2 1 214 Filter 2 404 Piston 2
110 Pin 1 4 215 Spring 1 405 Cap 2
111 Pin 2 3 216 Ball bearing 1 406 Spring 2
112 Seal ring 1 217 Ball bearing 1 407 Spacer *
113 Thrust collar 1 218 O-ring; 1B G120 1 408 O-ring; 1B P14 2
114 Pre-load collar (semi-circular) 2 221 Snap ring 1 409 O-ring; 1B P18 2
115 Taper roller bearing 1 223 Socket bolt; M12× 35 5 410 O-ring; 1B P22 2
116 Taper roller bearing 1 224 Spring pin 1 411 O-ring; 1B P28 2
117 Roller 68 225 Parallel pin; ø6× 14 1 412 Backup ring 4
118 Roller 69 226 Parallel pin 1 (Timer assy)
119 Thrust washer 14 231 Piston 1 501 Valve block 1
123 Snap ring (for shaft 30) 1 232 Spring B 12 502 Spool 1
124 Snap ring (for shaft 20) 7 233 Friction plate 2 503 Piston 1
125 Spring pin 7 234 Separator plate 2 504 Stopper 1
127 Pin 4 235 O-ring; 1B G100 1 505 Spring (1) 1
128 Oil seal 1 236 O-ring; 1B G110 1 506 Spring (2) 1
129 O-ring 1 237 Backup ring 1 507 Spring seat 1
130 Socket bolt; M8× 25 5 238 Backup ring 1 508 Plug; PF1/4 4
136 Ring 1 242 Socket bolt; M6× 15 4 509 O-ring; 1B P11 4
(Motor assy) 244 Socket bolt; M8× 50 4 510 O-ring; 1B P7 2
201 Body 1 245 O-ring; 1B P18 2 511 Plug 2
202 Housing 1 (Valve assy) 512 Plug 1
203 Shaft 1 301 Cover 1

1. General Precautions 4. Handle the removed parts carefully so as not
1. Work at a clean place and take care so dirt, to score them.
paint particles and water do not adhere to the 5. Clean the removed parts thoroughly in
parts. Prepare a container to put removed cleaning oil.
parts in. 6. Inspect that the removed parts are not worn
2. Before removing it, clean the outside of the or seized abnormally and eliminate fins and
body to be free from dirt and remove paint at burrs, using emery paper.
joints with a wire brush. 7. Replace seals and snap rings with new ones.
3. Put markings on jointing parts before removal
so all parts are correctly reinstalled.
33-94 Issued 01-2006 Bur 6-81090 NA

2. Tools
No. Tools required
1 Torque Wrench (Pre-set type) 45N {10.1 lbf f} (JIS B4650)
2 90N {198 lbf f} (JIS B4650)
3 180N {397 lbf f} (JIS B4650)
4 Hexagon Wrench for Torque Wrench Opposing flat 6
5 Opposing flat 8
6 Opposing flat 10
T=147.1±19.6Nm {108±14.5 lbf m}
7 Torque Wrench (For single use)
Opposing flat 36
8 Allen Wrench Opposing flat 6
9 Opposing flat 8
10 Opposing flat 10
11 Spanner Opposing flat 36
12 Flat-Blade Screwdriver Width 6~10
13 Snap Ring Pliers ø 28 for hole
ø 20, 30 for shaft
14 Hammer
15 Plastic Hammer
20 Others Grease
Oil (Specified hydraulic oil)
Wire brush
Emery paper
Sealant (Three Bond #1305)
3. Disassembly

SPH33000081J01 Figure 239 2. Loosen socket bolt (244) and remove valve
1. Loosen the socket bolts (130) fastening the assy.
hydraulic motor assy to the reduction unit and
remove the hydraulic motor assy from the : 5mm
reduction unit. • Do not remove the valve assy except when
necessary.
: 6mm
• When removing the hydraulic motor assy
from the reduction, open the drain port.
6-81090 NA Issued 01-2006 Bur 33-95


3. Remove the relief valve assy. 6. Remove valve plate (205), spring (232) and
O-rings (218), (245).
: 36mm
• Do not remove the relief valve assy except
when necessary.

7. Remove brake piston (231) assy from
housing (202). Then remove O-rings (235),
SPH33000084J01 Figure 242 (236) and backup rings (237), (238).
4. Remove plug (303), O-rings (305), spring • Brake piston (231) may be removed if air is
(304) and check valve (302). blown slowly from brake release pressure
port Pop.
: 8mm
NOTE: Blow low pressure air in slowly so the brake
piston does not pop up suddenly.

5. Loosen socket bolt (223) and remove the
body (201).
: 10mm
33-96 Issued 01-2006 Bur 6-81090 NA


8. Remove two separator plates (234) and two
friction plates (233).

11. Remove snap ring (221), retainer (212) and
SPH33000089J01 Figure 247 spring (215) from cylinder (204).
9. Remove cylinder (204) as an assy.

SPH33000090J01 Figure 248 12. Remove shaft (203) and swash plate (210).
10. Remove the piston (206) assy and shoe • In case the shaft is hard to remove, tap it
(207), shoe holder (208), barrel holder (209), lightly from the end face of the opposite
pin (213). side with a plastic mallet.
• The piston and the shoe can not be • Ball bearing (216) is press fitted to the shaft,
removed as they are press formed together. do not separate the shaft and bearing
• When replacing the pistons because of the except when the ball bearing needs to be
wear of the shoes, order nine pistons as a replaced.
set.
6-81090 NA Issued 01-2006 Bur 33-97


13. Remove two filters (214) and parallel pin 3. Remove the thrust collar (113) installed on
(225). the back side of the carrier 2 assy (103).

4. Disassembly of Reduction Unit
1. Remove sun gear 2 (109).

4. Remove the snap ring (123) of the carrier 2
(103), then remove the thrust washer (119),
spur gear 2 (107) and roller (118).
• Number of rollers (118)
: Twenty three rollers per spur gear 2.

2. Remove carrier 2 assy (103) and carrier 1
assy (102).
33-98 Issued 01-2006 Bur 6-81090 NA


5. Remove the snap ring (123), then remove 7. Remove ring (136) and split preload collar
sun gear 1 (108). (114).
• Pin 2 (111) is fixed by spring pin (125) after
• Place the tip of a flat-blade screwdriver in
press-fitting. Do not remove it except where the clearance between two preload collars
necessary. and remove them by striking them with a
hammer.
• Since the clearance of it to the taper roller
bearing has been adjusted, do not separate
the ring and the preload collars except
when necessary.

8. Remove the pinion shaft (104).
• In order to remove the pinion shaft, place a
support of about 150mm under the flange
of the casing for clearance, remove the
pinion shaft with a press.
NOTE: Since the clearance of the taper roller
6. Remove the snap ring (124) of the carrier 1
bearing is preset, do not remove it except when
(102), then remove the thrust washer (119),
necessary.
spur gear 1 (106) and roller (117).
• Number of rollers (117)
:Seventeen rollers per spur gear.
• Pin 1 (110) is fixed to spring pin (125) after
press-fitting.
6-81090 NA Issued 01-2006 Bur 33-99


9. Remove the outer race of the taper roller 10. Remove the inner race of the taper roller
bearings (115), (116) and oil seal (128). bearing (115) and seal ring (112) from pinion
• Since the taper roller bearing and the outer shaft (104).
race are hard to remove, do not remove • The taper roller bearing is press fitted to the
them except when necessary. inner race; do not separate them except
when necessary.
33-100 Issued 01-2006 Bur 6-81090 NA

5. Assembly

1. Drive the parallel pin (225) into housing (202).

3. Press-fit ball bearing (216) onto shaft (203).
• Note direction of ball bearing

2. Install two filters (214) and parallel pin (226)
into the housing (202).
• Note direction of filter
4. Install the swash plate (210) into shaft (203)
and install it to the housing (202).
• Align the parallel pin (226) on the housing
side with the pin hole of the swash plate.
6-81090 NA Issued 01-2006 Bur 33-101


6. Install the piston (206) assy and shoe (207) in
the shoe holder (208) to make the shoe
holder assy.

5. Install the retainer (212) and spring (215) in
the cylinder (204) and secure them with the
snap ring (221). SPH33000114J01 Figure 274

7. Install three pins (213) into cylinder (204). Fit
two friction plates (233) and one separator
plate (234) in that order of the figure.
33-102 Issued 01-2006 Bur 6-81090 NA


8. Install the cylinder assy assembled in para. 7 11. Install second separator plate (234) into the
into housing (202) through shaft (203) till groove of housing (202).
shoes (207) touche the swash plate (210).

SPH33000088J01 Figure 277 12. Install O-rings (235), (236) and backup rings
9. Install one separator plate (234) into the (237), (238) to assemble the piston assy
groove of housing (202). (231).
SPH33000116J01.TIF Figure 278 SPH33000087J01 Figure 281

10. Install one friction plate (233) on the outer 13. Installing the piston assy into the housing
circumference of the cylinder assy to the (202).
groove of housing (202). • Coat the O-ring with a thin film of grease.
Use care not to damage seal.
6-81090 NA Issued 01-2006 Bur 33-103


14. Install spring pin (224) and ball bearing (217) 17. Install twelve springs (232) into the hole of
to body (201). cover (301).
• Coat the spring seat with grease so the
spring does not fall.

15. Install O-ring (218) on the cover (301).

18. Assembly housing (202) and cover (301).
• Align the spring pin of cover (301) with the
pin bore of housing (202).
• Use care so springs do not fall or are bent.

16. Install the valve plate (205) on the cover
(301).
• Install the valve plate by directing the metal
lining surface toward the cylinder.
• Coat the cover of the valve plate with a thin
film of grease so the valve plate does not SPH33000085J01 Figure 287
fall. 19. Tighten the socket bolt (223).
: 10mm
• Tightening torque:
88.3~112.8 Nm {65.1~83.2 lbf•ft}
33-104 Issued 01-2006 Bur 6-81090 NA

SPH33000084J01.TIF Figure 288

20. Install O-ring (305) onto plug (303), install SPH33000123J01 Figure 291
spring (304) and check valve (302) into cover 23. Install the hydraulic timer to housing (202) of
(301), and tighten it. the hydraulic pump with four socket bolts
(137).
: 8mm
• Tightening torque: : 6mm
58.8±2.9 Nm {43.4±2.1 lbf•ft} • Tightening torque:
25.5~32.4 Nm {18.8~23.9 lbf•ft}

21. Install the relief valve. SPH33000082J01 Figure 292
24. Install timer valve assy.
: 36mm • Tightening torque:
• Tightening torque: 11.8±1.0 Nm {8.7±0.7 lbf•ft}
147.1±19.6 Nm {108.5±14.5 lbf•ft}

22. Install two O-rings (306) to valve assy.
6-81090 NA Issued 01-2006 Bur 33-105

6. Assembling reduction unit.


SPH33000125J01 Figure 294 2. Install the seal ring (112) onto the pinion shaft
1. Press-fit oil seal (128) into the casing (101). (104).
• Use seal driver and press in the oil seal, • Note direction of installation of seal.
make sure the installing direction of the oil
seal is correct.

3. Press-fit the inner race of the taper roller
bearing (115) into the shaft (104).
• After press-fitting, coat the roller surface of
the taper roller bearing with grease and
rotate it so grease spreads all over the
roller.
33-106 Issued 01-2006 Bur 6-81090 NA


4. Press-fit the outer race of the taper roller 7. Install the shaft (104) into the casing (101).
bearing (116) into the casing (101). • Make sure that the oil seal lip is not
damaged by the shaft.

5. Press-fit the outer race of the taper roller SPH33000134J01 Figure 302
bearing (115) into the casing (101). 8. Turn over the casing (101) and press-fit the
inner race of the taper roller bearing (116).

6. Apply grease in the space in the casing (101)
where the taper roller bearing (115) is to be
installed.
• Grease amount: Approx 80% of the empty
capacity
6-81090 NA Issued 01-2006 Bur 33-107


11. Install the spur gear (106) and insert the roller
(117).
• Number of rollers: Seventeen rollers per
spur gear (106)

9. Install two semicircular preload collars (114).
• The thickness of the preload collar shall be
plus 0 to 0.05mm (0.002") against actual
value: (L) between the end face of the taper
roller bearing and the end face of the
groove on the shaft side.

12. Install the thrust washer (119), then install the
snap ring (123).

10. Install the thrust washer (119) on the pin 1
(110) of the carrier 1 (102).

13. Install the sun gear 1 (108) to back side of the
carrier 2 (103) and secure it with the snap
ring (123).
33-108 Issued 01-2006 Bur 6-81090 NA


14. Install the thrust washer (119) on the pin 2 17. Install ring (136) between the outside of
(111) of the carrier 2 (103). semicircular preload collar (114) and casing
(101).

15. Install the spur gear 2 (107) and insert the SPH33000142J01 Figure 313
roller (118). 18. Install the carrier 1 assy (102) in the casing
• Number of rollers: Twenty three rollers per (101).
spur gear (107)

SPH33000099J01 Figure 311 19. Install the thrust collar (113) to back side of
16. Install the thrust washer (119), then fix the the carrier 2 assy (103).
snap ring (124).
6-81090 NA Issued 01-2006 Bur 33-109


20. Install the carrier 2 assy (103) in the casing 23. Install O ring (129) to the spigot joint of the
(101). hydraulic motor housing.
• Make sure the thrust collar on the rear face • Apply a thin film of grease to the O-ring.
does not fall.

SPH33000095J01 Figure 316 24. Install the hydraulic motor in the casing (101),
21. Install the sun gear 2 (109) in the center of then torque the bolt (130).
the carrier 2 assy (103).
: 6mm
• Tightening torque:
29.4±2.9 Nm {21.7±2.1 lbf•ft}
• Install the hydraulic motor shaft into the
splined part of sun gear 2 (109).
• Apply Three-Bond #1305 to the socket bolts.

22. Fill the casing (101) with hydraulic oil.
• Oil level: Above the center of the tooth width
of spur gear 2 (107) and below the upper
end face of it.
• Oil type: ISO VG46
33-110 Issued 01-2006 Bur 6-81090 NA

7. Troubleshooting
Problem Location Cause Remedy

Oil pressure is low
Relief valve Replace valve assy
Malfunction of motion
Not slewing Seizure of sliding surface
Hydraulic motor Replace motor assy
(Pressure rises) Internal leakage
Reduction unit Damaged gear Replace reduction unit assy
Overload Reduce overload
Pressure setting is low
Relief valve Replace valve assy
Malfunction of motion
Insufficient torque Wear of sliding surface
(Pressure rises) Internal leakage
Damaged gear
Reduction unit Replace pinion kit or carrier kit
Damaged bearing
Noise in piping
Insufficient flow-rate Correct piping
(Cavitation sound)
Hydraulic motor Damage of sliding surface Replace motor assy
Abnormal noise
Damaged gear
Damaged bearing
Pinion Damaged gear Replace pinion kit
Damaged O-ring Replace O-ring
Mating surface of valve
Loose bolt Retighten bolt
Damaged O-ring Replace O-ring
Mating surface of motor
Oil leaks Loose bolt Retighten bolt
Mating surface of Damaged O-ring Replace O-ring
reduction unit Loose bolt Retighten bolt
Pinion Damaged oil seal Replace pinion kit
Relief valve Malfunction of motion
Time-lag of starting and stopping Replace valve assy
Check valve Internal leakage
Damaged or seized sliding
surface
Abnormal heat
Abnormal gear teeth
Abnormal bearing
6-81090 NA Issued 01-2006 Bur 33-111

8. Maintenance Standard
1.Slewing Motor
Part Judgment Service Limit Remedy
Shaft Abnormal wear of output shaft splines. Wear depth 25µm (0.001") or more Replace
Cylinder Contact surface with valve plate. Wear depth 20µm (0.0008") or more Replace
Valve plate Sliding surface of cylinder. Wear depth 20µm (0.0008") or more Replace
Piston and shoe Caulked part of shoe. Sliding surface of shoe. Play 0.3mm (0.012") or more Replace
Swash plate Wear of sliding surface of shoe. Wear depth 0.1mm (0.004") or more Replace
Inside of the body Damage, rust Replace
9. Valve
2.Reduction Unit
Part Judgment Service Limit Remedy
Ratio of pitted area to tooth surface.
Pitting extending over

Replace it as a
Gears in the casing Abnormal wear of gear. 5% or more of tooth
pinion kit.
surface.
Deformed or damaged
Carrier 1, 2 Visible damage
splined part. More than 0.005mm play when Replace
Play of pin 1 (carrier 1) Eccentric wear of pin checked by hand. carrier kit.
Play of pin 2 (carrier 2) bore.
Sun gear 1,
Abnormal wear of tooth Pitting, extending over
Sun gear 2
surface. 5% or more of tooth Replace
Spur gear 1,
Damaged tooth. surface.
Spur gear 2
Wear of rolling surface of

Visible flaking or
needle bearing roller (spur Replace
pitting.
gear 1, 2).
Wear of rolling surface of

Pin 1, Visible flaking or Replace it as a
needle bearing
Pin 2 pitting. carrier kit.
roller.
Pitting on roller needle.

Visible flaking or
Each bearing. Pitting on rolling surface of Replace
pitting.
inner and outer race.
Other parts
(Socket bolt and Damage, abnormal rust. Replace
thrust washer)
33-112 Issued 01-2006 Bur 6-81090 NA

33.2.6 SWIVEL JOINT


FIG. 33-118
Table 33-5 Construction

1 STEM 1 10 DUST SEAL 1
2 BODY 1 11 DUST SEAL 1
3 FLANGE 1 12 SNAP RING 1
4 SPACER 1 13 BOLT (M10× 30) 4
5 PIN 1 14 PLUG (PF1/4) 3
6 SLIPPER SEAL 7 15 SPRING WASHER 4
7 NAME PLATE 1 16 BACK-UP RING 1
8 O-ring 1 17 CLEVIS 2
9 O-ring 1
6-81090 NA Issued 01-2006 Bur 33-113


33.2.6.2.1 GENERAL PRECAUTIONS
• For disassembly and assembly, select the clean
area and prepare clean containers to put the
removed parts.
• Clean around the ports.
• Clean the removed parts with cleaning solvent.
• Replace seals, apply grease during assembly.
• Check every part for severe wear and seizure, and
remove burrs, etc. with emery paper.
• Check that seal groove is free from foreign
substances, dust, etc.
33.2.6.2.2 DISASSEMBLY SPW33000297E01 Figure 323
3. Remove shaft (1) from the body (2).
• Use a brass drift and drive the shaft from the
body.

1. Mount the body (2) in a soft jawed vise. Loosen
bolt and remove flange (3).
: 17 mm or : 17 mm 4. Remove dust seal (10) from the shaft.

2. Take out O-ring (8), snap ring (11) and thrust ring 5. Remove seals from the inside of the body.
(4). • Note the position of seal, referring to the
sectional drawing.
33-114 Issued 01-2006 Bur 6-81090 NA

33.2.6.2.3 ASSEMBLING

SPW33000300J01 Figure 326 4. Install thrust ring (4) and snap ring (11).
1. Insert seals in the body. • Install the snap ring in the groove, check for
• Check the seal position refer to the sectional correct fit.
drawing.
• Ensure that O-rings are free from twisting.
• Don’t deform or bend the slipper seal.

5. Install O-ring (8) and flange (3).
6. Install washer (14) and bolt (12).
2. Install dust seal (10) to shaft (1). : 17 mm or : 17 mm
• Apply grease to the lip section of the dust seal. • Tightening torque: 52~57 Nm (38~42 lb ft)
• Put pipe through the locking pin of the shaft, and
check that the shaft rotates smoothly at a torque
of approx. 78~108 Nm (58~80 lb ft)

3. Install shaft (1) to body (2).
• Apply a light coat of oil or grease to the shaft.
• Strike the shaft with a plastic hammer carefully,
do not to damage seals.
6-81090 NA Issued 01-2006 Bur 33-115


33.2.6.3.1 CHECK PROCEDURES AND REMEDY
33.2.6.3.2 PARTS SERVICE LIMIT
Check Interval Place Checked Check Procedure Remedy

Seals which prevent
Replace the O-rings if there is
2000 hr external leakage of Check for oil leaks.
leakage.
hydraulic oil.
4000 hr All seal parts. – Replace all the seal parts
Disassemble and check Check for abnormal wear, defects,
Recondition in accordance with the
whether there is leakage All sliding portion. corrosion, etc. due to seizing, foreign
service limit.
or not material being caught, etc.
Check for abnormal wear, defects, Recondition in accordance with the
When disassembling
All parts. corrosion, etc. due to seizing, foreign service limit.
due to trouble
material being caught, etc. Replace the seals
1. Body and Shaft
Portion Judgment Criteria Remedy

Wearing of surface treated with induction hardening, and
Seal Parts and Sliding Portion coming off of surface due to seizing, foreign material getting Replace
caught, etc.
Abnormal wear or defects by 0.1 mm (0.004 in) deep or
Body and shaft sliding portion Replace
deeper due to seizing or foreign material getting caught, etc.
other than seals.
Defects less than 0.1 mm (0.004 in) deep. Repair with an oil stone.
Wearing by 0.5 mm (0.020 in) or more, or abnormal wear. Replace.
Wear less than 0.5 mm (0.020 in). Repair so that is smooth.
Portions which slide against the
thrust ring. Defects due to seizing or foreign material getting caught, etc.
which are within the wear limit of 0.5 mm (0.020 in) and within Repair so that is smooth.
repairable level.
2. Flange and Thrust Ring
Portion Judgment Criteria Remedy

Wearing by 0.5 mm (0.020 in) or more, or abnormal wear. Replace
Portions of flange which slide Wear less than 0.5 mm (0.020 in). Repair so that is smooth.
against the shaft end. Defects due to seizing or foreign material catching, etc.,
Thrust ring which are within the wear limit of 0.5 mm (0.020 in) and to Repair so that is smooth.
within repairable level.
33-116 Issued 01-2006 Bur 6-81090 NA

25. Slipper Seal 26. O-ring
Judgment Judgment
Remedy Remedy
Criteria Criteria
Seal is O-ring is
excessively excessively
Replace Replace
extruded from extruded from
groove. groove.
Slipper seal
width is 1.5 mm
(0.059 in) or Unequal wear
more smaller Replace of 0.5 mm
Replace
than the width (0.020 in) or
of the seal more.
SPW33000083E01 Figure 332 groove. SPW33000086E01 Figure 335
Unequal wear 3. Backup Ring

of 0.5 mm
Replace
(0.020 in) or
more. Judgment
Remedy
Criteria
Thickness of
1.5 mm (0.059
in) or less
Replace
Width of 4 mm
(0.16 in) or
less.
6-81090 NA Issued 01-2006 Bur 33-117

33.2.6.3.3 INSPECTION AFTER ASSEMBLY

• After assembly is completed, check for oil leaks in each circuit using the equipment shown below.

1. Connect a pipe (3) between the hydraulic pump • Open the neighboring ports on both sides and
(2) and the shaft (1) side port. check visually for leakage from the ports.
2. Connect a pressure gauge to the body (4) side. • Check the body for cracks which may cause oil
leakage.
3. Increase the pressure gradually to 22.6 MPa
(3270 psi) adjusting the relief valve (6), then
perform 1 minute leak test.

External Oil Leakage O-ring is defective. Replace all the seal parts.
Thrust ring is defective. Replace all the seal parts.
Internal Oil Leakage
Excessive wear on sliding surfaces. Replace the assembly.
Carry out grinding and honing. If excessive looseness cause
Shaft Sticks Shaft and body are stuck together.
oil leakage, replace the assembly.
Flange Looseness Capscrew tightening is insufficient. Retighten to the specified torque.
33-118 Issued 01-2006 Bur 6-81090 NA

CHAPTER 34
E50
TRAVEL SYSTEM
Issued January 2006

CHAPTER 34 - TRAVEL SYSTEM
Revision History
First edition 01-2006 E50 6-81100 NA
PREFACE
1. This manual covers all the procedures required for the disassembly and assembly of the travel system.
2. This manual consists of 34.1;REMOVING AND INSTALLING, and 34.2;DISASSEMBLING AND
ASSEMBLING.
3. General dis/re-assembling procedures are in the Table of Contents, some items may be omitted
because of the circumstances at the time of printing.
4. Please understand that it is impossible to account for all cases of the actual process for the removal/
installation of the assembled components, because of difference in the field conditions or defects.
5. Please be aware the importance to establish the working order.
Prior to carry out the removal/installation and the disassembly/assembly, select the sections required,
fully understand the description, and itemize the working procedures, then start the work.
34-II Issued 01-2006 Bur 6-81100 NA

CHAPTER 34
TRAVEL SYSTEM
TABLE OF CONTENTS
34.1 REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-3

34.1.1 SYSTEM PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-3
34.1.2 TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-3
34.1.2.1 Removal And Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-3
34.1.2.1.1 Removing Rubber Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-3
34.1.2.1.2 Installing Rubber Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-4
34.1.2.2 Removal And Installation Procedures (Steel: Opt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-5
34.1.2.3 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-7
34.1.2.4 Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-8
34.1.3 UPPER ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-10
34.1.3.1 Removal And Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-10
34.1.3.1.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-10
34.1.3.1.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-10
34.1.3.2 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-11
34.1.3.3.1 Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-11
34.1.4 Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-14
34.1.5 TOOLS AND JIGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-14
34.1.5.1 Tightening tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-14
34.1.5.2 Jigs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-14
34.1.6 LOWER ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-15
34.1.6.1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-15
34.1.6.1.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-15
34.1.6.2 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-16
34.1.6.3.1 Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-17
34.1.6.5 Special jigs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-21
34.1.7 FRONT IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-22
34.1.7.1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-22
34.1.7.2 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-23
34.1.7.3.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-23
34.1.7.4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-24
34.1.8 IDLER ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-28
34.1.8.1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-28
34.1.8.2 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-28
34.1.9 SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-32
34.1.9.1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-32
34.1.10 TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-33
34.1.10.1 Removal and Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-33
34.1.10.1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-33
34.1.10.1.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-33
34.1.10.2 Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-34
6-81100 NA Issued 01-2006 Bur 34-1
34.1.11 SLEWING BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-35

34.1.11.1 Removal And Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-35
34.1.11.1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-35
34.1.11.2 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-36
34.1.11.3 Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-36
34.1.11.3.1 Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-36
34.1.11.4 Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-37
34.2 DISASSEMBLING AND ASSEMBLING34-38
34.2.1 TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-38
34.2.1.1 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-38
34.2.1.2 Tools And Jigs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-42
34.2.1.3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-45
34.2.1.3.1 Preparations for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-45
34.2.1.3.2 General Precautions for Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-45
34.2.1.3.3 Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-45
34.2.1.4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-58
34.2.1.4.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-58
34.2.1.4.2 General Precautions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-58
34.2.1.5 Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-70
34.2.1.6 Performance verification test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-72
34-2 Issued 01-2006 Bur 6-81100 NA

34.1 REMOVAL AND INSTALLATION

34.1.1 SYSTEM PARTS
FIG. 34-1 NAME AND LOCATION OF PARTS
34.1.2 TRACK
34.1.2.1 REMOVAL AND INSTALLATION
PROCEDURES
34.1.2.1.1 REMOVING RUBBER TRACK
FIG. 34-3 LOOSING TRACK TENSION
2. Loosen grease fitting for track adjuster,
discharging grease in cylinder, and release
tension of track.
FIG. 34-2 TRACK REMOVING POSTURE
: 17mm
1. Lift the one side of machine with attachment and • When loosening the grease fitting of the
place suppor t under lower frame to suppor t adjuster, do not loosen it more than one turn.
machine. • When grease does not come out, move the track
forward/reverse. Over loosening of grease fitting
will cause it to pop out. Keep body and face
away from the grease fitting for safety.
6-81100 NA Issued 01-2006 Bur 34-3


FIG. 34-4 REMOVING RUBBER TRACK FIG. 34-6 FEEDING GREASE
3. Put steel pipes in the rubber track, turn the 5. Tighten the grease fitting for the track adjuster.
sprocket in the reverse direction slowly and when
the rubber track is off of the idler stop the : 17mm,
rotation. T=74 Nm (54.6 lb ft)
4. Slide the rubber track sideways, and remove it. 6. Adjust the track tension according to
specifications.
34.1.2.1.2 INSTALLING RUBBER TRACK
NOTE: Installation is performed in reverse order of
removal.
1. Engage the rubber track with the sprocket and
mount it on the idler.
FIG. 34-7 TRACK TENSION
Rubber shoe
Appropriate tension A:
85~95 mm(3.35~3.74 in)
Steel shoe
FIG. 34-5 INSTALLING RUBBER TRACK Appropriate tension A:
2. Put steel pipes in the rubber track, turn the 130~150 mm (5.12~5.91 in)
sprocket in the reverse direction slowly and when
the rubber track is positioned with the idler, stop
the rotating.
3. Slide the rubber track onto the idler.
4. Confirm that the rubber track is engaged
securely with the sprocket, idler and lower roller.
34-4 Issued 01-2006 Bur 6-81100 NA

34.1.2.2 REMOVAL AND INSTALLATION PROCEDURES (STEEL: OPT)

• When loosening the grease fitting of the
adjuster, do not loosen it more than one turn.
• When grease does not come out, move the track
forward/reverse. Over loosening of grease fitting
will cause it to pop out. Keep body and face
away from the grease fitting for safety.
FIG. 34-8 POSITION OF MASTER PIN
1. Removal
A. The track link includes a master pin(6), which
should be placed in front of the front idler.
FIG. 34-11 REMOVING LOCK PIN
D. Straighten the curve of lock pin.
• Remove lock pin (8).
FIG. 34-9 REMOVING OF MASTER PIN
B. Put square timbers A and B under the shoe at
the top end of the track and between the track
and the link over the track frame to reduce the
load on the master pin.
FIG. 34-12 REMOVING MASTER PIN
E. Use master pin driving jig (a) on the small
diameter section of master pin (6) and drive it
out.
WARNING: Pay attention to the front idler

which may spring out due to the force of
spring when driving out master pin (6).
Be careful not to be injured by flying material
while driving the pin out.
FIG. 34-10 LOOSENING GREASE FITTING FOR ADJUSTMENT
C. Loosen grease fitting for track spring
adjustment, slack the tension of the shoe.
: 17mm
6-81100 NA Issued 01-2006 Bur 34-5

FIG. 34-13 REMOVING TRACK
NOTE: Put wooden blocks at each end of the track
to keep the machine from rolling off of the track. FIG. 34-16 ALIGNMENT OF PIN HOLES
F. Move the machine back slowly, and remove C. Align the master pin hole by using blocks.
the track extending it to the ground.
Weight of steel track (One side):
275 kg (610 lb)
2. Installation
FIG. 34-17 PRESS FITTING MASTER PIN
SPH34000092E01 Figure 14 NOTE: Apply grease to the master pin before

installation.
FIG. 34-14 DIRECTION OF TRACK
A. Install the track in direction shown. D. Align master link holes on the both ends of
the track link with a pry-bar, drive the master
pin in.
WARNING: Be careful of flying material

while driving the pin in.
E. After installing the master pin (6), insert lock

pin (8) and secure by bending.
FIG. 34-15 INSTALLING TRACK
B. Move the machine forward slowly. By
inserting a bar in the master pin hole on the
end of the track, put the track on the sprocket
so that the sprocket engages with the track
link.
34-6 Issued 01-2006 Bur 6-81100 NA

1. Construction of rubber track
FIG. 34-18 EXTENSION OF TRACK LINK (EXAMPLE FOR
RUBBER TRACK) SPM34000029E01 Figure 20
3. Tighten the grease fitting for the track adjuster. FIG. 34-19 RUBBER TRACK ASSY
: 17mm, No. Name Quantity Part Number

T=74 Nm (54.6 lb ft) 1 Rubber Track 2 PV61D00015P1
• This standard machines are equipped with

rubber track.
2. Construction of steel track
FIG. 34-7 TRACK TENSION
F. Adjust the tension.
Rubber shoe
85~95 mm(3.35~3.74 in)
Steel shoe
130~150 mm (5.12~5.91 in) SPW34000020E01 Figure 21
FIG. 34-20 CONSTRUCTION OF STEEL TRACK
No. Name Quantity Part Number

Track Assy 2 PY60D00003F1
1 Shoe master 1
1-2 Bushing 1
2 Shoe Track 37
2-2 Bushing 37
3 Pin Master 1
4 Ping Track 37
5 Pin 1
6-81100 NA Issued 01-2006 Bur 34-7


1. Rubber track
FIG. 34-21 RUBBER TRACK SHOE
ITEM STANDARD VALUE REPAIRABLE LEVEL SERVICEABILITY LIMIT REMEDY

Sag of rubber track L 85~95 (3.35~3.74) — — Adjustment
Where the depth of them
Cracks and notch on rubber Where the depth of them
None does not reach to the steel Replace
track reaches to the steel cords.
cords.
Breakage of steel cords None None Exist Replace
Contact surface of rubber track Where 10 percent of cores Where half of cores are
None Replace
and lower roller are visible from outside. visible from outside.
Height (H) 94(3.7) — 70(2.8) Replace
Lug projection (h) 25 (0.98) — 0 (0) Replace
Unit: mm (in)
34-8 Issued 01-2006 Bur 6-81100 NA

2. Steel track (Track link)
Unit: mm (in)
Symbol ITEM Reference value Repairable level Service limit Remedy
A Link pitch 135 (5.32) 139 (5.47) 143 (5.63) Parts over the critical
B Bushing O.D. ø35 (ø1.38 ) ø32 (ø1.26) ø31 (ø1.22) value in use should be
replaced with link
C Link height 67 (2.64) 63 (2.48) 62 (2.44) assembly.
Basic dimension Fit Fit
ø35
Shaft Interference
Interference of bushing and
D (ø1.38 ) 0.11~0.35 Interference
link
(0.0043~ 0
ø34.85
Hole 0.0138)
(ø1.37 ) Replace
ø22.3
Shaft
Interference
Interference of track pin and (ø0.878 ) Interference
E 0.1~0.18
link 0
ø22.16 (0.004~0.007)
Hole
(ø0.872 )
ø22.16
Shaft Clearance
(ø0.872 ) 0.0~0.07
F Fitting of master pin and link — Replace link.
(0.0~
ø22.16
Hole 0.0028)
(ø0.872 )
5 7
0.5 (One side)
G Clearance gap of link (both side) (both side) Replace
(0.02)
(0.197) (0.276)
Tightening torque of shoe
H 216 Nm {159 lbf•ft} Retighten
bolt
L Slack of iron crawler 130~150mm (5.12~5.91) — Adjust the tension.
6-81100 NA Issued 01-2006 Bur 34-9

34.1.3 UPPER ROLLER

34.1.3.1 REMOVAL AND INSTALLATION PROCEDURES
34.1.3.1.1 REMOVAL 34.1.3.1.2 INSTALLATION
SPW34000003E01 Figure 24 FIG. 34-24 REMOVING/INSTALLING UPPER ROLLER
FIG. 34-22 RELEASING TRACK TENSION NOTE: Before installing the upper roller, make sure
that it is filled with oil and that the upper roller rotates
smoothly by hand. If the upper roller does not rotate
smoothly or oil is leaking, check the bearing and the
seals and replace them as necessary.
Oil: Engine oil SAE#30, API CD grade
Volume: 20 cc (1.2 cu in)
1. Insert the shaft of the upper roller assembly into
the lower frame.
2. Coat mounting bolts with Loctite #262 and
SPW34000024E01 Figure 25 torque.
FIG. 34-23 SUPPORTING WITH WOODEN BLOCKS
1. Loosen the grease fitting for track adjusting : 17mm, Tightening torque:
within one turn to discharge grease and release • 66 Nm (48.7 lb ft)
tension on the track. • Install it so the nut is located on the idler side.
3. After installing upper roller, remove the wooden
: 17mm blocks, tighten grease fitting for track adjuster,
2. Push up the track with a hydraulic jack, and place adjust track tension.
suitable wooden block for clearance between the
track and lower frame. : 17mm, Tightening torque:
• 74 Nm (54.6 lb ft)
3. Remove the bolts and nuts, remove the upper
roller from the lower frame.
: 17mm
• Weight of upper roller assembly: 5 kg (11 lbs)
34-10 Issued 01-2006 Bur 6-81100 NA

34.1.3.3.1 DISASSEMBLING
1. Remove plug (10), and drain the oil.
: 5mm
2. Place the end face inside upper roller (1) on
stand jig (f) and remove snap ring (9).
3. Remove cover (4) upwards, using the threaded
hole for the plug.
4. Remove O-ring (7) from cover (4).
5. Loosen two socket bolts (8) and remove plate (3)
: 6mm
FIG. 34-25 CONSTRUCTION OF UPPER ROLLER
FIG. 34-26 PREPARATION FOR DISASSEMBLY
6. Put the extrusion jig (g) against the end face of
shaft (2) and extrude shaft (2) with retainer for
floating seal (6), using a press or hammer.
FIG. 34-27 EXTRUDING SHAFT
6-81100 NA Issued 01-2006 Bur 34-11

34.1.3.3.2 ASSEMBLING
• Installing of the upper roller is performed in the
reverse order of removing.
1. Place the upper roller (1) on the stand jig (f), and
press the jig (h) against the end face of the
bushing, and press it in a specified position.
FIG. 34-28 REMOVING OUT FLOATING SEAL
7. Remove floating seal (6) from upper roller (1).
FIG. 34-30 INSTALLING FLOATING SEAL
FIG. 34-29 ESTRUDING BUSHING
2. There are two floating seals in the upper roller
8. Remove the floating seal (6) from collar (11).
assembly 6. Attach one floating seal to retainer
9. When extruding bushing (5), place upper roller fixed in shaft (2), and another to the inside of
(1) on the stand jig (f), put the extrusion jig (j) upper roller (1).
against the end face of bushing (5) and extrude it • Prior to placing floating seal (6) in, apply engine
by means of a press. oil lightly to seal surface.
FIG. 34-31 PRESSING SHAFT
3. Put shaft (2) in upper roller (1), and press-fit it.
34-12 Issued 01-2006 Bur 6-81100 NA

FIG. 34-32 INSTALLING COVER
4. Place upper roller (1) on the stand jig (f) and
attach plate (3) to the end face of the shaft with SPH34000029E01 Figure 35
socket bolts (8). In that case, coat the threaded FIG. 34-33 FILLING WITH OIL
par t of socket bolts (8) with Loctite #242 8. Fill with 20cc (1.2 cu in) of engine oil API grade
beforehand. CD #30 through the plug in the cover (4).
: 6mm 9. Place seal tape around plug (10) and tighten it

into the plug hole of cover (4).
5. Install O-ring (7) in the groove of cover (4). : 5mm
• Coat O-ring with grease Tightening torque: 23 Nm (17 lb ft)
6. Press cover (4) into upper roller (1).
NOTE: After assembling the upper roller, confirm
7. Install snap ring (9) into upper roller (1). that oil is not leaking from it and that it rotates
smoothly by hand.
6-81100 NA Issued 01-2006 Bur 34-13

34.1.4 MAINTENANCE STANDARDS
FIG. 34-34 UPPER ROLLER
REPAIRABLE
CODE ITEM STANDARD VALUE SERVICE LIMIT REMEDY
LEVEL
A Tread dia. ø82 (3.23) ø73 (2.87) ø70 (2.76)
Replace
B Tread width 102 (4.01) 95 (3.74) 92 (3.62)
Basic
Tolerance Fit Fit
Clearance between dimension
C
shaft and bushing ø32 –0.025 (–0.001) Clearance Clearance Replace
Shaft
(1.26) –0.050 (–0.002) 0.7 (0.03) 1.0 (0.04) bushing
Interference between ø36 +0.03 (+0.0012) Interference Clearance
D Hole
roller and bushing (1.42) 0 0 (0) 0.01 (0.0004)
Tightening torque of Apply Loctite
E 34kgf m (25 lbf•ft)
socket bolt #242
Oil Engine oil API grade CD SAE #30, 20cc (1.2 cu•in) Replenish
Roller rotation Roller rotates smoothly by hand Reassembly
34.1.5 TOOLS AND JIGS

34.1.5.1 TIGHTENING TOOLS
Socket 17
Allen wrench 5, 6
34.1.5.2 JIGS
Symbol Jig Sketch Symbol Jig Sketch
g Fixing jig
f Stand jig
Fixing jig
h {j} {Extruding
jig}
34-14 Issued 01-2006 Bur 6-81100 NA

34.1.6 LOWER ROLLER

Quantity on one side: 5 pcs. 5. Remove the capscrews (2) fastening the lower
roller, and remove the lower roller assembly.
34.1.6.1.1 REMOVING
: 24mm
• Weight of lower roller assembly: 8.7 kg (19.2 lbs)
34.1.6.1.2 INSTALLING
FIG. 34-35 LOWER ROLLER ASSEMBLY
1. Slightly loosen capscrews (M14× 50) (2)
fastening lower roller assembly (1) to the lower
frame.
: 24mm FIG. 34-37 INSTALLING LOWER ROLLER
2. Loosen the grease fitting for track adjusting 1. Install the lower roller so that the plug is directed
within one turn to discharge the grease, release outward from the machine.
the tension on the track. 2. Coat the mounting capscrews (2) with Loctite
#262. Place the roller (4) between the track and
: 17mm lower frame. Hand tighten the capscrews (2).
3. Lift the lower frame high enough to remove the
lower roller using the attachment. : 24mm
3. Lower the machine to the ground and torque the
capscrews (2) as specified.
: 24mm,
T=280 Nm (207 lb ft)
4. Tighten the grease fitting of the track adjuster.
Lift the machine, and adjust the track tension.
: 17mm, T=74 Nm (54.6 lb ft)
FIG. 34-36 TRACK REMOVING POSTURE
4. After lifting the lower frame to a proper height,
place suitable safety stands under the machine.
6-81100 NA Issued 01-2006 Bur 34-15

FIG. 34-38 LOWER ROLLER CONSTRUCTION
34-16 Issued 01-2006 Bur 6-81100 NA

34.1.6.3 DISASSEMBLY AND ASSEMBLY 4. Push the shaft (4) and remove it and the lower
collar (with seal) (13) in one piece.
1. Loosen the plug (9) to drain oil.
: 5mm
2. Remove the snap ring (6).
NOTE: Prior to removing the shaft, place a drain pan
under the lower roller to catch the remaining oil.
FIG. 34-40 REMOVING COLLAR (13)
5. Place the shaft (4) with the collar (13) on the jig
(O). Using jig (P), push out the shaft.

FIG. 34-39 REMOVING SHAFT (4), COLLAR (12)
AND O-RING (8) FIG. 34-41 REMOVING THE SEAL (7)
3. Place the lower roller on the jig (A) so that the 6. Remove seal (7) from collars (12) and (13).
shaft (4) stands vertically. Apply the extruding jig
(P) to the upper shaft end. Push the shaft (4) with
a press until the O-ring comes out from the collar
(12), remove the upper collar (with seal) and O-
ring (8).
FIG. 34-42 REMOVING THE SEAL (7)
7. Take out seal (7) from roller (1).
6-81100 NA Issued 01-2006 Bur 34-17

34.1.6.3.2 ASSEMBLY
FIG. 34-44 INSTALLING O-RING (8) TO ONE SIDE
1. Install O-ring (8) to shaft groove.
• Grease O-ring
FIG. 34-43 REMOVING BUSH (5)
8. A bushing (5) that is worn very thin cut it out with
a lathe. Place the roller (1) on the jig (M) and
drive the bushing (5) out.
NOTE: In order to avoid damage to the bore of the
FIG. 34-45 PRESS FITTING BUSHING (5)
roller (1), drive the bushing (5) out slowly and change
the driver position often. 2. Align the center of the bushing (5) with the bore
of the roller (1). With the bushing jig (Q) press
bushing (5) in. Do the same procedure for the
opposite side.
• Apply grease to the bushing, press the bushing
at room temperature.
FIG. 34-46 PRESS FITTING COLLAR (13)
3. Install floating seal (7). Install O-ring on one side
of shaft (4) mating pin hole of collar (3).
• Care should be taken not to damage O-ring (8)
while press-fitting collar (13) to shaft (4)
4. Installing snap ring (6).
5. Install floating seal (7) to inner holes on both
ends of roller (1).
34-18 Issued 01-2006 Bur 6-81100 NA

8. Insert the collar (12) onto shaft (4).

• Insert it until the ring groove of the shaft (4) is
aligned with the end surface of the collar (2).
9. Install the ring (6) in the ring groove of the shaft
(4).
SPH34000042J01 Figure 49 FIG. 34-49 INSTALLING OIL FILL PLUG (9)
FIG. 34-47 INSTALLING ROLLER (1) 10. Fill with 70 cc (4.2 cu in) of SAE #30 CD class
6. Insert shaft (4) into roller (1). engine oil through the plug (9).
11. Perform a leak test with 2.0 kgf/cm2 (14 psi) of air
pressure.
12. Apply oil resistant sealing agent to the plug (4),
install and tighten.
: 5mm
NOTE: After assembling the lower roller make sure
that it has no oil leaks and rotates smoothly.
FIG. 34-48 INSTALLING THE COLLAR (2)
7. Install O-ring (8) into the shaft groove.
• Apply grease to the O-ring.
• Always replace the O-ring with new one prior to
reassembling.
6-81100 NA Issued 01-2006 Bur 34-19

FIG. 34-50 LOWER ROLLER
Unit: mm (in)
REPAIRABLE SERVICE
Code ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Flange O.D. ø130 (5.12) — —
Welding repair or
B Tread O.D. ø100 (3.94) ø94 (3.70) ø92 (3.62)
replacement
C Flange width 40 (1.58) 36 (1.42) 34 (1.34)
Basic
Tolerance Fit Fit Fit
dimension
0 (0)
Clearance Shaft –0.025 Clearance
D between shaft and (–0.001) 0.10 (0.004)
ø35 Clearance
bushing +0.25 ~ —
(1.38) 0.5 (0.02)
(+0.01) 0.275
Bushing
+0.10 (0.011)
Replace bushing
(+0.004)
+0.16
(+0.0063) Interference
Bushing
Interference +0.12 0.095
Interference
E between roller and ø39 (1.54) (+0.0047) (0.0037) —
0
bushing +0.025 ~
Roller (+0.0010) 0.16 (0.0063)
0 (0)
— Oil Engine oil (Shell Rimula CT #30) 70cc (4.2cu•in) Replenish
— Roller rotation Rollers rotate smoothly by hand Reassembly
34-20 Issued 01-2006 Bur 6-81100 NA

34.1.6.5 SPECIAL JIGS

Bushing Shaft
n p
extrusion rod extrusion jig
Bushing
m {o} Stand jig q
fixing jig
6-81100 NA Issued 01-2006 Bur 34-21

34.1.7 FRONT IDLER

34.1.7.1.1 REMOVING 34.1.7.1.2 INSTALLING
1. Remove the track assembly.

FIG. 34-51 REMOVING IDLER ASSEMBLY FIG. 34-53 INSTALLING IDLER ASSEMBLY
2. Remove idler together with idler adjuster 1. Assemble idler (a) to the idler adjuster assembly
assembly, rolling it, using a pry-bar or equivalent. (b) with capscrews (c). Coat the threaded part of
capscrews (c) with Loctite #262.
: 17mm,
• T=66 Nm (48.7 lb ft)
2. Install the idler and idler adjuster into the lower
frame so that the grease fitting (1) is positioned
up, and the grease fitting (2) is facing to outside.
3. Following procedures of section 2, install the
SPH34000050J01 Figure 54 track assembly, and adjust the track tension.
FIG. 34-52 DISASSEMBLING IDLER ASSEMBLY
3. Loosen capscrews (M10× 50) (c), and separate
idler assembly (a) from idler adjuster assembly
(b).
: 17mm
• Weight of idler assembly: 37 kgf (82 lbs)
• Weight of idler adjuster assembly:
33 kgf (73 lbs).
NOTE: The separated idler assembly (a) can easily
fall over. Lay it on it’s side so it will not fall.
34-22 Issued 01-2006 Bur 6-81100 NA

FIG. 34-54 IDLER ASSEMBLY CONSTRUCTION
No. NAME QTY No. NAME QTY

1 Idler 1 5 Pin 2
2 Bushing 2 6 Shaft 1
3 Collar 2 7 O-ring 2
4 Seal 2 8 Plug: PT 1/8 2

1. Remove the plug (8) and drain the oil.
: 5mm
FIG. 34-56 EXTRUDING SHAFT
SPH34000053E01 Figure 57 3. Place idler (1) on repair stand (U), apply push out
FIG. 34-55 EXTRUDING PIN jig (S) on shaft (6), push out shaft (6) with collar
(3), then remove collar (3).
2. Use pin push bar (jig R) on the pin, strike it lightly
with a hammer.
6-81100 NA Issued 01-2006 Bur 34-23

34.1.7.4 ASSEMBLY
FIG. 34-58 INSERTING SHAFT AND BEARING
1. Align inner hole of idler (1) and bushing (2) and
press fit it vertically with press.
FIG. 34-57 REMOVING BUSHING 2. Fit O-ring (7) to O-ring groove on shaft (2).
• Apply grease to O-ring
4. With idler (1) placed on the stand, tap bushing
(2) lightly with a hammer, while placing the
bushing extruding rod (T) against the end face of
bushing (2) evenly all a round until it comes out.
5. Take out floating seals (4) from idler (1), collar
(3). If you intend to re-use floating seals (4),
confirm that there is no scoring and rusting on
the contact surface and store the floating seals in
pairs by placing thick paper between the sealing
faces.
6. Remove O-ring (7) from shaft (6).
FIG. 34-59 PRESSING IN SHAFT
3. Press fit the O-ring installed side of shaft into
collar (3), and drive in pin (5).
34-24 Issued 01-2006 Bur 6-81100 NA

7. Install floating seal (4) on the other collar (3),

press fit it onto the shaft, and drive in pin (5).
FIG. 34-60 INSERTING FLOATING SEAL (4)
4. Install one piece of two (2) pieces type floating SPH34000060J01.TIF Figure 64
seal (4) on each side of collar (3) and idler (1). FIG. 34-62 INSTALLING PIN (5)
5. Insert shaft (6) into idler (1). 8. Fill with 70~80 cc (4.3~4.9 cu in) of the gear oil
• Apply gear oil to shaft SAE #90 GL-4 through the plug hole in the idler
6. Fit floating seal (4) on the other side of idler (1). (1).
9. Tighten the plug (8).
: 5mm
NOTE: After installing the idler assy to the idler
adjuster assy, make certain that there are no oil leaks
from the floating seal and plug (8) and that idler (1)
rotates smoothly.
FIG. 34-61 INSERTING FLOATING SEAL (4)
6-81100 NA Issued 01-2006 Bur 34-25

FIG. 34-63 IDLER ASSEMBLY
Unit: mm (in)
REPAIRABLE
Code ITEM STANDARD VALUE SERVICE LIMIT REMEDY
LEVEL
Dia. of idler
A ø364 (14.3) —
projection
ø312 Replace
B Tread dia. ø320 (12.6)
(12.3)
C Flange width 40 (1.57) 36 (1.42)
Basic dimension Fit Fit Fit
Clearance
Clearance
D between shaft Clearance
ø45 (1.77) 0.278~0.183
and bushing 1.5 (0.059)
(0.0109~0.0072) Replace bushing
Interference Interference
Interference
F between idler ø50 (1.97) 0.093~0.015
0 (0)
and bushing (0.0037~0.0006)
— Oil Gear oil SAE #90 GL-4, 70~80cc (4.3~4.9 cu in) Replenish
— Idler rotation Idler rotates smoothly by hand Reassembly
Unit: mm
Tools Opposing flats
Socket 19, 24
Allen wrench 5, 6
34-26 Issued 01-2006 Bur 6-81100 NA

Unit: mm (in)
Pin extruding
R U Repair stand
jig
Bushing
Shaft
S V press fitting
extruding jig
jig
Bushing Collar press

T W
striking rod fitting jig
6-81100 NA Issued 01-2006 Bur 34-27

34.1.8 IDLER ADJUSTER

34.1.8.1.1 REMOVING : 17 mm
• Weight of idler assembly: 37 kg (82 lbs)
• Weight of idler adjuster assembly: 33 kg (73 lbs)
NOTE: The idler can easily fall over, to prevent this,
lay it on its side.
1. Installation is done in the reverse order of
removal:
FIG. 34-64 DISASSEMBLING IDLER ASSEMBLY 2. Put Loctite #262 on the capscrews (c).
1. Remove idler adjuster and idler assembly from 3. Put the idler (a) on idler adjuster (b), and tighten
the lower frame. capscrews (c).
Refer to 34.1.7.1.1 page 34-22.
2. Loosen capscrews (c) and separate idler : 17mm,
assembly (a) from idler adjuster assembly (b). T=66 Nm (48.7 lb ft)
4. Install the idler adjuster in the track frame. Refer
to the construction illustration.
CONSTRUCTION
FIG. 34-65 IDLER ADJUSTER ASSEMBLY
34-28 Issued 01-2006 Bur 6-81100 NA


1. Disassembly
FIG. 34-68 FIXING HOLDING-DOWN NUT
G. Install retainer plate to plate (4) tighten down
SPW34000056E01 Figure 68 the nuts alternately, and secure idler adjuster
assembly.
FIG. 34-66 SPRING SET SPECIAL JIG (V)
A. Before disassembling and assembling the
idler adjuster assembly, prepare spring
setting jig (V). Use a hydraulic jack with a
capacity of more than 5 tons (11000 lb)
B. Place a hydraulic jack between the jig base
and the stand.
C. Loosen the hold down nuts of the jig and
remove the retainer plate.
D. Remove the piston (1) from grease cylinder
(2) of the idler adjuster assembly.
E. Taken out oil seal (7) and O-ring (8) from SPW34000062E01 Figure 71
grease cylinder (2).
FIG. 34-69 ATTACH IDLER ADJUSTER ASSEMBLY TO THE
JIG
H. Remove split pin (9).
FIG. 34-67 SLINGING WORK OF IDLER ADJUSTER
FIG. 34-70 COMPRESSION OF SPRING
F. Set the idler adjuster assembly on the stand
(V) with its plate (4) facing up. I. Press spring (3) with the jack so that nut (5)
can be turned freely, remove nut (5).
6-81100 NA Issued 01-2006 Bur 34-29

2. Assembly
• Perform assembly in the reverse order of
disassembly.
A. Insert grease cylinder (2) into spring (3) and
place it in the center of the jig.
B. Install the plate (4) on top of spring (3).
Center the rod of grease cylinder (2) and the
holes in bracket (4). Attach the retainer plate
and four hold down nuts. Fasten the nuts
evenly securing the idler adjuster assembly in
the jig.
C. Raise the hydraulic jack, compress spring (3)
and screw nut (5) onto the cylinder (2).
Set length of the spring: 335 mm (13.2 in)
FIG. 34-71 REMOVING RETAINER PLATE
J. Lower the jack slowly until the spring is
extended to its free length. Remove the
retainer plate and spring plate (4).
Free length of the spring:
Approx. 412 mm (16.2 in)
FIG. 34-72 INSTALLING SPLIT PIN
D. Tighten nut (5) till the holes for locking split
pins (9) are aligned, install split pin (9).
: 46mm
E. Remove the idler adjuster assembly from the
jig.
F. Replace oil seal (7) and O-ring (8) in grease
FIG. 34-72 REMOVING AND INSTALLING OF IDLER
ADJUSTER ASSEMBLY cylinder (2). Apply grease on oil seal (7) and
O-ring (8).
K. Hook lifting eye nut (W) to screw M30× P3 on
cylinder (2). G. Remove the grease fitting from piston (1) and
Lifting nut: M30× P3 press the piston by hand to discharge the
inside air.
L. Remove the cylinder (2) from the spring (3).
H. Tighten grease fitting in piston (1).
: 17mm
Tightening torque: 74 Nm (54.6 lb ft)
34-30 Issued 01-2006 Bur 6-81100 NA


Table 34-1 Table 34-1
Code ITEM Rubber track Steel shoe
Code ITEM Rubber track Steel shoe
Installed length of D Set length 674 (2’2.5”) 631 (24.8)
A 335 (13.2) 335 (13.2) Outside view of No scoring and No scoring
spring E
Free length of piston rusting and rusting
B 412 (16.2) 412 (16.2) Tightening torque 73.5 Nm 73.5 Nm
spring F
C Stroke 28 (1.1) 28 (1.1) of grease fitting (54.2 lb ft) (54.2 lb ft)
Unit: mm (in)
FIG. 34-73 IDLER ADJUSTER ASSEMBLY
6-81100 NA Issued 01-2006 Bur 34-31

34.1.9 SPROCKET
Refer to Paragraph 34-1-2-1 page 34-3.
FIG. 34-76 TIGHTENING CAPSCREW
1. Check the mounting surfaces of the travel motor
and the sprocket, eliminate burrs and dirt, install
FIG. 34-74 MAKING SPROCKET FREE
the sprocket.
2. Place wooden block under the lower frame so the
2. Apply Loctite #262 to the capscrews, install and
sprocket is off the ground.
hand tighten.
3. Remove the wooden block under the lower
frame, lower the fram e until the sprocket
engages the track. Tighten capscrews.
: 22 mm,
T=181 Nm (133 lb ft)
4. Install track.
FIG. 34-75 REMOVING SPROCKET
3. Loosen capscrew (M14) for the mounting of the
sprocket with an Allen wrench. Remove the
sprocket.
: 22 mm
Single weight of sprocket: 14 kg (31 lbs) SPH34000075E01 Figure 80
FIG. 34-77 SPROCKET
Code A B
Width of sprocket
ITEM O.D. of sprocket
teeth
STANDARD VALUE 32 (1.26) ø435.8 (17.16)
REPAIRABLE LEVEL 29 (1.14) ø429 (16.9)
SERVICE LIMIT 27 (1.06) ø427 (16.8)
Welded repair, or
REMEDY Replace
replace
Unit: mm (in)
34-32 Issued 01-2006 Bur 6-81100 NA

34.1.10 TRAVEL MOTOR

34.1.10.1.1 REMOVING
FIG. 34-80 REMOVING AND INSTALLING TRAVEL MOTOR.
6. Attach a lifting strap near the sprocket of the
travel motor for balance.
SPW34000068E01 Figure 81 7. Put a matching mark between the lower frame
FIG. 34-78 MAKING SPROCKET FREE and the travel motor. Loosen the capscrews
2. Place wooden block under the lower frame so the M14× 35 (B2) that fasten the travel motor to the
sprocket is off the ground. lower frame.
: 22 mm
8. Remove the unit out of the lower frame.
Weight of travel motor (with sprocket):
79 kg (174 lbs)
FIG. 34-79 REMOVING COVER AND TRAVEL MOTOR
3. Remove the capscrews (A4) located inside the
lower frame and remove the covers (A1).
: 17 mm
4. Push the air bleeding cap with the boots on SPH34000077E01 Figure 84
hydraulic oil tank to release air in the tank.
2. Capscrew (Travel
5. Tag and disconnect the hoses connected to the 1. Capscrew (Sprocket)
Motor)
travel motor, plug the lines and fittings in order to 181 Nm (133 lb ft)
prevent oil loss and contamination. 181 Nm (133 lb ft)
Loctite #262
Loctite #262
: 19 mm, 22 mm and 32mm
FIG. 34-81 INSTALLING TRAVEL MOTOR
1. If there are burrs and dirt on the mounting
surface of the travel motor and frame, remove
them. Place a lifting strap on the travel motor as
in the removal, install it into the lower frame.
6-81100 NA Issued 01-2006 Bur 34-33

2. Coat the threaded part of the mounting capscrew

(B3) with Loctite #262 and tighten them.
: 22 mm,T=181 Nm (133 lb ft)
FIG. 34-83 CHECKING OIL LEVEL
7. Checking oil level in reduction unit
A. Stop the machine so that the drain plug of the
reduction unit is loc ated in the lowe st
position.
FIG. 34-82 INSTALLING HYDRAULIC PIPINGS (LH-TRAVEL
MOTOR) B. Remove the level plug and check the oil level.
3. Reconnect the hydraulic hoses, tighten the joints If the oil level is correct, close to the plug
to the specified torque. Remove tags. bore.
• Make sure the motor is full of hydraulic oil prior C. Start and run the engine at low idle and the
to connecting return hose. travel motor at low speed for several minutes.
Check for oil leaks and noise.
ITEM SPEC.
TIGHTENING TORQUE
Sprocket mounting
Capscrew M14
4. Install the covers (A1) located inside the lower Apply Loctite #262
frame, and tighten capscrews (A4). (See Fig. 34- Travel motor mounting 181 Nm (133 lb ft)
79) Capscrew M14
: 17mm
Spec. and grade Gear oil SAE#90 GL-4
OIL
5. Remove the wooden block supporting the lower Volume 900cc (55 cu in)
frame and install the track.
6. Check the oil level in the reduction unit of travel
motor [See Item (7) below] and fill as required.
Oil: GEAR OIL SAE#90 GL-4
900 cc (55 cu in)
: 8mm
34-34 Issued 01-2006 Bur 6-81100 NA

34.1.11 SLEWING BEARING

1. Remove the upper slewing structure. (See 1. Before installing the slewing bearing, clean the
Chapter 33 “Upper Slewing Structure”). bearing and the mating surface of the lower
frame.
FIG. 34-84 SLEWING BEARING
2. Remove capscrews (B) that fix the inner race of
slewing bearing (A)
: 22 mm
3. Remove the grease in the inner race of slewing
bearing.
FIG. 34-86 LOCATION OF “S” MARK TO INSTALL SLEWING
BEARING
2. Lift up the bearing and place it on the lower
frame, aligning the “S” mark engraved on the
inner race as shown in Fig. 34-86.
3. Coat the threads of the capscrews (B) with
Loctite #262 and tighten all capscrews
SPW34000076J01 Figure 88 temporarily.
FIG. 34-85 LIFTING SLEWING BEARING
4. Tighten the capscrews as per pattern in figure
4. Screw lifting-bolts in the slewing bearing (A), and 34-75 to the specified torque.
lift it by crane.
Weight of slewing bearing assembly: : 22 mm,
79 kgf (168 lbs)
T=181 Nm (133 lb ft)
5. Fill the “grease bath” with “Lithium grease”
4.8 kg (10.6 lbs).
6. After installing the slewing bearing on the lower
frame, install upper slewing structure. (See
Chapter 33 “Upper Slewing Structure”).
6-81100 NA Issued 01-2006 Bur 34-35

NAME QTY NAME QTY

1. INNER RACE 1 6. PLUG 1
2. OUTER RACE 1 7. TAPER PIN 1
3. BALL 95 8. SEAL A 1 SPH34000083E01 Figure 91
4. SPACER 70 9. SEAL B 1
FIG. 34-88 DISASSEMBLING SLEWING BEARING
5. SPACER/ADJUSTING 25 10. GREASE NIPPLE 1
1. Remove seal A (8) fitted in the groove in the
FIG. 34-87 CROSS-SECTION OF SLEWING BEARING inner circumference on top of outer race (2) and
seal B (9) fitted in the groove in the outer
circumference under inner race (1), from the
bearing, and place the bearing level on wood
block.
2. Remove taper pin (7).
3. Remove plug (6).
FIG. 34-89 REMOVING BALLS / SPACERS
4. After removing plug (6), remove balls (3) and
spacers (4 and 5) from the bore by rotating the
outer race (2).
34-36 Issued 01-2006 Bur 6-81100 NA

34.1.11.3.2 ASSEMBLING 34.1.11.4 MAINTENANCE STANDARDS

1. Degrease the groove for seal A thoroughly (8) Regarding the maintenance standards for the wear of
located in the inner circumference of outer race the slewing bearing, refer to the Article Measuring
(2) and the groove for seal B (9) located in the Slewing Performances in Chapter 13, Maintenance
outer circumference of inner race (1). Coat the Standards and Test Procedures.
grooves with adhesive (Cyanoacrylate instant
glue), install seal B (9), and place inner race (1)
on a surface plate.
2. Lift and lower outer race (2) slowly till the top
surface of inner race (1) matches the bottom of
the sealing groove of outer race (2). Place an
adjusting washer under outer race (2) in order to
support the outer race so the track surface of ball
(3) is aligned.
FIG. 34-90 INSTALLING BALLS
3. Insert balls (3) and spacers (4 and 5) coating
with grease (NLGI No.2 Lithium base with MoS2)
alternately through the hole for plug (6) on outer
race (2).
NOTE: Do not use your finger to install the balls and
spacers; always use a push rod.
4. Install plug (6) to outer race (2).
5. Push taper pin (7) into bore, and caulk the head
of the taper pin with a punch.
6. Grease the slewing bearing and confirm that the
outer race rotates smoothly and that the lip of the
seal is not scored.
Grease (NLGI-2 EP type):
Approx. 180 g(6.3 oz.)
6-81100 NA Issued 01-2006 Bur 34-37


34.2.1 TRAVEL MOTOR
34.2.1.1 SUMMARY
1. General View
SPH34000001E01. Figure 94
34-38 Issued 01-2006 Bur 6-81100 NA

2. Exploded View of Motor and Reduction Unit
6-81100 NA Issued 01-2006 Bur 34-39


1 Hub 1 102 Shaft 1
2 Spindle 1 103 Swash plate 1
3 Carrier 1 107 Retainer plate 1
4 Sun gear (1) 1 108 Thrust ball 1
5 Planetary gear (1) 3 109 Timing plate 1
6 Sun gear (2) 1 110 Washer 2
7 Planetary gear (2) 4 112 Piston 1
9 Thrust washer (1) 2 113 Spring 8
11 Thrust collar (4) 4 114 Spring 1
12 Thrust washer (3) 7 115 Friction plate 2
13 Cover 1 116 Separator plate 3
14 Coupling 1 132 Oil seal 1
22 Ring nut 1 135 O-ring 1
24 Ball bearing 2 139 O-ring 1
27 Needle roller bearing with retainer 3 145 Snap ring 1
28 Needle roller bearing with retainer 4 149 Ball bearing 1
29 Inner race 3 150 Ball bearing 1
30 Inner race 4 151 Roller 3
167 Pivot 2
Floating seal kit 1 177 Parallel pin 2
31 Floating seal 2 190 Spring 1
33 Plug with flange 1 Rear flange assembly 1

35 O-ring 1 •Rear flange kit 1
37 O-ring 3 201 ••Rear flange 1
39 Plug 2 223 ••Spool 1
40 Hexagon head screw 7 •Spool kit 1
41 Steel ball 1 263 ••Spool 1
42 Parallel pin 2 264 ••Oil stopper 1
43 O-ring 2 221 •Plug 2
44 O-ring 1 224 •Plug 2
45 Ring 1 225 •Stopper 2
47 Hexagon socket set screw 2 226 •Plug 2
227 •Valve 2
228 •Spring 2
Cylinder and piston kit 1 230 •Spring 2
104 •Cylinder block 1 236 •O-ring 2
•Piston kit 1 237 •O-ring 2
••Piston assembly 9 252 •Hexagon socket plug 4
105 •••Piston 1 254 •Hexagon socket plug 6
106 •••Shoe 1 266 •Spring 1
268 •Steel ball 1
Piston kit 1 273 •O-ring 2
•Piston assembly 1 275 •Orifice 5
161 ••Piston 1 276 •Orifice 1
162 ••Shoe 1 279 •Filter 1
163 •Seal ring 1 280 •Plug with flange 1
34-40 Issued 01-2006 Bur 6-81100 NA


299 •Name plate 1
241 Parallel pin 2
243 Capscrew 6
3. Hydraulic circuit diagram
6-81100 NA Issued 01-2006 Bur 34-41

34.2.1.2 TOOLS AND JIGS

1. Standard tools
No. NAME SIZE Q’TY

1 Allen wrench 3 (For M6), 6 (For M8 & PF1/4), 8 (For PF3/8) 1 each
2 Socket wrench (Ratchet handle) Barrel type 1
Dial type, about 12 Nm (8.7 lb ft)
3 Torque wrench Dial type, about 90 Nm (65 lb ft) 1 each
Dial type, about 560 Nm (406 lb ft)
Nominal socket size 13 and 30
4 Torque wrench adaptor 1 each
Nominal rod size 3, 6 and 8
5 Hexagon socket For width across flats of 3 mm 1
6 Extension bar 150 mm (6") 1
7 Hammer Nominal size 12 1
8 Plastic hammer L= about 300 mm (12") 1
9 Flat screwdriver about 150 mm (6"), 50 mm (2") 1
For shaft 1
10 Snap ring pliers
For hole 1
11 Cutting pliers (JIS B 4623) 200 mm (8") 2
12 Lifting tool Lifting capacity: 300 kg (660 lbs) or over 1 set
Lifting eye (for M14) (2)
Lifting eye (for PF 3/8) (2)
Wire with hooks (1)
13 Container Vat for general use: W450× D300× H120 (W17.7’× D11.8’× H4.7’) 2
14 Leather gloves 1 pair
2. Bolts
No. Name Description Q’TY
Approx. M6 (P1.0)× 50 1
Hexagon socket head cap screw
1 Approx. M16 (P2.0)× 40 2
(JIS B 1176)
Approx. M16 (P2.0)× 150 3
3. Tools
APPLICATION ITEM
NAME SIZE REMARKS Q’TY
(Item in cross-sectional or exploded view)
Disassembly and assembly General workbench 1 set

Parts cleaning Cleaning bath For rough and finish cleaning 1 set
Pressing capacity:
104 and 149 Workbench for press 1 set
1.96 kN [440 lbs] or over
Heating capacity: 100 °C or over
(212 °F)
149 Heating bath 1 set
Volume 500× 500× 500 mm
(20’× 20’× 20’)
Pressure
Disassembly 161, 162, 163, and 112 Drying
Compressed air (294~490 kPa)
after cleaning
(43~71 psi)
34-42 Issued 01-2006 Bur 6-81100 NA

4. Jigs E. Oil seal press fit tool

A. Working bench for travel motor

For press fitting the oil seal (132) in the oil seal hole
of the spindle (2).
F. Bearing press fit tool
Used for assembly and disassembly work.
B. Fixing metal

For press fitting the ball bearing (24) in the hub (1).
G. Jig for adjusting the preload to the bearing
Used to connect the spindle (2) and hub (1).
C. Retainer metal (I)

For installing the ring nut (22) to the spindle (2).
H. Steel rod (1)
Used to insert spring (114), washer (110), snap ring

(145) into cylinder block (104), and also used to
remove spring (114) from cylinder block (104).
D. Retainer metal (II)
Used to remove the ring (45) from the hub (1).

Used to pull out bearing (149) from drive shaft (102).
6-81100 NA Issued 01-2006 Bur 34-43

I. Long lifting eye M. Floating seal (F/S) inserting jig (I)

For building the floating seal (31) into the hub (1).
N. Floating seal (F/S) inserting jig (II)
Application A Spindle M14

Hub M14 Travel Motor M14
This lifting eye is used to sling up travel motor, the
spindle (2) and the hub (1).
J. Spatula

For building the floating seal (31) into the hub (1) and
spindle (2).
O. Floating seal (F/S) inserting jig (III)
Used to remove the timing plate (109) from rear
flange (201).
K. Pin punch

For building the floating seal (31) into the spindle (2).

Used to remove the outer race of floating seal (31).
L. Jig for cover removal

Used to remove the cover (13) from the hub (1).
34-44 Issued 01-2006 Bur 6-81100 NA

34.2.1.3 DISASSEMBLY
34.2.1.3.1 PREPARATIONS FOR DISASSEMBLY 34.2.1.3.3 DISASSEMBLING
Pr ior to disassembly, carr y out the following
preparations:
1. Workbench preparation
A. Prepare workbench for travel motor.
B. Workbench should be strong enough to
support the travel motor and have a wide
enough area for removed parts.
C. Cover workbench with rubber, vinyl, etc.
2. Preparations of tools and materials
Prepare materials shown in 34.2.1.2.
34.2.1.3.2 GENERAL PRECAUTIONS FOR
WORKING SPW34000101E01 Figure 112
FIG. 34-92 MOUNTING LIFTING EYE
CAUTION: Internal parts are slippery
1. Cleaning travel motor
because they are covered by hydraulic oil.
Handle them with extreme care, do not drop A. Tighten the lifting eyes into the spindle (2).
them. You may be injured or the parts may B. Attach suitable lifting equipment and place it
be damaged. into a cleaning bath.
1. All parts are manufactured with high precision,

handle them with care and do not bump them
against each other or drop them.
2. Do not strike or pry sticking parts during
disassembly. This may result in burrs, damages,
and performance deterioration.
3. Protect disassembled parts from rust or being
contaminated by dust.
4. Put a match mark on each mating surface of part
during disassembly.
5. Put removed parts in order.
6. Replace seals and O-rings. SPW34000102J01 Figure 113
7. Photos and figures of typical models are shown. FIG. 34-93 CLEANING TRAVEL MOTOR
Any partial difference between them and the C. Clean the travel motor with a brush.
product in use does not affect the disassembly
procedure. NOTE: Since dirt and sand can accumulate in the
clearance where the floating seal is located, between
the hub (1) and the spindle (2), clean it with particular
care.
6-81100 NA Issued 01-2006 Bur 34-45

C. Turn over the travel motor.

FIG. 34-94 PLACING TRAVEL MOTOR ON WORKBENCH SPW34000106J01 Figure 117
FIG. 34-97 DRAINING OIL
D. Place a container under the work bench to
catch the oil.
(Oil quantity 0.6 liter (0.16 gal)
E. Remove the plug (33) and two socket plugs
(39) from the cover (13) and drain out the
lubricating oil.
F. Remove the O-rings (37) from the plug (33)
and two socket plugs (39).

FIG. 34-95 FIXING TRAVEL MOTOR ON WORKBENCH
2. Mounting the travel motor on the work stand.
A. Place travel motor on a workbench.
B. Mount the travel motor with two bolts to the
workbench.
3. Draining lubricating oil
A. Turn over the travel motor.
FIG. 34-98 REMOVING RING (45)
4. Removing cover (13)
A. Turn the travel motor over.
B. Remove the ring (45).

FIG. 34-96 REMOVING PLUG (33)
B. Loosen a plug (33) and two socket plugs (39).
Loosen them so they can be turned by hand.
34-46 Issued 01-2006 Bur 6-81100 NA


FIG. 34-99 REMOVING COVER (13) FIG. 34-101 REMOVING CARRIER ASSEMBLY
C. Install the removal jig in the holes from which 6. Removing carrier assembly set 1
the plugs (33) and (39) were removed. A. Take out the carrier assembly from the hub
D. Tighten the outer screws to remove the cover (1).
(13). B. Take out the sun gear set 2 (6) from the hub.
E. Lift the cover while lightly tapping the external C. Remove the coupling (14) from the shaft
periphery of the cover with a plastic hammer. (102).
F. Remove the O-ring (35) from the hub (1).

SPW34000109J01 Figure 120 FIG. 34-102 DISASSEMBLING CARRIER ASSEMBLY
FIG. 34-100 REMOVING SUN GEAR 1 (4) 7. Disassembling carrier assembly
5. Removing sun gear set 1 (4) A. Loosen the hexagonal head screws (40) to
A. Pull out the sun gear 1 (4), coupling (14) may remove three thrust washers (12).
come out with the sun gear. B. Remove three thrust washers (12), three
B. Remove the steel ball (41) from the shaft planetary gears set 1 (5), three needle roller
(102). bearings with retainers (27) and three bearing
inner races (29) from the carrier (3).
6-81100 NA Issued 01-2006 Bur 34-47

A. Remove four thrust collars 4 (11) from the

spindle (2).
B. Remove the thrust washer 1 (9) from the
spindle (2).
11. Removing rear flange
A. Turn the travel motor over.
• Do not loosen the plugs unless
disassembling the interior of the rear
flange.

FIG. 34-103 REMOVING THRUST WASHER (9)
8. Remove the thrust washer (9) from the carrier
(3).

FIG. 34-106 UNSCREWING PLUG (224)
B. Loosen two plugs (224).

FIG. 34-104 UNSCREWING HEXAGONAL HEAD SCREW (40)
9. Removing planetary gear set 2 (7)
A. Loosen four hexagonal head screws (40) and
remove them from spindle (2).

FIG. 34-107 UNSCREWING PLUG (226)
12. Loosen two plugs (226).

FIG. 34-105 REMOVING PLANETARY GEAR 2 (7)
10. Remove four planetary gears set 2 (7), four
needle roller bearings with cages (28) and four
inner races (30).
34-48 Issued 01-2006 Bur 6-81100 NA


FIG. 34-108 REMOVING SOCKET BOLT (243) FIG. 34-111 REMOVING O-RINGS (43) AND (44)
13. Loosen six socket bolts (243) and remove them 16. Remove the O-rings (43) and (44) from the
from the rear flange (201). spindle (2).
NOTE: Do not reuse the removed O-rings (43) and
(44).
17. Removing rear flange fittings

A. Place the rear flange (201) on the workbench,
with the mating surface for the spindle (2)
facing up.

FIG. 34-109 REMOVING REAL FLANGE (201)
14. Remove the rear flange (201) from the spindle
(2).
A. Hold the rear flange by both hands, pull it up
and remove it. Do not pry or strike the flange.
• Watch for the timing plate (109), do not drop it.

FIG. 34-112 REMOVING TIMING PLATE (109)
B. Remove the timing plate (109) from the rear
flange (201).

FIG. 34-110 REMOVING PARALLEL PIN (42)
15. Remove the parallel pins (42) from the spindle
(2).
6-81100 NA Issued 01-2006 Bur 34-49


FIG. 34-113 REMOVING PARALLEL PIN (241) FIG. 34-116 REMOVING STOPPER (225), SPRING (228) AND
SPOOL (223)
C. Remove the parallel pins (241) from the rear
flange (201). 20. Remove two stoppers (225) and two springs
(228) from the rear flange (201).
A. Remove the spool (223) from the rear flange
(201).

FIG. 34-114 REMOVING BEARING (150)
18. Remove bearing (150) from the rear flange SPH34000008J01 Figure 137
(201). FIG. 34-117 REMOVE THE PLUG (226)
21. Remove two plugs (226) from the rear flange
(201).

19. Removing brake valve parts from rear flange
FIG. 34-118 REMOVING SPRING (230) AND VALVE (227)
A. Remove two plugs (224) from the rear flange
(201). 22. Remove two springs (230) and two valves (227)
from the rear flange (201).
34-50 Issued 01-2006 Bur 6-81100 NA


FIG. 34-119 REMOVING O-RING (236)
23. Remove O-ring (236) from plug (224).
• Do not reuse the removed O-ring (236). FIG. 34-122 REMOVING SPOOL (263)
26. Remove the spool (263) and spring (266) from
the rear flange (201).

FIG. 34-120 REMOVING O-RING (237)
24. Remove the O-ring (237) from the plug (226).
• Do not reuse the removed O-ring (237). FIG. 34-123 REMOVING PISTON (112)
27. Removing the parking brake section.
CAUTION: Install a protection cover on the

piston (112), the piston may fly out suddenly
from the spindle (2) due to compressed air.
A. Blow compressed air into the passage hole

for the parking brake of the spindle (2) and
take out the piston (112) from the spindle (2).

25. Removing two-speed switching spool
A. Remove the plug (221) from the rear flange
(201).
B. Remove the O-ring (273) from the plug (221).
• Do not reuse the removed O-ring (273).
6-81100 NA Issued 01-2006 Bur 34-51


FIG. 34-124 REMOVING PISTON (112) FIG. 34-126 REMOVING CYLINDER BLOCK (104)
B. Remove the O-rings (135) and (139) from the D. Remove two separator plates (116) and, one
piston (112). friction plate (115).
• Do not reuse the removed O-rings (135) and E. Hold the cylinder block (104) by hand and
(139). turn it 2 or 3 times alternatively to separate
the shoe (106) from the swash plate (103).
NOTE: If the cylinder block (104) is pulled out
without separating the shoes (106) from the swash
plate (103), parts (piston, shoe, etc.) in the cylinder
block (104) will fall out and drop into the spindle (2).

FIG. 34-125 LIFTING CYLINDER BLOCK (104)
28. Disassembling hydraulic motor section
A. When placing the travel motor on its side, SPW34000136J01 Figure 147
place an oil pan under the travel motor to FIG. 34-127 REMOVING RETAINER PLATE (107)
catch oil from the travel motor.
29. Remove the cylinder block (104) from the drive
B. Incline travel motor 90 degrees. shaft (102).
C. Drain oil out of the travel motor. A. Remove piston assembly [piston (105) and
shoe (106)] and the retainer plate (107)) from
the cylinder block (104).
B. When removing the cylinder block, hold the
retainer plate (107) by both hands to remove
it with the piston assemblies.
C. The pistons (105) and the shoes (106) are
one piece. It is not possible to remove the
piston from the shoe without damaging the
shoe. When replacement is required, replace
the piston and shoe as a set.
34-52 Issued 01-2006 Bur 6-81100 NA


FIG. 34-128 REMOVING PISTON ASSEMBLY (105) AND (106) SPW34000140E01 Figure 151
D. Remove the retainer plate (107) from piston FIG. 34-131 REMOVING SPRING (114)
assembly (105) and (106) [seven sets]. 30. Removing spring inside cylinder block.
NOTE: Remove the spring only when replacement is
necessary.
A. Place the cylinder block (104) on a press.
B. When removing the spring, align the center of
the retainer metal (I) with the washer center in
order to prevent the cylinder block from being
damaged by contact.
C. Put a vinyl sheet over the cylinder block so as
not to damage the surface of the cylinder
block.

FIG. 34-129 REMOVING THRUST BALL (105)
E. Remove the thrust ball (108) from the cylinder
block (104).

FIG. 34-132 REMOVING SPRING (114)
31. Place the retainer metal (I) against the washer
(110), remove the snap ring (145) from the snap
ring groove of the cylinder block (104) with a
snap ring plier.
CAUTION: Release pressing force slowly, the spring
may fly out.
FIG. 34-130 REMOVING ROLLER (104)
F. Remove three rollers (151) from the cylinder
block (104).
6-81100 NA Issued 01-2006 Bur 34-53

34. Pull the drive shaft (102) and the ball bearing
(149) out of the spindle (2).
A. Lightly strike the tip of the shaft on the
reduction side using a plastic hammer to
drive the shaft out.
B. Remove two pivots (167) and two parallel
pins (177) from the spindle (2).

FIG. 34-133 REMOVING INTERNAL OF CYLINDER BLOCK
(104)
32. Remove the snap ring (145), washer (110),
spring (114), and washer (110) from the cylinder
block.

FIG. 34-136 REMOVING 2-SPEED SWITCHING PISTON KIT
C. Remove the 2-speed switching piston (piston
and seal ring) and the spring (190) from the
spindle (2).

FIG. 34-134 REMOVING SWASH PLATE (103)
33. Removing swash plate
A. Remove the swash plate (103) from the drive
shaft (102).
• When removing the swash plate (103),
ensure that pivot (167) is not stuck on the
swash plate (103). SPW34000146E01 Figure 157
FIG. 34-137 REMOVING BALL BEARING (149)
35. Removing ball bearing
NOTE: Remove the bearing only when replacement
is necessary.
A. Place retainer metal (II) on the press and put
the drive shaft (102) into it.
B. Press down the drive shaft (102) and remove
the bearing (149) from the shaft.
• Do not reuse the ball bearing.

FIG. 34-135 REMOVING DRIVE SHAFT (102)
34-54 Issued 01-2006 Bur 6-81100 NA

SPW34000147J01 Figure 158 SPW34000150E01 Figure 161

FIG. 34-138 FIXING SPINDLE (2) FIG. 34-141 INSTALLING JIG
36. Removing spindle 38. Loosen the ring nut (22) using jig.
A. Apply the clamp plates to the spindle (2) in A. Do not reuse the ring nut (22) if a tooth is
the equally spaced positions, and fasten damaged.
t h r e e M 1 6 × 2 . 0 × 1 5 0 ( a p p r ox . ) t o t h e
workbench.
Tightening torque: 59±20 Nm (43±14 lb ft)
B. Turn the travel motor over. (Reduction unit
side up.)

FIG. 34-142 REMOVING RING NUT (22)
39. Remove the ring nut (22) from the spindle (2).

FIG. 34-139 REMOVING HEXAGON SET SCREW (47)
37. Remove two hexagon set screws (47).

FIG. 34-140 LOOSEN RING NUT (22)
6-81100 NA Issued 01-2006 Bur 34-55


FIG. 34-143 REMOVING SPINDLE (2) FIG. 34-145 REMOVING BALL BEARING (24)
40. Removal of the ring nut B. Use a hammer and punch on the main
A. Turn the travel motor over. (Motor side up.) bearing (24) to remove it.
• Be prepared to catch the ball bearing when
B. Remove the clamp plates from the spindle. it comes out of the hub.
C. Tighten two M16 eyebolts in the holes of the C. Turn the travel motor over.
spindle (2) in a diagonal position.
D. Remove the outer ball bearing from hub (1).
D. Attach lifting equipment to the M16 eyebolts,
remove the spindle (2) from the hub (1). The
floating seal (31) and oil seal (132) will come
out with the spindle (2).

FIG. 34-146 REMOVING FLOATING SEAL (31)
42. Removing spindle floating seal.
SPW34000153J01 Figure 164 A. Remove the floating seal (31) from the
FIG. 34-144 REMOVING FLOATING SEAL (31) spindle (2).
41. Removing main bearing
A. Remove the floating seal (31) from the hub
(1).
• Do not reuse the removed floating seal (31).
34-56 Issued 01-2006 Bur 6-81100 NA

C. Put the remaining parts in a rough cleaning

bath and clean them.

FIG. 34-147 REMOVING OIL SEAL (132)
43. Remove the oil seal (132) from the spindle (2)
• Never reuse the removed oil seal (132). FIG. 34-150 FINISH CLEANING
44. Rough washing of parts

A. Separate the four parts, namely the hub (1),
spindle (2), cover (13), and rear flange (201),
from the other parts.

FIG. 34-151 FINISH CLEANING
45. Finish cleaning
A. Put parts in a finish cleaning bath containing
SPW34000157J01 Figure 168 clean solvent.
FIG. 34-148 CLEANING EACH PART B. Wipe the parts using a clean cloth.
C. Dry the inner surfaces of the hub (1) and the
spindle (2) in dust-free conditions by blowing
compressed air on them. After drying, apply
hydraulic oil to every part.
D. Dry the inner surface of the rear flange (201)
and the hydraulic motor components in dust-
free conditions by blowing compressed air on
them. After drying, apply hydraulic oil to every
part.

FIG. 34-149 CLEANING EACH SECTION
B. Put the hub, spindle, cover, and rear flange in
a cleaning bath and clean them.
6-81100 NA Issued 01-2006 Bur 34-57

34.2.1.4 ASSEMBLY 34.2.1.4.3 ASSEMBLING PROCEDURE

Perform assembly basically in reverse order of NOTE: After replacing hub (1), spindle (2) and ball
disassembly. bearing (21), adjust the preload of the ball bearing.
34.2.1.4.1 PREPARATION
Prepare a workbench, tools and jigs.
34.2.1.4.2 GENERAL PRECAUTIONS FOR
ASSEMBLY
1. For assembly, use the same general precautions
described in Section 34.2.1.3; DISASSEMBLY.
2. For assembly, remove any metallic dust or
foreign material from all parts and make sure that
the par ts are free of burrs and dents which
should be ground off using an oilstone.
3. Replace the O-rings, oil seals, and floating seals
with new ones. SPW34000161E01 Figure 172
4. Bonding adhesive is applied to the threaded FIG. 34-152 INSERTING BEARING (24)
portions and tapped holes of spindle (2) and 1. Assembling hub section
carrier (3) when assembling.
Clean threads by using the tap (M8p1.25), and A. Place the hub (1) on a press.
washing with solvent, dry the holes with air. B. Insert the main bearing (24) in the hub (1).
Replace bolts (40) with new ones. Place the main bearing press fit jig on the
outer race of the main bearing (24). Push
5. Be careful not to damage the O-rings, oil seals,
down the jig by a press to press fit the bearing
and floating seals at installation (Lightly apply
into the hub (1).
grease on them for ease of installation).
6. Prior to assembly, apply clean hydraulic oil (NAS C. Turn over the hub (1).
standards class 9 or higher) to movable and D. Press fit the main bearing (24) into the hub
sliding portions of hydraulic motor components (1) in the same way as the above item 2).
and valves. E. Be careful not to mistake orientation of the
7. Use no cloth gloves during assembly to prevent main bearing (24) when press fitting.
malfunctions due to textile lint.
8. On completion of assembly, plug every opening
to prevent the entry of dirt.
9. Photos and figures of typical models are shown.
Any partial difference between them and the
product in use does not affect the assembling
procedure.

FIG. 34-153 INSTALLING FLOATING SEAL (31)
F. Apply grease to the O-ring of the floating seal
(31). Install the floating seal into the floating
seal groove of the hub (1).
G. Apply a small amount of grease to the entire
surface of the O-ring after removing it from
the floating seal.
34-58 Issued 01-2006 Bur 6-81100 NA

H. Place the FS inserting tool (I), the floating

seal and the FS inserting tool (II) in this order,
and press in until the FS inserting tool (II)
contacts with the FS inser ting tool (I).
Remove the FS inserting tools and ensure
that the end surface of the hub is in alignment
with the face of the floating seal at an
accuracy of 1 mm (0.04") or less.

FIG. 34-156 INSTALLING FLOATING SEAL (31)
2. Assembling spindle section
A. Apply grease to the O-ring of the floating seal
(31), and install the floating seal in the groove
of the spindle (2).
B. Place the FS inserting tool (III), the floating
SPW34000163E01 Figure 174 seal and the FS inserting tool (II) in this order,
FIG. 34-154 LIFTING HUB (1) and press in until the FS inserting tool (II)
I. Attach two lifting eyes to the tapped holes of contacts with the FS inserting tool (III).
the hub (1) in diagonal position. Remove the FS inserting tools and ensure
that the end surface of the hub is in alignment
J. Attach lifting equipment to the lifting eyes, with the face of the floating seal at an
place the hub (1) on the workbench. accuracy of 1 mm (0.04") or less.
SPW34000164E01 Figure 175 SPW34000166J01 Figure 177

FIG. 34-155 INSTALLING HUB (1) TO THE WORKBENCH
FIG. 34-157 INSERTING SPINDLE (2)
K. Align the tapped hole in the hub (1) with the C. Attach two lifting eyes to the spindle (2) in
mounting holes in the workbench. diagonal position.
L. Attach the hub (1) to the workbench and D. Attach lifting equipment to lifting eyes, insert
tighten the bolts. the spindle (2) in the hub (1) slowly.
CAUTION: Fully tighten the bolts, the travel motor
may fall off when it is turned over
6-81100 NA Issued 01-2006 Bur 34-59


FIG. 34-158 INSTALL FIXING PLATE FIG. 34-160 ATTACHING HEXAGON SET SCREW (47)
E. Secure the hub (1) and the spindle (2) with H. Tighten two hexagon socket set screws (47).
fixing plate in diagonal position. Tightening torque: 4.9±1.0 Nm (3.7±0.7 lb ft)
F. Turn the travel motor over.
(Reduction unit side up.)

FIG. 34-161 REMOVING FIXING PLATE
I. Turn the travel motor over. (Motor side up.)
J. Remove the clamp plates from the
FIG. 34-159 INSTALLING RING NUT (22) workbench.
G. Apply Loctite #638 to thread part of ring nut
and tighten the ring nut (22) into the spindle
using jig.
34-60 Issued 01-2006 Bur 6-81100 NA

3. Assembling motor parts inside spindle

FIG. 34-164 INSERTING BEARING (149)
FIG. 34-162 INSTALLING OIL SEAL (132)
4. Inserting shaft
A. Install the oil seal (132) into the spindle (2)
using the seal tool and a hammer.
CAUTION: Use heat resistant gloves to
• Apply lithium grease to the lip of the oil seal
prevent possible burns.
before installing.
• Be sure of the orientation of the oil seal. A. Put the ball bearing (149) in a heating bath to
B. Insert two parallel pins (177) into the pin heat it at 100 ± 10°C (212 ±18°F) for 10
holes of the spindle (2). minutes and then install it on the drive shaft
(102).
C. Apply grease to the semi-spherical surface of
two pivots (167) and install them onto the B. Incline the travel motor by 90 degrees.
parallel pins (177) installed to the spindle (2).
D. Apply grease to the spring pin (190) to be
installed into the pistons consisting of pistons
(161), shoes (162) and seal ring (163).

FIG. 34-165 INSERTING SHAFT
C. Insert the shaft (102) into the spindle (2)
carefully, do not damage the seal.

FIG. 34-163 INSTALLING PISTON KIT
E. Apply grease to the sliding surface of the
piston assembly to be installed into the piston
hole of the spindle (2).
6-81100 NA Issued 01-2006 Bur 34-61


SPW34000174J01 Figure 186 FIG. 34-168 INSTALLING SNAP RING (145)
FIG. 34-166 INSTALLING SWASH PLATE (103) D. Place the cylinder block (104) on the press.
D. Install the swash plate (103) into the spindle E. Cover the cylinder block (104) with a vinyl
(2). sheet to prevent damage to the contact plane
E. Apply grease to the surface between the between the cylinder block (104) and the
swash plate (103) and the spindle (2). timing plate (109).
F. Align two pivots (167) installed in the spindle F. Place the retainer metal (I) against the
(2) with the pivot mounting holes of the swash wa sh er (1 10). While h olding down the
plate, install the swash plate (103) into the retainer metal (I) with a press, install the snap
spindle (2). ring (145) into the snap ring groove of the
cylinder block (104) with snap ring pliers.
• Force of the spring (114) is more than 1180
Nm (265 lb-ft).

FIG. 34-167 ASSEMBLING CYLINDER BLOCK
5. Installing cylinder block
A. Place the washer (110), spring (114), washer
(110), and snap ring (145) in this order, into
the cylinder block (104). SPH34000011J01 Figure 189
B. Direct the sharp edge side of the snap ring FIG. 34-169 INSTALLING ROLLERS (151)
(145) toward the inlet side. 6. Assembling hydraulic motor section
C. Direct the sharp edge side of the washer A. Put three rollers (151) into the holes of the
(110) contacting the snap ring (145) toward cylinder block (104).
the snap ring (145) side.
B. Place the thrust ball (108) on the cylinder
block (104).
34-62 Issued 01-2006 Bur 6-81100 NA


FIG. 34-170 ASSEMBLING PISTON ASSEMBLY INTO SPW34000180J01 Figure 192
RETAINER PLATE (107)
FIG. 34-172 INSTALLING FRICTION PLATES (115) AND
C. Install seven piston assemblies to the retainer SEPARATOR PLATES (116)
plate (107). 7. Installing parking brake
D. After assembling, immerse the whole unit in A. Prior to installing, immerse the friction plate
hydraulic oil. (115) in hydraulic oil.
E. Install the retainer plate (107) and the seven B. Incline the workbench by 90 degrees.
piston assemblies to the cylinder block (104). C. Install one friction plate (115) and two
F. Match the retainer plate (107) with the thrust separator plates (116) into the cylinder block
ball (108) for installation. (104) alternately.
D. Lightly coat the O-rings (135) and (139) with
grease and install them into the O-ring
grooves of the piston (112).
E. Install the piston (112) into the spindle (2).
F. If it is hard to fit the piston (112) into the
spindle (2) due to the resistance of the O-
rings (135) and (139), lightly tap the end face
of the piston (112) with a plastic hammer.
G. Do not damage the O-rings when installing
the piston (112).

FIG. 34-171 INSERTING CYLINDER BLOCK (104)
G. Insert the cylinder block (104) onto the drive
shaft (102).
H. Align the spline hole in the cylinder block
(104) with the spline shaft of the drive shaft
(102).
I. After installing the cylinder block, turn it by
hand to make sure that it fits properly.
J. Do not pick up on the cylinder block (104), the
thr ust balls (108) may become canted, SPW34000181J01 Figure 193
leading to abnormality in rotation. FIG. 34-173 INSTALLING PISTON (112)
6-81100 NA Issued 01-2006 Bur 34-63


FIG. 34-174 INSERTING PLUG (226) FIG. 34-176 INSERTING SPOOL (223)
8. Assembling brake valve parts inside rear flange F. Insert the spool (223) into the rear flange
A. Install two O-rings (237) onto the two plugs (201).
(226). G. Apply hydraulic oil to the spool and insert the
B. Coat the O-rings (237) with grease. spool into the rear flange.
C. Install the valve (227) and spring (230) onto

the plug (226).
D. Insert the plug (226) with the valve (227) and
spring (230) into the rear flange (201).

FIG. 34-177 INSTALLING O-RING (236)
H. Install the O-ring (236) onto plug (224).
I. Install the spring retainer (225) and spring
SPW34000183J01 Figure 195 (228) into the plug (224).
FIG. 34-175 TEMPORARILY TIGHTENING PLUG (226)
E. After installing two plugs (226) into the rear
flange (201), snug them using an Allen
wrench.

FIG. 34-178 TEMPORARILY TIGHTENING PLUG (224)
J. Temporarily tighten two plugs (224) to the
rear flange (201) with a wrench.
34-64 Issued 01-2006 Bur 6-81100 NA


FIG. 34-179 INSERTING SPOOL (263) FIG. 34-181 INSTALLING TIMING PLATE (109)
9. Assembling rear flange fittings G. Apply grease to the mating face of the timing
A. Installing two-speed switching spool inside plate (109) that comes in contact with the rear
rear flange flange (201).
B. Insert the spring (266) and the spool (263) H. Install the timing plate (109) into the rear
into the rear flange (201). flange (201), using the parallel pin (241) as a
guide.
C. Install the O-ring (273) on plug (221).
• Apply grease to the O-ring (273). I. Install eight springs (113) into the rear flange
(201).
D. Tighten the plug (221) in the rear flange (201)
at the specified torque. J. Coat the springs (113) with grease so they
Tightening torque: 59±9.8 Nm (43±7 lb ft) will not drop out of the rear flange (201).

FIG. 34-182 INSTALLING O-RINGS (43) AND (44)
FIG. 34-180 INSTALLING BEARING (150)
E. Coat the ball bearing (150) with hydraulic oil 10. Connecting rear flange with the spindle
and install it into the rear flange (201). A. Insert the O-rings (43) and (44) into the O-
F. Put two the parallel pins (241) into the pin ring groove of the spindle (2).
holes in the rear flange (201). NOTE: Insert the O-rings (43) without applying
grease.
6-81100 NA Issued 01-2006 Bur 34-65


FIG. 34-183 INSTALLING PARALLEL PIN (42) FIG. 34-185 TIGHTENING SOCKET BOLTS (243)
B. Install two the guide pins (42) into the spindle E. Screw six hexagonal bolts (243) into the
(2). spindle (2) and torque them to:
C. Put 0.3 L (0.08 gal) of hydraulic oil into the Tightening torque: 29.4±4.9 Nm (22±4 lb ft)
spindle (2).

SPW34000192J01 Figure 204 FIG. 34-186 TIGHTENING PLUG (226)
FIG. 34-184 INSTALLING REAR FLANGE (201) F. Tighten the plug (226) and torque to;
D. Align the two guides pins (42) in the spindle Tightening torque: 78.5±9.8 Nm (58±7 lb ft)
(2) with the pin holes of the rear flange and
install the rear flange (201) onto the spindle
(2).

FIG. 34-187 TIGHTENING PLUG (224)
G. Tighten the plug (224) and torque to;
Tightening torque: 196±14.7 Nm (145±11 lb
ft)
34-66 Issued 01-2006 Bur 6-81100 NA


FIG. 34-188 INSTALLING PLANETARY GEAR 1 (5) FIG. 34-190 INSTALLING PLANETARY GEAR 2
11. Installing carrier assembly 12. Tightening planetary gear 2
A. Insert three thrust washers (9), three bearing A. Turn the travel motor over. (Reduction unit
inner races (29), three needle roller bearings side up.)
with cage (27) and three planetary gears 1 (5) B. Install the thrust washer 1 (9) onto the spindle
in this order onto the column section of the (2).
carrier (3).
C. Insert four thrust collars 4 (11) and four inner
NOTE: If the bolt holes of carrier (3) has oil or races (30) into the column section of the
grease in it, clean it with solvent, and dry with spindle (2).
compressed air.
D. Insert four needle roller bearings with retainer
(28) into the column section of the spindle (2).
E. Insert four planetary gears set 2 (7),
intermesh with the internal teeth of the hub
(1).
F. Clean the thread hole at the tip of the column
section of the spindle (2) by removing oil and
grease using degreasing agent if necessary.
G. Remove oil and grease from four hexagon
head screws (40).

FIG. 34-189 TIGHTENING HEXAGON HEAD SCREW (40)
B. Tighten three hexagon head screws (40) with
three thrust washers 3 (12) and torque to:
Tightening torque: 33.3±4.9 Nm (25±4 lb ft)

FIG. 34-191 TIGHTENING HEXAGON HEAD SCREW (40)
H. Tighten four thrust washers (12) into the
column sections of the spindle (2) with four
hexagon screws (40) and torque to:
6-81100 NA Issued 01-2006 Bur 34-67


FIG. 34-192 INSTALLING SUN GEAR (102) FIG. 34-194 INSTALLING SUN GEAR 1 (4)
13. Installing sun gear 2 15. Installing sun gear 1
A. Install the coupling (14) to the shaft (102). A. Insert the sun gear 1 (4) into the coupling
B. Mesh the sun gear (6) with the planetary gear (14). Insert the steel ball (41) into the sun
(7). gear 1 (4) prior to installation.
B. Apply grease to the steel ball (41) to prevent it
from dropping out of the sun gear 1 (4).
C. Install the sun gear 1 (4) while meshing it with
the planetary gears 1 (5).

FIG. 34-193 INSTALLING CARRIER ASSEMBLY
14. Installing carrier assembly
A. Install the carrier assembly assembled while
meshing the sun gear 2 (6) and the internal
teeth of the hub (1). FIG. 34-195 SUPPLYING LUBRICATING OIL
16. Installing cover
A. Put 0.9 liters (0.24 gal.) of lubricating oil to the
hub (1).
B. Apply grease to the O-ring (35).
C. Install the O-ring (35) into the O-ring groove
of the hub (1).
34-68 Issued 01-2006 Bur 6-81100 NA


FIG. 34-196 INSTALLING COVER (13) FIG. 34-197 REMOVING TRAVEL MOTOR
D. Install the cover (13) into the hub (1). 17. Removing travel motor
E. If it is difficult for the cover (139) to go into the A. Turn the travel motor over. (Motor side up.)
hub (1), tap the cover (13) lightly with a plastic B. Remove the travel motor mounting screws
hammer. The O-ring (35) may be damaged from the workbench.
and cause oil leakage.
C. Screw two eyebolts into the spindle (2).
F. Install the ring (45) into the ring groove of the
hub (1). D. Arrange the two eyebolts in the diagonal
position.
G. Install the O-rings (37) onto plugs (33) and
(39). E. Attach lifting equipment to the eyebolts and
remove the travel motor from the workbench
H. Apply grease to the O-ring (37). using a crane.
I. Tighten the plugs (33) and (39) into the cover
(13) and torque to;
6-81100 NA Issued 01-2006 Bur 34-69


A f t e r d i s a s s e m bl i n g G M m o t o r, fo l l ow t h e s e 2. Wear parts maintenance standard
standards to perform maintenance. Handle every A. Replace any part heavily damaged visually.
part with care to avoid damaging the moving and
sliding components. B. Replace a part that shows the following
abnormalities.
1. Replace any seal (O-ring, oil seal, and floating
seal) once used even if no damage is found.
Standard value
Allowable value
Item No. Part name Phenomenon (Standard
(Criteria)
dimension)
Severe visual damage
(1) Hub Pitting on ring gear tooth flank – –
Abnormal wear such as galling
Severe visual damage
(2) Spindle – –
Abnormal wear such as galling.
(3) etc. Carrier assembly Abnormal wear such as galling – –
(4) Sun gear 1
(6) Sun gear 2 Pitting on tooth flank
– –
(5) Planetary gear 1 Flaking on bearing rolling surface
(7) Planetary gear 2
(9) Thrust washer 1
(11) Thrust collar 4 Sliding surface discolored and/or abnormally worn – –
(12) Thrust washer 3
Dent
(24) Main bearing Flaking – –
Uneven wear
(27) Pitting on roller
Needle roller bearing – –
(28) Abnormal wear on cage end surface
(29) (30) Bearing inner race Flaking on bearing rolling surface – –
(201) Rear flange Scratch on valve (263) sliding surface – –
Oil seal (132) contacting surface worn
(102) Shaft – –
Spline worn
(103) Swash plate Seizure – –
Spline worn
Bore severely worn
(104) Cylinder block – –
Scratch and uneven wear on timing plate (109) sliding
surface
Piston assembly Clearance Clearance
Clearance exists between piston (105) and shoe (106)
(105) Piston 0.05 mm 0.15 mm
Abnormal and uneven wear on shoe surface
(106) Shoe (0.002") (0.006")
Uneven wear on shoe (106) sliding surface
(107) Retainer plate – –
Scratch and uneven wear on thrust ball (108) surface
Uneven wear on retainer plate (107) sliding spherical
(108) Thrust ball – –
surface
(109) Timing plate Seizure and uneven wear on sliding surface
(115) Friction plate Uneven wear on both end surfaces Braking torque Braking torque
Specified torque not attained 64.7 Nm 64.7 Nm
(116) Mating plate Seizure (47.7 lb ft) (47.7 lb ft)
(105) Piston Scratch on periphery – –
34-70 Issued 01-2006 Bur 6-81100 NA

Standard value
Allowable value
Item No. Part name Phenomenon (Standard
(Criteria)
dimension)
Dent
(149)
Ball bearing Flaking – –
(150)
Wear
Two-speed piston kit
Abnormal wear on periphery
(161) Piston
Abnormal and/or uneven wear on shoe surface – –
(162) Shoe
Abnormal wear on Seal ring
(163) Seal ring
(223) Uneven wear on periphery
Spool – –
(263) Scratch on periphery
6-81100 NA Issued 01-2006 Bur 34-71

34.2.1.6 PERFORMANCE VERIFICATION TEST

After finishing maintenance of the GM motor, carry 2 Measuring cylinder (for 5 liters) (1.32 gal) 1
out performance verification tests according to the
3 Stop watch 1
procedures below:
1. Measuring instruments to be used 2. Test procedure
1 Pressure gauge for 35 kgf/cm2 (500 psi) 2
34-72 Issued 01-2006 Bur 6-81100 NA

E50
TROUBLESHOOTING
Issued January 2006

SECTION 4 - TROUBLESHOOTING
Revision History
SECTION 4
TROUBLESHOOTING
TABLE OF CONTENTS
CHAPTER 42
42.1 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-3
42.2 TROUBLE DIAGNOSIS: HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-4
42.3 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-5
CHAPTER 43
43.1 TROUBLE DIAGNOSIS: ELECTRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-3
CHAPTER 44
44.1 TROUBLE DIAGNOSIS: ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-3
6-81110 NA Issued 01-2006 Bur 0-I

NOTES
CHAPTER 42
E50
TROUBLE SHOOTING
(HYDRAULIC SYSTEM)
Issued January 2006

CHAPTER 42 - TROUBLESHOOTING (HYDRAULIC SYSTEM)
Revision History
42-II Issued 01-2006 Bur 6-81120 NA

CHAPTER 42
TABLE OF CONTENTS
42.1 GENERAL PRECAUTIONS

42.1.1 Confirm Actual Troubled Conditions At Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-3
42.2 TROUBLE DIAGNOSIS: HYDRAULIC
42.3 TROUBLESHOOTING
42.3.1 Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-5
42.3.1.1 Attachment operational failure (Excluding swing operations) . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-5
42.3.1.2 Attachment speed is slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-5
42.3.1.3 Attachment operating power is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-6
42.3.1.4 Malfunction of attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-7
42.3.2 Travel operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-8
42.3.2.1 Travel operational failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-8
42.3.2.2 Travel speed is slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-8
42.3.2.3 Travel power is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-9
42.3.2.4 It deviates in travel independent operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-9
42.3.3 Slewing operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-10
42.3.3.1 Slewing operational failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-10
42.3.3.2 Slewing speed is slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-10
42.3.3.3 Slewing power is low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-11
42.3.3.4 Malfunction of slewing operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-11
42.3.4 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-11
42.3.4.1 Engine speed is reduced due to pump load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-11
42.3.4.2 Malfunction of pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-12
6-81120 NA Issued 01-2006 Bur 42-1

NOTES
42-2 Issued 01-2006 Bur 6-81120 NA

42.1 GENERAL PRECAUTIONS

Troubleshooting provides a process to investigate the cause of trouble. This manual describes how to solve a
specific problem systematically and as quickly as possible. For the troubleshooting concerning a specific
components, refer to the troubleshooting for each component.
42.1.1 CONFIRM ACTUAL PROBLEM CONDITIONS AT SITE

1. Verify the machine model, serial number, C. Where the defective part can not be
problem, notify possible arrival time of service verified, surmise the possible causes
crew to the user. systematically.
D. Verify the surmised cause.
E. Report estimated repairing method/
procedures to the user.
FIG. 42-1 MAKE FIELD INVESTIGATION

2. Verify background of trouble.
A. Model name and serial number.
B. Kind of attachment. FIG. 42-3 DIAGNOSING TROUBLE BY MEANS
TROUBLESHOOTING.
Check that the combination of attachments 4. Explanation of the cause
was proper and that the operating manner
was not unreasonable. A. Explain the cause to the user.
C. Operating time on the hour-meter. For example, explain the oil leakage
through the piston is caused by defect on
D. Record of problems. the piston rod. And the proper operating
First occurrence or repeated problems. manner of the machine should be
E. History of the problem and additional ex p l a i n e d t o t h e u s e r t o p r ev e n t
modifications. reoccurrence of the same kind of problem.
Reoccurrence of the same problem in the B. Handling of damaged parts

past or due to additional modification. The damaged parts to be claimed and
returned are the evidence, so they should
be handled with care. For example,
protect them from contamination of water,
soil, etc., from getting into por ts on a
hydraulic system. Also use care not to
damage or break removed components.
FIG. 42-2 VERIFYING BACKGROUND OF TROUBLE

OCCURRED.
3. How to diagnose
A. Verify defective part.
B. Reproduce the conditions.
6-81120 NA Issued 01-2006 Bur 42-3

42.2 TROUBLE DIAGNOSIS: HYDRAULIC
Causes Pump Valve Actuator
Travel & ATT main R/V

Main gear pump R/V
Travel straight valve

Each overload R/V
Slewing motor unit
Hydraulic cylinder
Attachment spool
Travel motor unit

Trochoid pump
Reference No.
Pump Slewing operation Travel operation Attachment Classification
Shuttle valve
Phenomenon
Check valve
Travel spool
Gear pump
Main pump
(1) Attachment operational failure X X X
(2) Travel speed is slow. X X X
1
(3) Attachment operating power is low. X X X
(4) Malfunction of attachment X X X
(1) Travel operational failure X X X
(2) Travel speed is slow. X X X
2 (3) Travel operating power is low. X X
(4) It deviates in travel independent operation. X X X X
(1) Slewing operational failure X X

(2) Slewing speed is slow. X
3 (3) Slewing operating power is low. X X X
(4) Malfunction of slewing operation X X X
(1) Engine speed is reduced due to pump load. X

4
(2) Malfunction of pump X X X
Abbreviation
E/G : Engine
SOL : Solenoid
SW : Switch
ATT : Attachment
C/V : Control valve
R/V : Relief valve
V : Valve
42-4 Issued 01-2006 Bur 6-81120 NA

42.3.1 ATTACHMENT
42.3.1.1 ATTACHMENT OPERATIONAL FAILURE (EXCLUDING SWING OPERATIONS)
42.3.1.2 ATTACHMENT SPEED IS SLOW
6-81120 NA Issued 01-2006 Bur 42-5

42.3.1.3 ATTACHMENT OPERATING POWER IS LOW
42-6 Issued 01-2006 Bur 6-81120 NA

42.3.1.4 MALFUNCTION OF ATTACHMENT
6-81120 NA Issued 01-2006 Bur 42-7

42.3.2 TRAVEL OPERATION

42.3.2.1 TRAVEL OPERATIONAL FAILURE
42.3.2.2 TRAVEL SPEED IS SLOW
42-8 Issued 01-2006 Bur 6-81120 NA

42.3.2.3 TRAVEL POWER IS LOW
42.3.2.4 IT DEVIATES IN TRAVEL INDEPENDENT OPERATION
6-81120 NA Issued 01-2006 Bur 42-9

42.3.3 SLEWING OPERATION

42.3.3.1 SLEWING OPERATIONAL FAILURE
42.3.3.2 SLEWING SPEED IS SLOW
42-10 Issued 01-2006 Bur 6-81120 NA

42.3.3.3 SLEWING POWER IS LOW
42.3.3.4 MALFUNCTION OF SLEWING OPERATION
42.3.4 PUMP
42.3.4.1 ENGINE SPEED IS REDUCED DUE TO PUMP LOAD
6-81120 NA Issued 01-2006 Bur 42-11

42.3.4.2 MALFUNCTION OF PUMP
42-12 Issued 01-2006 Bur 6-81120 NA

CHAPTER 43
E50
TROUBLE SHOOTING
(ELECTRICAL SYSTEM)
Issued January 2006

CHAPTER 43 - TROUBLESHOOTING (ELECTRICAL SYSTEM)
Revision History
43-II Issued 01-2006 Bur 6-81130 NA

CHAPTER 43
TABLE OF CONTENTS
43.1 TROUBLE DIAGNOSIS: ELECTRIC SYSTEM

43.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-4
43.2.1.1 Engine does not start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-4
43.2.1.2 Horn does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-6
43.2.1.3 Working lights do not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-7
43.2.1.4 Hourmeter does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-7
43.2.1.5 Fuel gauge does not work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-8
43.2.1.6 Water temperature gauge does not work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-8
43.2.2 Attachment operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-9
43.2.2.1 All controls do not function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-9
43.2.3 Travel operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-12
43.2.3.1 Travel 1 & 2 speed change does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-12
43.2.4 Deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-13
43.2.4.1 Optional decel motor does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-13
6-81130 NA Issued 01-2006 Bur 43-1

NOTES
43-2 Issued 01-2006 Bur 6-81130 NA

43.1 TROUBLE DIAGNOSIS: ELECTRIC SYSTEM
6-81130 NA Issued 01-2006 Bur 43-3

43.2.1 GENERAL
43.2.1.1 ENGINE DOES NOT START.
43-4 Issued 01-2006 Bur 6-81130 NA

6-81130 NA Issued 01-2006 Bur 43-5

43.2.1.2 HORN DOES NOT WORK
43-6 Issued 01-2006 Bur 6-81130 NA

43.2.1.3 WORKING LIGHTS DO NOT WORK
43.2.1.4 HOUR METER DOES NOT WORK
6-81130 NA Issued 01-2006 Bur 43-7

43.2.1.5 FUEL GAUGE DOES NOT WORK.
43.2.1.6 WATER TEMPERATURE GAUGE DOES NOT WORK.
43-8 Issued 01-2006 Bur 6-81130 NA

43.2.2 ATTACHMENT OPERATION

43.2.2.1 ALL CONTROLS DO NOT FUNCTION
6-81130 NA Issued 01-2006 Bur 43-9

43-10 Issued 01-2006 Bur 6-81130 NA

6-81130 NA Issued 01-2006 Bur 43-11

43.2.3 TRAVEL OPERATION

43.2.3.1 TRAVEL 1 & 2 SPEED CHANGE DOES NOT WORK
43-12 Issued 01-2006 Bur 6-81130 NA

43.2.4 DECELERATION
43.2.4.1 OPTIONAL DECEL MOTOR DOES NOT WORK
6-81130 NA Issued 01-2006 Bur 43-13

NOTES
43-14 Issued 01-2006 Bur 6-81130 NA

CHAPTER 44
E50
TROUBLE SHOOTING
(ENGINE)
Issued January 2006

CHAPTER 44 - TROUBLESHOOTING (ENGINE)
Revision History
44-II Issued 01-2006 Bur 6-81140 NA

CHAPTER 44
TABLE OF CONTENTS
44.1 TROUBLE DIAGNOSIS: ENGINE

44.2.1 Starting trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-6
44.2.1.1 Starter does not rotate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-6
44.2.1.2 Starter rotates but hard to start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-7
44.2.2 Engine runs rough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-8
44.2.3 Output power low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-9
44.2.3.1 Engine low power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-9
44.2.3.2 Knocking at high temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-10
44.2.4 Other trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-11
44.2.4.1 Exhaust trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-11
44.2.4.2 Excessive oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-12
44.2.4.3 Excessive fuel consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-12
44.2.4.4 Engine does not stop when ignition switch is turned OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-12
6-81140 NA Issued 01-2006 Bur 44-1

NOTES
44-2 Issued 01-2006 Bur 6-81140 NA

44.1 TROUBLE DIAGNOSIS: ENGINE
Cause Serviceman
Inspection Visual check
Filters Fluid Gas/fluid
Improper viscosity or level of engine oil, or leakage

Improper specific gravity of battery electrolyte
Breather hose clogged or collapsed
Classification
Improper battery electrolyte level

Air or water entered fuel system
Poor quality fuel or wrong grade
Excessive amount of engine oil

Group
Trouble
Secondary fuel filter clogged

No.
Poor quality fuel or leakage

Primary fuel filter clogged
Large amount of blow-by

Leaking head gasket
Air cleaner clogged
No fuel or leakage
Fan belt slipping

Oil filter clogged
Coolant level
Starting (1) Starter does not rotate X X
1
trouble (2) Starter rotates but hard to start X X X X X X X X X
(1) Idling not smooth X X X X
Rotation (2) Medium speed hunting X
2
trouble High speed not smooth X X
(3)
Not reaching max. speed X
Engine low power X X X X X X X
Output drops (1)
3 Overheat X X X X X X
down
(2) Knocking at high temperature X X X
Black exhaust smoke X X X
(1)
White exhaust smoke X X X
(2) Excessive oil consumption X X X X
(3) Excessive fuel consumption X X X X
Other trouble 4 Engine does not stop when key
(4)
turned OFF
When key is turned OFF,
(5) power supply disconnects but
the engine does not stop
6-81140 NA Issued 01-2006 Bur 44-3

Cause Serviceman Engine dealer

Mechanism Engine Suction/
Fuel system exhaust
Electric Electric
system
Classification
Group
Trouble
No.
Generator current limiter
Air cleaner and muffler

Check injection timing
Connector and wiring
Feed pump function
Valve spring fatigue

Stop solenoid valve
Valve clearance
Glow plug relay
Injection pump
Ignition switch
Check nozzle
Starter motor
Safety relay
Glow plug
Fuse
Starting (1) Starter does not rotate X X X X X X

1
trouble (2) Starter rotates but hard to start X X X X X X X X X
(1) Idling not smooth X X X X
Rotation (2) Medium speed hunting
2
(3)
Not reaching max. speed X X
Engine low power X X X X X X
Output drops (1)
3 Overheat
down
(2) Knocking at high temperature X X
Black exhaust smoke X X X X
(1)
White exhaust smoke X
(2) Excessive oil consumption
(3) Excessive fuel consumption X X X
(4) X X
turned OFF
When key is turned OFF, power
(5) supply disconnects but the engine X
does not stop
44-4 Issued 01-2006 Bur 6-81140 NA

Cause Engine dealer

Lubrication Coolin
Mechanical
system g
Oil gets into comb. chamber through piston / valve guide
Control rack movement not smooth

Group
Classification Trouble
Crank shaft oil seal defective

Oil cooler element damaged
No.
Flywheel gear damaged

Governor spring fatigue
Defective head gasket

Internal part seizure
Valve spring fatigue
Fuel mixed with oil
Check thermostat
Check relief valve
Compression low
Piston liner worn

Piston ring worn
Check fuel feed

Starting (1) Starter does not rotate
1
trouble (2) Starter rotates but hard to start X X X X X X X X
(1) Idling not smooth X X X X X X X X
Rotation (2) Medium speed hunting
2
(3)
Not reaching max. speed X
Engine low power X X X
Output drops (1)
3 Overheat X X X X X
down
(2) Knocking at high temperature X X
Black exhaust smoke X X X X X
(1)
White exhaust smoke X X
(2) Excessive oil consumption X X X X
(3) Excessive fuel consumption X
(4)
turned OFF
When key is turned OFF, power
(5) supply disconnects but the engine
does not stop
6-81140 NA Issued 01-2006 Bur 44-5

44.2.1 STARTING TROUBLE
44.2.1.1 STARTER DOES NOT ROTATE
44-6 Issued 01-2006 Bur 6-81140 NA

44.2.1.2 STARTER ROTATES BUT HARD TO START
6-81140 NA Issued 01-2006 Bur 44-7

44.2.2 ENGINE RUNS ROUGH
44-8 Issued 01-2006 Bur 6-81140 NA

44.2.3 OUTPUT POWER LOW

44.2.3.1 ENGINE LOW POWER
6-81140 NA Issued 01-2006 Bur 44-9

44.2.3.2 KNOCKING AT HIGH TEMPERATURE
44-10 Issued 01-2006 Bur 6-81140 NA

44.2.4 OTHER TROUBLE

44.2.4.1 EXHAUST TROUBLE
A recycling mechanism for blow-by gas is on the
engine as shown. Remove and plug the intake
manifold to check blow-by.
6-81140 NA Issued 01-2006 Bur 44-11

44.2.4.2 EXCESSIVE OIL CONSUMPTION
44.2.4.3 EXCESSIVE FUEL CONSUMPTION
44.2.4.4 ENGINE DOES NOT STOP WHEN IGNITION SWITCH IS TURNED OFF
44-12 Issued 01-2006 Bur 6-81140 NA

E50
ENGINE
Issued January 2006

SECTION 5 - ENGINE
Revision History
SECTION 5 - ENGINE
SECTION 5
ENGINE
TABLE OF CONTENTS
CHAPTER 51
6-81150 NA Issued 01-2006 Bur 0-I

NOTES
CHAPTER 51
E27, E30, E35, &E50

ENGINE
Issued January 2006

CHAPTER 51 - ENGINE
Revision History
51-II Issued 01-2006 Bur 6-80460 NA

CHAPTER 51
6-80460 NA Issued 01-2006 Bur 51-1

CHAPTER 51 - ENGINE
NOTES
51-2 Issued 01-2006 Bur 6-80460 NA

CHAPTER 51 - ENGINE
51.1 REFER TO YANMAR ENGINE SERVICE MANUAL

This manual explains the engine proper and is faithful to YANMAR DIESEL ENGINE’S service manuals.
6-80460 NA Issued 01-2006 Bur 51-3

CHAPTER 51 - ENGINE
NOTES
51-4 Issued 01-2006 Bur 6-80460 NA

BOOM CIRCUIT - BOOM-UP OPERATION ARM CIRCUIT - ARM-IN OPERATION
4 4 9 4 4 9
D2 P3 P P P2 D1 D2 P3 P P P2 D1
401 401 401 401

R1 A1G A1 A2 A2G A4 A3 407 407 404 R1 A1G A1 A2 A2G A4 A3 407 407 404
A2 A1 404 406 22 A2 A1 404 406 22
406 406
5 5
13 13
408 408
408
403 23 3 408
403 23 3
1 403 B B 1 403 B B
T T1 T T1
A A 6 A A 6
13-1 402 402 13-1 402 402
R R
405 302 405 302
P 405 P 405
P1 24 P1 24
P2 P2
301 301
19 19
407 407 7 407 407 7
30 15 30 15
304 304
D1 P2 P3 D2 D1 P2 P3 D2
S1 R2 S1 R2
304 304
A B A B
303 R1 303 R1
8 8
10 D 10 D
305 305 305 305
C C
B D P G A C F E B D P G A C F E
PG DR B T A PG DR B T A
29 29
29 29
A B A B
28 28
P
27 P
27
T A2B2 A1 B1 T A2B2 A1 B1
T T
PP PP
P2 P1 P2 P1
P P P P
SW31 SW30 SW31 SW30
25 25
16 16
3 7 4 8 3 7 4 8
2 D
2 D
21 B9 A9 Pa9 Pb8 Dr B8 A8 Pa8 B7 A7 Pa7 P1 P2 Pa6 A6 B6 Pa5 A5 B5 Pa4 A4 B4 Pa3 A3 B3 P3 B2 A2 Pa2 B1 A1 Pa1 21 B9 A9 Pa9 Pb8 Dr B8 A8 Pa8 B7 A7 Pa7 P1 P2 Pa6 A6 B6 Pa5 A5 B5 Pa4 A4 B4 Pa3 A3 B3 P3 B2 A2 Pa2 B1 A1 Pa1
20 3 7 4 8 20 3 7 4 8
11 11
2 4 1 3 2 4 1 3
11 2 4 1 3 2 4 1 3
11
206 206
202 202
204 204
203 MRV3 203 MRV3

204 204
18 17 26 203 18 17 26 203
204 204
204 P T P T 204 P T P T
201 MRV 201 MRV
P T P T
204 204
14 14
2 204 2 204
P T P T
T2 Pb9 T2 Pb8 Pb7 Pb6 Pb5 Pb4 Pb3 T1 Pb2 Pb1 T2 Pb9 T2 Pb8 Pb7 Pb6 Pb5 Pb4 Pb3 T1 Pb2 Pb1
Pp1 Pp1
2 1 4 3 2 1 4 3
12 12
SWING CIRCUIT - BOOM SWING-LEFT OPERATION DOZER CIRCUIT - DOZER-DOWN OPERATION
4 4 9 4 4 9
D2 P3 P P P2 D1 D2 P3 P P P2 D1
401 401 401 401

A2 A1 404 A2 A1 404
22
406 406
5 22 406 406
5
13 13
408 408
408
403 23 3 408
403 23 3
1 403 B B 1 403 B B
T T1 T T1
A A 6 A A 6
13-1 402 402 13-1 402 402
405 302 405 302
P 405 P 405
P1 24 P1 24
P2 P2
301 301
19 19
407 407 7 407 407 7
30 15 30 15
304 304
D1 P2 P3 D2 D1 P2 P3 D2
S1 R2 S1 R2
304 304
A B A B
303 R1 303 R1
8 8
10 D 10 D
305 305 305 305
C C
29 29
29 29
A B A B
28 28
P
27 P
27
T T
PP PP
P2 P1 P2 P1
P P P P
SW31 SW30 SW31 SW30
25 25
16 16
3 7 4 8 3 7 4 8
2 D
2 D
20 3 7 4 8 20 3 7 4 8
11 11
2 4 1 3 2 4 1 3
11 2 4 1 3 2 4 1 3
11
206 206
202 202
204 204
203 MRV3 203 MRV3

204 204
18 17 26 203 18 17 26 203
204 204
204 P T P T 204 P T P T
201 MRV 201 MRV
P T P T
204 204
14 14
2 204 2 204
P T P T
Pp1 Pp1
2 1 4 3 2 1 4 3
12 12
COMPONENT IDENTIFICATION NOTES HYDRAULIC SYMBOLS

1. PUMP ASSEMBLY 8. SWING CYLINDER 15. SHUTTLE VALVE 22. NIBBLER CYLINDER 29. ORIFICE 1. 201 (MAIN RELIEF VALVE P1,P2) 23.0 MPa (3340 psi) PRESSURE
2. CONTROL VALVE 9. DOZER CYLINDER 16. MULTI CONTROL VALVE 23. STOP VALVE 2. 202 (MAIN RELIEF VALVE P3) 23.0 MPa (3340 psi) HYDRAULIC SCHEMATIC
3. SLEWING MOTOR 10. SWIVEL JOINT 17. RETURN FILTER (ELEMENT) 24. SELECTOR VALVE PILOT MAIN PRESSURE
4. TRAVEL MOTOR 11. PILOT VALVE (ATT) 18. SUCTION STRAINER 25. OIL COOLER
3. 203 (OVERLOAD RELIEF VALVE) 27.5 MPa (4000 psi) 54 CHECK VALVE FILTER OR SCREEN E50 HYDRAULIC EXCAVATORS
4. 204 (OVERLOAD RELIEF VALVE) 25.5 MPa (3700 psi) PILOT SEC PRESSURE
5. BOOM CYLINDER / CANOPY CAB 12. PILOT VALVE (TRAVEL) 19. INLINE FILTER 26. HYDRAULIC OIL TANK Additional copies of this Hydraulic and Electrical Schematic can be ordered through
COMPONENT SHOWS
6. ARM CYLINDER 13. SOLENOID VALVE 20. CHECK VALVE 27. SOLENOID VALVE 5. 304 (SLEW RELIEF VALVE) 21.0 MPa (3050 psi) CASE DRAIN NUMBER Technical Publications Distribution System. The part number is 6-80930
SHOWS CIRCUIT CROSSING CIRCUIT
7. BUCKET CYLINDER 14. PILOT VALVE (DOZER) 21. HYDRAULIC RESERVOIR VENT 28. SOLENOID VALVE 6. 13-1 (PILOT RELIEF VALVE) 3.5MPa (508 psi) RESTRICTOR
COMPONENT NOT CONNECTED CONNECTED OIL COOLER
BC05H034
NIBBLER AND BREAKER CIRCUIT - NIBBLER CLOSE OPERATION COMBINED OPERATION CIRCUIT - TRAVEL FORWARD, 1ST SPEED / DOZER-DOWN OPERATION
4 4 9 4 4 9
D2 P3 P P P2 D1 D2 P3 P P P2 D1
401 401 401 401

A2 A1 404 406 22 A2 A1 404 406 22
406 406
5 5
13 13
408 408
408
403 23 3 408
403 23 3
1 403 B B 1 403 B B
T T1 T T1
A A 6 A A 6
13-1 402 402 13-1 402 402
R R
405 302 405 302
P 405 P 405
P1 24 P1 24
P2 P2
301 301
19 19
407 407 7 407 407 7
30 15 30 15
304 304
D1 P2 P3 D2 D1 P2 P3 D2
S1 R2 S1 R2
304 304
A B A B
303 R1 303 R1
8 8
10 D 10 D
305 305 305 305
C C
29 29
29 29
A B A B
28 28
P
27 P
27
T T
PP PP
P2 P1 P2 P1
P P P P
SW31 SW30 SW31 SW30
25 25
16 16
3 7 4 8 3 7 4 8
2 D
2 D
20 3 7 4 8 20 3 7 4 8
11 11
2 4 1 3 2 4 1 3
11 2 4 1 3 2 4 1 3
11
206 206
202 202
204 204
203 MRV3 203 MRV3

204 204
18 17 26 203 18 17 26 203
204 204
204 P T P T 204 P T P T
201 MRV 201 MRV
P T P T
204 204
14 14
2 204 2 204
P T P T
Pp1 Pp1
2 1 4 3 2 1 4 3
12 12
COMBINED OPERATION CIRCUIT - TRAVEL FORWARD, 1ST SPEED / BOOM-UP OPERATION SCHEMATIC PIPING FOR HYDRAULIC SYSTEM
9 (LEFT) (RIGHT)
4 4
D2 P3 P P P2 D1
TRAVEL PILOT VALVE
3 1
401 401 H R
R1 A1G A1 A2 A2G A4 A3 407 407 404
A2 A1 404 406 22
406
5 4 2
13
T B A BUCKET CYLINDER
408 408
3 P T
1 403 B B 403 23
T T1
P
A A 6 NIBBLER & BREAKER C
13-1 H R
402 402
302 SOLENOID VALVE SHUTTLE
P 405 405
P1 24 D VALVE T2
P2
301
BOOM CYLINDER
19 B9 A9
407 407 7 Pb9 BUCKET
A B Pa9
30 15 BOOM
304 Pb8' Dr B8 H R
D1 P2 P3 D2 Pb8 A8 Pa8
S1 R2 TRAVEL
304 LEFT B7 A7 SWING CYLINDER
A B Pb7 Pa7
303 R1
8 ATT PILOT VALVE (L.H.) ATT PILOT VALVE (R.H.)
10 D P1
305 305 P2
C
H R
BREAKER
B D P G A C F E i8 j i4 j A6
29
PG DR B T A
MULTI
Pb6 TRAVEL B6
Pa6
29 CONTROL RIGHT ARM CYLINDER
4 i6 j 4 i2 j B5
P 1 P 1 VALVE Pb5 SWING Pa5
A B i5 j i1 j A5
3 3
2 T 2 T A4
28 Pb4 SERVICE B4 Pa4 H R
27 i7 j i3 j BOOM UP 3
Pb3 B3 Pa3
P ARM A3 NIBBLER CYLINDER
T A2B2 A1 B1 BOOM DOWN 4
T
ARM IN 7 T1 P3
ARM OUT Pp1 SELECTOR
8
VALVE
PP BUCKET DUMP
SLEWING MOTOR A2 RETURN FILTER
BUCKET DIGGING Pb2 SLEW B2 Pa2
P2 P1
CHECK HYDRAULIC OIL TANK
P P
PP A1 VALVE
PB Pb1 DOZER B1 Pa1
SW31 SW30
B1 BOOM SWING LEFT
PP SLEW (Swing) LEFT P1 A1 SLEW LEFT
CONTROL VALVE
25 SLEW (Swing) RIGHT P2 B2 BOOM SWING RIGHT
16 B T DR A
3 7 4 8
A2 SLEW RIGHT
2 SOLENOID
D T VALVE
21 B9 A9 Pa9 Pb8 Dr B8 A8 Pa8 B7 A7 Pa7 P1 P2 Pa6 A6 B6 Pa5 A5 B5 Pa4 A4 B4 Pa3 A3 B3 P3 B2 A2 Pa2 B1 A1 Pa1
SLEW RIGHT
20 3 7 4 8
SUCTION
11 SLEW LEFT STRAINER
2 4 1 3 2 4 1 3
11
206
202 IN OUT
204
MRV3 A4 DOZER PILOT

203 A3 A1
18 17 26 203 204
ENGINE FILTER VALVE
A2
204
204 HYDRAULIC PUMP P1 T
P T P T RELIEF
201 MRV S OIL COOLER VALVE
P T
204 E F C A G P B D
14 P
SWIVEL JOINT P2
2 204 DOZER CYLINDER 2 1
P T
T2 Pb9 T2 Pb8 Pb7 Pb6 Pb5 Pb4 Pb3 T1 Pb2 Pb1
A1
R H
Pp1
A2 TRAVEL 2-SPEED
2 1 4 3 PILOT CIRCUIT SOLENOID VALVE LEVER LOCK

12 D1 D2 T1
FORWARD FORWARD
A B
MAIN CIRCUIT
P BACKWARD BACKWARD
B A
SUPPLY / RETURN (DRAIN) CIRCUIT
TRAVEL MOTOR (LEFT) TRAVEL MOTOR (RIGHT)
COMPONENT IDENTIFICATION NOTES HYDRAULIC SYMBOLS

1. PUMP ASSEMBLY 8. SWING CYLINDER 15. SHUTTLE VALVE 22. NIBBLER CYLINDER 29. ORIFICE 1. 201 (MAIN RELIEF VALVE P1,P2) 23.0 MPa (3340 psi) PRESSURE
2. CONTROL VALVE 9. DOZER CYLINDER 16. MULTI CONTROL VALVE 23. STOP VALVE 2. 202 (MAIN RELIEF VALVE P3) 23.0 MPa (3340 psi) HYDRAULIC SCHEMATIC
3. SLEWING MOTOR 10. SWIVEL JOINT 17. RETURN FILTER (ELEMENT) 24. SELECTOR VALVE PILOT MAIN PRESSURE
4. TRAVEL MOTOR 11. PILOT VALVE (ATT) 18. SUCTION STRAINER 25. OIL COOLER
3. 203 (OVERLOAD RELIEF VALVE) 27.5 MPa (4000 psi) 54 CHECK VALVE FILTER OR SCREEN E50 HYDRAULIC EXCAVATORS
4. 204 (OVERLOAD RELIEF VALVE) 25.5 MPa (3700 psi) PILOT SEC PRESSURE
5. BOOM CYLINDER / CANOPY CAB 12. PILOT VALVE (TRAVEL) 19. INLINE FILTER 26. HYDRAULIC OIL TANK Additional copies of this Hydraulic and Electrical Schematic can be ordered through
COMPONENT SHOWS
6. ARM CYLINDER 13. SOLENOID VALVE 20. CHECK VALVE 27. SOLENOID VALVE 5. 304 (SLEW RELIEF VALVE) 21.0 MPa (3050 psi) CASE DRAIN NUMBER Technical Publications Distribution System. The part number is 6-80930
SHOWS CIRCUIT CROSSING CIRCUIT
7. BUCKET CYLINDER 14. PILOT VALVE (DOZER) 21. HYDRAULIC RESERVOIR VENT 28. SOLENOID VALVE 6. 13-1 (PILOT RELIEF VALVE) 3.5MPa (508 psi) RESTRICTOR
COMPONENT NOT CONNECTED CONNECTED OIL COOLER
BC05H035
39 GW 74 65
26 6 112 WR 87
59 20A 91 1.25 O 82
108 LW B 76 80
90 WY 54 PL 55 YL
4 1.25 RG 20A 89 1.25 RL 1
4 88 B
56 M
58 1 LR
1
B 110 G 83 86
61 75
20B 20R B YB
2
113 OW 14 2WR S
1 M 2 73
B 84
109 LO B B 90 RW
5R
7 66
63 9 67
60 51 YG 85
62
B 111 GL 47
9 5R 8 69
64 71
50 GW
11 WY BAT P L IG 72 M
54 81 O 81
55 1 9 68
52 IC 52 YR 70
B 82
REG 5 WY 54 PL 55 YL
2 YB 1
2 106 W 101 GW B
6 B
WG
105 LG B 10
53 47 3LY 92 L B B 83 86
5 HOLD
51 W
31
4 70 2BR
107 WR
PULL
B 84
50 6
100 Lg
E 2B 85
49 4 B
RG
15
12 77
R +1 - B
20 11 M 81 O 78
1
Y S 14 16
46 +B L
B 1.25 YG 87 1.25 BrR B
2 YB M 3
R 17 PB B 86 LgR B
B 3
B 57 M B 79
B
13
91 3 21
RADIO, HEATER, WIPER
HORN, ROOM LAMP
GAUGE CLUSTER
2
ENG. STOP SOL.
WORK LIGHT
17
RELAY,SOL
RG
4
WG WY 1 WY 5 22
6 1
POSITION
POSITION
18
1
4
44 37
OFF
OFF
LO
HI
2RG
2YG
1.25
WG
WY
2W
YB
POSTION 6 WG TWO-SPEED 57 LB
6 5 7 2 TERMINAL ON 3
B
EMPTY 58 GB
30A
30A
30A
30A
30A
10A
45 B 6 25
38 E 86 LgR B
ENG. WATER TEMP. 51 YG E
8 2R 27 4
18 LY
71 3Y 8 3R 14 2WR L
L
7 2RB 19 LB
M ENG. OIL PRESS. 50 GW YG 3 YG
72 L 8 2 3
1 WY CHARGE 48 LgB B 2 YB
8 5R 3 YB
POSITION 2
POSITON PREHEATING 6
B S 6
C P 11 WY 32
WASHER
OFF
ON
WASHER
19 26
OFF
ON
START
FUEL METER 56 YB 39 GW B
10 11
AC TERMO METER
TERMINAL E POSITION 52 YR
13
ILLUMINATION 63 BY
12 B
8 5R 42 20 G 1
6 WG L 64 LW
B A
39 33
47 3LY 22 BR P1 M
R1 E
28
43 47 3LY 40 21 WB B B
5 W H
R2 AIR FILTER RESTRICTION 60 GY
2W 5 2W 70 2BR
7 2RB 5 1 WY 9 P2
ACC 5 W 15 YG M 61 LB
8 29
72 L 16 RW 36
BR
86 LgR 49 P
13 BW B 23 4 H EM 30
C 41 61 LB 34
1.25 2
48
2B E 2B 6 WG 45 BW B
1 4
HOLD 2 YB
B 43 Lg
6 3
46 WB 24
5
HOLD 2 35
B
COMPONENTS
1. BATTERY (E-13) 16. RADIO (FOR CAB OPTION) (E-10) 32. OPERATING LEVER 48. HOUR METER (E-26) 63. NIBBLER CLOSE SWITCH (SW-34) 81. TRAVEL ALARM NORTH AMERICAN OPTION
2. STARTER MOTOR (M-1) 17. HORN SWITCH (SW-7) LOCK SOLENOID (SV-1) 49. SLEW/SWING PRESERVATION RELAY (R-23) 64. SLEW SWING CIRCUIT 82. TRAVEL RIGHT (FORWARD) PRESSURE SWITCH (SW-24)
3. DIODE (D-1) 18. GAUGE CLUSTER (E-6) 33. DECEL MOTOR (M-4) (NORTH AMERICA: STANDARD) 65. AIR CONDITIONER (FOR CAB OPTION) 83. TRAVEL RIGHT (REVERSE) PRESSURE SWITCH (SW-25)
4. AIR HEATER (E-8) 19. CHARGE INDICATOR RELAY (R-8) 34. TWO-SPEED SELECT SOLENOID (SV-2). 50. SLEW/SWING LEVER PRESSURE SWITCH LEFT 66. CONDENSER SPEED SHIFT RELAY (R-10) 84. TRAVEL LEFT (FORWARD) PRESSURE SWITCH (SW-26)
5. GENERATOR (E-2) 20. DIODE (D-2) 35. TWO-SPEED SELECT SW (SW-3). (SW-30) 67. CONDENSER SPEED SHIFT SWITCH (SW-16) 85. TRAVEL LEFT (REVERSE) PRESSURE SWITCH (SW-27)
6. ENGINE STOP SOLENOID (SV-3) 21. FUEL SENSOR (SE-1) 36. SEQUENCE BOX (E-14) 51. SLEW/SWING LEVER PRESSURE SWITCH 68. CONDENSER RELAY (R-11) 86. TRAVEL ALARM (E-20)
7. ENGINE WATER TEMP SWITCH 22. INDICATOR (OPTION) (C-8) (NOT SHOWN) 37. WORKING LIGHT SWITCH (SW-2) RIGHT (SW-31) 69. CONDENSER MOTOR (E-17) 87. TRAVEL ALARM EUROPEAN OPTION
(SW-5) 23. DIODE (D-3) 38. HEATER SWITCH (OPTION) (SW-10) 52. SWITCH SELECT RELAY (R-22) 70. COMPRESSOR (E-18) 88. POWER SOCKET (E-7)
8. ENGINE OIL PRESS SWITCH (SW-6) 24. DIODE (D-4) 39. WIPER WASHER SWITCH 53. SLEW/SWING SELECT SWITCH (SW-28) 71. HI, LOW PRESSURE SWITCH (SW-15) 90. ENGINE
9. COOLANT THERMO SENSOR (SE-2) 25. BOOM WORKING (L-2) (FOR CAB) (SW-4) 54. SLEW/SWING SELECT RELAY (R-14) 72. COOLING UNIT (E-16) 91. INST PANEL AND RELAY ASSY. (PART IN RELAY CONSOLE)
10. AIR FILTER RESTRICTION SWITCH LIGHT LEFT (55W) 40. ENGINE STOP RELAY (R-7) 55. SLEW/SWING SELECT SOLENOID (SV-12) 73. POWER SHIFT SOLENOID (SV-5)
(SW-14) NORTH AMERICAN AND 26. LEVER LOCK SWITCH (SW-9) 41. TIMER UNIT (R-6) 56. NIBBLER OPEN SWITCH (SW-33) 74. FUSE (E-15)
AUSTRAILIA: STANDARD 27. DIODE (D-12) 42. SAFETY RELAY (R-2) 57. DIODE (D-14) 75. COOLER RELAY (R-13)
11. HEATER (OPTIONAL) (E-12) 28. DECEL RELAY (R-3) 43. KEY SWITCH (SW-1) 58. NIBBLER OPEN RELAY (R-24) 76. BLOWER MOTOR
12. WIPER MOTOR (FOR CAB) (M-2) 29. CRANE TIMER RELAY (OPTION) (R-20) (NOT 44. BATTERY RELAY (R-1) 59. NIBBLER OPEN SOLENOID (SV-9) 77. WORK LIGHT CIRCUIT
13. WASHER MOTOR (FOR CAB) (M-3) SHOWN) 45. FUSE BOX (E-1) 60. NIBBLER CLOSE SOLENOID (SV-10) 78. WORK LIGHT RELAY (R-9)
14. HORN (E-3) 30. DECEL SWITCH (SW-11) 46. FEED PUMP (M-6) 61. NIBBLER CIRCUIT 79. CAB/CANOPY WORKING LIGHT (L-5)
15. CAB LAMP (L-1) 31. DIODE (D-13) 47. FUSIBLE LINK (45A) (E-4) 62. LEVER CLOSE RELAY (R-25) 80. TRAVEL ALARM SELECTOR SWITCH (SW-23)
CIRCUIT DIAGRAM LEGEND WIRE IDENTIFICATION NOTES
INDICATES
B . . Black
Br . . Brown
Lg. . Light Green
O . . Orange
V . . Violet
W . . White
1. Diagram shown with vehicle parked, power OFF, and controls in OFF or NEUTRAL position. ELECTRICAL SCHEMATIC
6 6 6 INDICATES 6 2 R
EXTERNAL
INTERNALLY G . . Green P . . Pink Y . . Yellow E50 HYDRAULIC EXCAVATORS
TO FROM GROUND
GROUNDED WIRE NUMBER
WIRE COLOR Gr. . Gray R . . Red
54 COMPONENT WIRE SIZE Sb . Sky Blue Additional copies of this Hydraulic and Electrical Schematic can be ordered through Technical
SHOWS CIRCUIT SHOWS COMPONENT FROM FUSE L. . . Blue
NUMBER REFERS TO Publications Distribution System. The Part Number is 6-80930
CROSSING CIRCUIT COMPONENT OUTLINE PANEL GROUND
NOT CONNECTED CONNECTED NUMBER CONTINUATION OF A CIRCUIT
BC05H036
CNH AMERICA LLC North American English
245 E NORTH AVENUE Part Number 87360588
CAROL STREAM, IL 60188 U.S.A. Printed in U.S.A. Bur
NEW HOLLAND CONSTRUCTION IS A BRAND OF CNH.

A GLOBAL LEADER FOR CONSTRUCTION EQUIPMENT, AGRICULTURE EQUIPMENT AND FINANCIAL SERVICES.

Bager New Holand E50

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COMPACT EXCAVATORS

Issued January 2006

6-78610NA Issued 01-06 Bur I

II Issued 01-06 Bur 6-78610NA

Issued January 2006

6-80950 NA Issued 01-2006 Bur 0-I

0-II Issued 01-2006 Bur 6-80950 NA

GENERAL INFORMATION AND

Issued January 2006

1-II Issued 01-06 Bur 6-80960 NA

1.1 GENERAL SAFETY INFORMATION

6-80960 NA Issued 01-06 Bur 1-1

1-2 Issued 01-06 Bur 6-80960 NA

1.1 GENERAL SAFETY INFORMATION

6-80960 NA Issued 01-06 Bur 1-3

1.2 SAFETY PRECAUTIONS

1-4 Issued 01-06 Bur 6-80960 NA

6-80960 NA Issued 01-06 Bur 1-5

1.3 GENERAL PRECAUTIONS FOR REPAIRS

1-6 Issued 01-06 Bur 6-80960 NA

WARNING: Operation of the hydraulic

6-80960 NA Issued 01-06 Bur 1-7

1-8 Issued 01-06 Bur 6-80960 NA

1.4 INTERNATIONAL UNIT CONVERSION SYSTEM

QUANTITY UNIT SYMBOL

Thermodynamic temperature kelvin K giga G 109

2. Derived Units hecto h 102

6-80960 NA Issued 01-06 Bur 1-9

QUANTITY GRAVITATIONAL SI CONVERSION FACTOR

1-10 Issued 01-06 Bur 6-80960 NA

Issued January 2006

2-II Issued 01-2006 Bur 6-80970 NA

2.1 COMPONENTS NAME

6-80970 NA Issued 01-2006 Bur 2-1

2-2 Issued 01-2006 Bur 6-80970 NA

2.1 COMPONENTS NAME

6-80970 NA Issued 01-2006 Bur 2-3

2.2 MACHINE DIMENSIONS

2.3 SPECIFICATIONS AND PERFORMANCE

Applicable Machines PJ04-03001~

Model (YANMAR) 4TNV88-XYB

Type Water-cooled, 4-cycle type Swirl chamber type diesel engine

Number of cylinders-Bore x Stroke 4 - ø88 mm x 90 mm (3.46 in x 3.54 in)

Total Displacement L 2.189 (134 cu. in)

Output Rating -1 30.4/2,400 {41.3/2,400}

2.3.3 HYDRAULIC COMPONENTS

Hydraulic Pump Variable displacement axial piston + gear pump

Hydraulic Motor Axial piston

Hydraulic Motor w/Reducer (Travel) 2-Axial piston, 2-Speed motor

Control Valve 11-spool multiple control valve

Cylinder (Boom, Arm, Swing, Bucket, Dozer) Double action cylinder

Return Filter Safety valve containing/Filter Type (30)

2.3.4 SIDE DIGGING & DOZER

Type Boom swing by hydraulic cylinder

Stroke of Dozer (above/below) mm (in) 495 / 375 (19.5/14.8)

Rubber shoe Iron shoe

Travel system kg (lb.) 1,720 (3,790) 1,820 (4,010)

Oil & Water kg (lb.) 95 (209)

6-80970 NA Issued 01-2006 Bur 2-5