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0.1 GENERAL SAFETY INFORMATION ………………………………………………………………………… 0-2
0.2 SAFETY PRECAUTIONS ……………………………………………………………………………………….. 0-3
1-OUTLINE
1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS ………………………………………………1-3
1.1.1 PREPARATION BEFORE DISASSEMBLING………………………………………………….1-3
1.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING…………………………………..1-3
1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT …………………..1-3
1.1.4 ELECTRICAL EQUIPMENT ………………………………………………………………………….1-4
1.1.5 HYDRAULIC PARTS ……………………………………………………………………………………1-5
1.1.6 WELD REPAIR ……………………………………………………………………………………………1-5
1.1.7 ENVIRONMENTAL ISSUES………………………………………………………………………….1-5
1.2 INTERNATIONAL UNIT CONVERSION SYSTEM……………………………………………………1-6
2-SPECIFICATIONS
2.1 COMPONENTS NAME…………………………………………………………………………………………2-3
2.2 MACHINE DIMENSIONS………………………………………………………………………………………2-4
2.3 SPECIFICATIONS AND PERFORMANCE………………………………………………………………2-5
2.4 MACHINE 7 COMPONENTS WEIGHT …………………………………………………………………..2-6
2.5 TRANSPORTATION …………………………………………………………………………………………….2-7
2.6 TYPE OF CRAWLER SHOES……………………………………………………………………………….2-9
2.7 TYPE OF BUCKET ………………………………………………………………………………………………2-9
2.8 ENGINE SPECIFICATIONS ………………………………………………………………………………….2-10
2.8.1 SPECIFICATIONS……………………………………………………………………………………….2-10
2.8.2 ENGINE PERFORMANCE CURVE………………………………………………………………..2-11
–
3-ATTACHMENT DIMENSIONS
3.1 BOOM………………………………………………………………………………………………………………..3-3
3.1.1 BOOM DIMENSIONAL DRAWING…………………………………………………………………3-3
3.1.2 BOOM MAINTENANCE STANDARD……………………………………………………………..3-4
3.2 ARM…………………………………………………………………………………………………………………..3-8
3.2.1 ARM DIMENSIONAL DRAWING……………………………………………………………………3-8
3.2.2 ARM MAINTENANCE STANDARD………………………………………………………………..3-10
3.3 BUCKET……………………………………………………………………………………………………………..3-14
3.3.1 BUCKET DIMENSIONAL DRAWING ……………………………………………………………..3-14
3.3.2 DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION …………………………………3-11
3.3.3 DETAIL DIMENSIONAL DRAWINGS OF BOSS SECTION……………………………….3-15
3.4 DOZER……………………………………………………………………………………………………………….3-16
3.4.1 DOZER DIMENSIONAL DRAWINGS……………………………………………………………..3-16
3.4.2 DOZER MAINTENANCE STANDARDS………………………………………………………….3-18
3.5 SWING……………………………………………………………………………………………………………….3-20
3.5.1 SWING BRACKET DIMENSIONAL DRAWINGS ……………………………………………..3-20
3.5.2 SWING PORTION MAINTENANCE STANDARDS…………………………………………..3-21‘
MAINTENANCE SECTION
11-TOOLS
11.1 STANDARD TORQUE SPECIFICATIONS FOR CAPSCREWS AND NUTS………………11-3
11.1.1 Metric Coarse Thread Standard Tightening Torque values. Make certain to tighten all
Capscrews & Nuts to proper torque values……………………………………………………..11-3
11.1.2 Metric Fine Thread Standard Tightening Torque values. Make certain to tighten all
Capscrews & Nuts to proper torque values……………………………………………………..11-4
11.2 SCREW AND TOOL SIZE …………………………………………………………………………………..11-5
11.2.1 CAPSCREW……………………………………………………………………………………………..11-5
11.2.2 CAPSCREW (SOCKET BOLT)…………………………………………………………………….11-5
11.2.3 SOCKET SET SCREW……………………………………………………………………………….11-5
11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES ……………………………………….11-5
11.3.1 JOINTS FOR PIPING (O-RING SEALING TYPE) …………………………………………..11-5
11.3.2 HYDRAULIC HOSE (30° FLARE TYPE) ……………………………………………………….11-5
11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS………………………..11-6
11.4.1 SLEEVE TYPE TUBE FITTING……………………………………………………………………11-6
11.4.2 PART NO. …………………………………………………………………………………………………11-6
11.5 PLUG ……………………………………………………………………………………………………………….11-7
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT ………………………………………………………….11-7
11.5.2 PLUG FOR HYDRAULIC EQUIPMENT ………………………………………………………..11-8
11.6 SPECIAL SPANNER FOR TUBE …………………………………………………………………11-9
11.7 SPECIAL TOOLS……………………………………………………………………………………………….11-9
11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND……11-9
11.9 COUNTER WEIGHT LIFTING JIG………………………………………………………………………..11-10
12-STANDARD MAINTENANCE TIMETABLE
12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR….12-4
13-MAINTENANCE STANDARD AND TEST PROCEDURE
13.1 HOW TO USE THE MAINTENANCE STANDARD………………………………………………….13-3
13.2 PERFORMANCE INSPECTION STANDARD TABLE……………………………………………..13-5
13.2.1 STANDARD VALUE TABLE………………………………………………………………………..13-5
13.3 MEASUREMENT ENGINE SPEED ………………………………………………………………………13-7
13.3.1 ENGINE SPEED MEASUREMENT………………………………………………………………13-7
13.4 MEASURING HYDRAULIC PRESSURE……………………………………………………………….13-9
13.4.1 STANDARD FOR HYDRAULIC PRESSURE MEASUREMENT ……………………….13-9
13.4.2 PRESSURE MEASUREMENT AND ADJUSTMENT ………………………………………13-9
13.5 MEASURING TRAVEL PERFORMANCES……………………………………………………………13-12
13.5.1 TRAVEL……………………………………………………………………………………………………13-12
13.5.2 TRAVEL DEVIATION………………………………………………………………………………….13-12
13.5.3 MOVEMENT DRIFT DUE TO GRAVITY ……………………………………………………….13-13
13.5.4 DRAIN RATE ON TRAVEL MOTOR …………………………………………………………….13-13
13.6 MEASURING SWING PERFORMANCES……………………………………………………………..13-14
13.6.1 SWING TIME …………………………………………………………………………………………….13-14
13.6.2 OVERRUN WHEN SWING STOPS………………………………………………………………13-14
13.6.3 SWING DRIFT DUE TO GRAVITY……………………………………………………………….13-14
13.6.4 DRAIN RATE OF SWING MOTOR……………………………………………………………….13-15
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES ………………………………13-16
13.7.1 CYLINDER SPEED…………………………………………………………………………………….13-16
13.7.2 GRAVITY DRIFT OF CYLINDERS……………………………………………………………….13-17
13.8 MEASURING SWING BEARING PERFORMANCES………………………………………………13-18
13.8.1 SWING BEARING BUCKET TIP PLAY …………………………………………………………13-18
13.8.2 SWING BEARING PLAY …………………………………………………………………………….13-18
13.9 MEASURING CRAWLER TENSION …………………………………………………………………….13-19
13.9.1 CRAWLER TENSION …………………………………………………………………………………13-19
–
SYSTEM SECTION
22-HYDRAULIC SYSTEM
22.1 SUMMARY………………………………………………………………………………………………………..22-3
22.2.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT ……………………………….22-3
22.2 HYDRAULIC CIRCUITS AND COMPONENT MODELS ………………………………………….22-4
22.3 HYDRAULIC CIRCUIT OPERATION…………………………………………………………………….22-5
22.3.1 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS………………………….22-5
22.3.2 NEUTRAL CIRCUIT……………………………………………………………………………………22-5
22.3.3 TRAVEL OPERATING CIRCUIT ………………………………………………………………….22-6
22.3.4 SWING OPERATING CIRCUIT ……………………………………………………………………22-7
22.3.5 BUCKET OPERATING CIRCUIT………………………………………………………………….22-7
22.3.6 BOOM OPERATING CIRCUIT …………………………………………………………………….22-8
22.3.7 ARM OPERATING CIRCUIT ……………………………………………………………………….22-8
22.3.8 SWING OPERATING CIRCUIT ……………………………………………………………………22-9
22.3.9 DOZER AND AJUUSTABLE CRAWLER FRAME WIDTH OPERATING CIRCUIT22-9
22.3.10 TRAVEL/DOZER COMBINED OPERATING CIRCUIT ……………………………………22-10
22.3.11 TRAVEL/BOOM COMBINED OPERATING CIRCUIT……………………………………..22-10
22.3.12 NIBBLER & BREAKER OPERATING CIRCUIT ……………………………………………..22-11
22.4 SCHEMATIC PIPING FOR HYDRAULIC SYSTEM…………………………………………………22-12
23-ELECTRICAL SYSTEM
23.1 HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION……………………..23-3
23.1.1 ELECTRICAL CIRCUIT DIAGRAM ………………………………………………………………23-3
23.1.2 HARNESS CONNECTION ………………………………………………………………………….23-3
23.2 ELECTRICAL EQUIPMENT & HARNESS……………………………………………………………..23-4
23.2.1 ELECTRICAL EQUIPMENT LIST…………………………………………………………………23-4
23.2.2 HARNESS & CABLE LIST…………………………………………………………………………..23-5
23.2.3 ARRANGEMENT DRAWING FOR COMPONENTS & HARNESS ……………………23-6
23.2.4 DETAIL OF HARNESS & CABLE…………………………………………………………………23-20
24-COMPONENTS SYSTEM
24.1 HYDRAULIC COMPONENTS………………………………………………………………………………24-3
24.1.1 HYDRAULIC PUMP……………………………………………………………………………………24-3
24.1.2 PILOT VALVE (ATT)…………………………………………………………………………………..24-6
24.1.3 PILOT VALVE (TRAVEL)…………………………………………………………………………….24-9
24.1.4 CONTROL VALVE……………………………………………………………………………………..24-14
24.1.5 SWING MOTOR ………………………………………………………………………………………..24-29
24.1.6 TRAVEL MOTOR……………………………………………………………………………………….24-36
24.1.7 SWIVEL JOINT ………………………………………………………………………………………….24-45
24.1.8 CYLINDER………………………………………………………………………………………………..24-49
24.2 ELECTRIC EQUIPMENT …………………………………………………………………………………….24-58
24.2.1 ELECTRIC EQUIPMENT LIST …………………………………………………………………….24-58
24.2.2 SPECIFICATION ELECTRIC EQUIPMENT …………………………………………………..24-60
DISASSEMBLING SECTION
31-DISASSEMBLY AND ASSEMBLING
31.1 GENERAL DISASSEMBLY & ASSEMBLY…………………………………………………………….31-3
31.1.1 CONTENTS OF GENERAL DISASSEMBLY & ASSEMBLY ……………………………31-3
31.1.2 SPECIFICATION OF TIGHTENING TORQUE……………………………………………….31-3
32-ATTACHMENT
32.1 REMOVING AND INSTALLING……………………………………………………………………………32-3
32.1.1 ATTACHMENT ASSEMBLY AND NAME………………………………………………………32-3
32.1.2 BUCKET …………………………………………………………………………………………………..32-4
32.1.3 ARM…………………………………………………………………………………………………………32-6
32.1.4 BOOM………………………………………………………………………………………………………32-9
32.1.5 SWING……………………………………………………………………………………………………..32-12
32.1.6 DOZER …………………………………………………………………………………………………….32-14
32.2 DISASSEMBLING AND ASSEMBLING…………………………………………………………………32-15
32.2.1 CYLINDER………………………………………………………………………………………………..32-15
33-UPPER STRUCTURE
33.1 REMOVING AND INSTALLING……………………………………………………………………………33-3
33.1.1 CANOPY…………………………………………………………………………………………………..33-3
33.1.2 GUARD (COVER)………………………………………………………………………………………33-4
33.1.3 COUNTERWEIGHT……………………………………………………………………………………33-6
33.1.4 BATTERY …………………………………………………………………………………………………33-7
33.1.5 FLOOR PLATE ASSEMBLY………………………………………………………………………..33-8
33.1.6 AIR CLEANER…………………………………………………………………………………………..33-10
33.1.7 HYDRAULIC OIL TANK………………………………………………………………………………33-11
33.1.8 FUEL TANK ………………………………………………………………………………………………33-13
33.1.9 PUMP……………………………………………………………………………………………………….33-14
33.1.10 CONTROL VALVE……………………………………………………………………………………..33-16
33.1.11 SOLENOID VALVE…………………………………………………………………………………….33-20
33.1.12 MULTI CONTROL VALVE…………………………………………………………………………..33-21
33.1.13 MUFFLER…………………………………………………………………………………………………33-22
33.1.14 ALTERNATOR…………………………………………………………………………………………..33-23
33.1.15 STARTOR…………………………………………………………………………………………………33-24
33.1.16 RADIATOR ……………………………………………………………………………………………….33-25
33.1.17 PILOT VALVE……………………………………………………………………………………………33-27
33.1.18 CONTROL STAND …………………………………………………………………………………….33-28
33.1.19 ENGINE ……………………………………………………………………………………………………33-33
33.1.20 SWING MOTOR ………………………………………………………………………………………..33-35
33.1.21 SWIVEL JOINT ………………………………………………………………………………………….33-37
33.1.22 UPPER FRAME…………………………………………………………………………………………33-40
33.2 DISASSEMBLING AND ASSEMBLING…………………………………………………………………33-43
33.2.1 HYDRAULIC PUMP……………………………………………………………………………………33-43
–
33.2.2 CONTROL VALVE……………………………………………………………………………………..33-57
33.2.3 PILOT VALVE (ATTACHMENT) …………………………………………………………………..33-77
33.2.4 PILOT VALVE (FOR TRAVEL) …………………………………………………………………….33-87
33.2.5 SWING MOTOR ……………………………………………………………………………………….33-92
33.2.6 SWIVEL JOINT ………………………………………………………………………………………….33-109
34-TRAVEL SYSTEM
34.1 REMOVING AND INSTALLING……………………………………………………………………………34-3
34.1.1 NAME OF TRAVEL SYSTEM PARTS………………………………………………………….34-3
34.1.2 CRAWLER………………………………………………………………………………………………..34-3
34.1.3 SIDE PLATE ……………………………………………………………………………………………..34-10
34.1.4 LOWER ROLLER ………………………………………………………………………………………34-11
34.1.5 FRONT IDLER…………………………………………………………………………………………..34-15
34.1.6 IDLER ADJUSTER …………………………………………………………………………………….34-19
34.1.7 SPROCKET ………………………………………………………………………………………………34-23
34.1.8 TRAVEL MOTOR………………………………………………………………………………………34-25
34.1.9 SWING BEARING………………………………………………………………………………………34-27
34.1.10 ADJUSTABLE CRAWLER FRAME WIDTH …………………………………………………..34-30
34.2 DISASSEMBLING AND ASSEMBLING…………………………………………………………………34-33
34.2.1 TRAVEL MOTOR……………………………………………………………………………………….34-33
TROUBLESHOOTING SECTION
42-TROUBLESHOOTING (HYDRAULIC SYSTEM)
42.1 GENERAL PRECAUTIONS…………………………………………………………………………………42-3
42.1.1 CONFIRM ACTUAL TROUBLED CONDITION AT SITE………………………………….42-3
42.2 TROUBLE DIAGNOSIS: HYDRAULIC ………………………………………………………………….42-4
42.3 TROUBLESHOOTING ……………………………………………………………………………………….42-5
42.3.1 ATTACHMENT ………………………………………………………………………………………….42-5
42.3.2 TRAVEL OPERATION………………………………………………………………………………..42-7
42.3.3 SWING OPERATION………………………………………………………………………………….42-9
42.3.4 PUMP……………………………………………………………………………………………………….42-10
43-TROUBLESHOOTING (ELECTRICAL SYSTEM)
43.1 TROUBLE DIAGNOSIS: ELECTRIC SYSTEM……………………………………………………….43-3
43.2 TROUBLESHOOTING………………………………………………………………………………………..43-4
43.2.1 GENERAL…………………………………………………………………………………………………43-4
43.2.2 ATTACHMENT OPERATION ………………………………………………………………………43-8
43.2.3 TRAVEL OPERATION………………………………………………………………………………..43-9
44-TROUBLESHOOTING (ENGINE)
44.1 TROUBLE DIAGNOSIS : ENGINE ……………………………………………………………………….44-3
44.2 TROUBLESHOOTING………………………………………………………………………………………..44-6
44.2.1 STARTING TROUBLE………………………………………………………………………………..44-6
44.2.2 E/G ROTATION TROUBLE …………………………………………………………………………44-8
44.2.3 OUTPUT DROUPS DOWN …………………………………………………………………………44-9
44.2.4 OTHER TROUBLE …………………………………………………………………………………….44-10
ENGINE SECTION
51-ENGINE
MITSUBISHI ENGINE SERVICE MANUAL 51-1
GENERAL ………………………………………………………………………………………………………………..1-1
SERVICE DATA………………………………………………………………………………………………………..2-1
BASIC AND SPECIAL TOOLS…………………………………………………………………………………….3-1
OVERHAUL DETERMINATION…………………………………………………………………………………..4-1
DISASSEMBLING ENGINE MAIN PARTS ……………………………………………………………………5-1
INSPECTION AND REPAIRING ENGINE MAIN PARTS ………………………………………………..6-1
REASSEMBLING ENGINE MAIN PARTS …………………………………………………………………….7-1
FUEL SYSTEM …………………………………………………………………………………………………………8-1
LUBRICATION SYSTEM ……………………………………………………………………………………………9-1
COOLING SYSTEM…………………………………………………………………………………………………10-1
INLET AND EXHAUST SYSTEM……………………………………………………………………………….11-1
ELECTRICAL SYSTEM ……………………………………………………………………………………………12-1
ENGINE ADJUSTMENT, BREAK IN OPERATION AND PERFORMANCE TESTS ………….13-1
TROUBLESHOOTING……………………………………………………………………………………………..14-1 71-SUPPORTING DATA
71.1 HYDRAULIC CIRCUIT DIAGRAM………………………………………………………………………..71-3
71.1.1 STANDARD SPECIFICATIONS …………………………………………………………………..71-3
71.1.2 HYDRAULIC CIRCUIT OPERATION ……………………………………………………………71-4
(1) NEUTRAL CIRCUIT……………………………………………………………………………………71-4
(2) TRAVEL CIRCUIT: TRAVEL FORWARDOPERATION AT 2ND SPEED……………71-5
(3) SWING CIRCUIT: SWING LEFT OPERATION ………………………………………………71-6
(4) BUCKET CIRCIT: BUCKET DIGGING OPERATION ………………………………………71-7
(5) BOOM CIRCUIT: BOOM UP OPERATION ……………………………………………………71-8
(6) ARM CIRCUIT: ARM IN OPERATION…………………………………………………………..71-9
(7) SWING CIRCUIT: BOOM SWING LEFT OPERATION……………………………………71-10
(8) DOZER CIRCUIT: DOZER DOWN OPERATION……………………………………………71-11
(9) COMBINED CIRCUIT: TRAVEL (FORWARD) 1ST SPEED/DOZER
DOWN OPERATION…………………………………………………………………………………..71-12
(10) COMBINED CIRCUIT: TRAVEL (FORWARD) 1ST SPEED/BOOM
UP OPERATION ………………………………………………………………………………………..71-13
(11) NIBBLER & BREAKER CIRCUIT: NIBBLER CLOSE OPERATION…………………..71-14
71.1.3 SCHEMATIC PIPING FOR HYDRAULIC SYSTEM ………………………………………..71-15
71.2 ELECTRIC CIRCUIT DIAGRAM…………………………………………………………………………..71-16
Case CX17B Compact Crawler Excavator Repair Manual 87630255 – PDF DOWNLOAD
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Case CX17B Compact Crawler Excavator Repair Manual 87630255 – PDF DOWNLOAD
DESCRIPTION:
Case CX17B Compact Crawler Excavator Repair Manual 87630255 – PDF DOWNLOAD
SAFETY PRECAUTIONS:
Improper performance of lubrication or maintenance procedures are dangerous and could result in injury or death. Read and understand the MANUAL before performing any lubrication or maintenance.
- The service technician may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work. A knowledge of the system and or components is important before the removal or disassembly of any component.
- Because of the size of some of the machine components, the technician should check the weights noted in this manual. Use proper lifting procedures when removing any components. Weight of components table is shown in the section ; SPECIFICATIONS.
The following is a list of basic precautions that must always be observed.
(1) Read and understand all Warning plates and decal
on the machine before Operating, Maintaining or
Repairing this machine.
(2) Always wear protective glasses and protective
shoes when working around machines. In particular,
wear protective glasses when using hammers,
punches or drifts on any part of the machine or attachments.
Use welders gloves, hood/goggles,
apron and the protective clothing appropriate to the
welding job being performed. Do not wear loose fitting
or torn clothing. Remove all rings from fingers,
loose jewelry, confine long hair and loose clothing
before working on this machinery.
(3) Disconnect the battery and hang a “Do Not Operate”
tag in the Operators Compartment. Remove ignition
keys.
(4) If possible, make all repairs with the machine
parked on a level, hard surface. Block the machine
so it does not roll while working on or under the machine.
Hang a “Do Not Operate” tag in the Operators
Compartment.
(5) Do not work on any machine that is supported only
by lift, jacks or a hoist. Always use blocks or jack
stands, capable of supporting the machine, before
performing any disassembly.
TABLE OF CONTENTS:
Case CX17B Compact Crawler Excavator Repair Manual 87630255 – PDF DOWNLOAD
0-SAFETY0.1 GENERAL SAFETY INFORMATION ………………………………………………………………………… 0-2
0.2 SAFETY PRECAUTIONS ……………………………………………………………………………………….. 0-3
1-OUTLINE
1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS ………………………………………………1-3
1.1.1 PREPARATION BEFORE DISASSEMBLING………………………………………………….1-3
1.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING…………………………………..1-3
1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT …………………..1-3
1.1.4 ELECTRICAL EQUIPMENT ………………………………………………………………………….1-4
1.1.5 HYDRAULIC PARTS ……………………………………………………………………………………1-5
1.1.6 WELD REPAIR ……………………………………………………………………………………………1-5
1.1.7 ENVIRONMENTAL ISSUES………………………………………………………………………….1-5
1.2 INTERNATIONAL UNIT CONVERSION SYSTEM……………………………………………………1-6
2-SPECIFICATIONS
2.1 COMPONENTS NAME…………………………………………………………………………………………2-3
2.2 MACHINE DIMENSIONS………………………………………………………………………………………2-4
2.3 SPECIFICATIONS AND PERFORMANCE………………………………………………………………2-5
2.4 MACHINE 7 COMPONENTS WEIGHT …………………………………………………………………..2-6
2.5 TRANSPORTATION …………………………………………………………………………………………….2-7
2.6 TYPE OF CRAWLER SHOES……………………………………………………………………………….2-9
2.7 TYPE OF BUCKET ………………………………………………………………………………………………2-9
2.8 ENGINE SPECIFICATIONS ………………………………………………………………………………….2-10
2.8.1 SPECIFICATIONS……………………………………………………………………………………….2-10
2.8.2 ENGINE PERFORMANCE CURVE………………………………………………………………..2-11
–
3-ATTACHMENT DIMENSIONS
3.1 BOOM………………………………………………………………………………………………………………..3-3
3.1.1 BOOM DIMENSIONAL DRAWING…………………………………………………………………3-3
3.1.2 BOOM MAINTENANCE STANDARD……………………………………………………………..3-4
3.2 ARM…………………………………………………………………………………………………………………..3-8
3.2.1 ARM DIMENSIONAL DRAWING……………………………………………………………………3-8
3.2.2 ARM MAINTENANCE STANDARD………………………………………………………………..3-10
3.3 BUCKET……………………………………………………………………………………………………………..3-14
3.3.1 BUCKET DIMENSIONAL DRAWING ……………………………………………………………..3-14
3.3.2 DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION …………………………………3-11
3.3.3 DETAIL DIMENSIONAL DRAWINGS OF BOSS SECTION……………………………….3-15
3.4 DOZER……………………………………………………………………………………………………………….3-16
3.4.1 DOZER DIMENSIONAL DRAWINGS……………………………………………………………..3-16
3.4.2 DOZER MAINTENANCE STANDARDS………………………………………………………….3-18
3.5 SWING……………………………………………………………………………………………………………….3-20
3.5.1 SWING BRACKET DIMENSIONAL DRAWINGS ……………………………………………..3-20
3.5.2 SWING PORTION MAINTENANCE STANDARDS…………………………………………..3-21‘
MAINTENANCE SECTION
11-TOOLS
11.1 STANDARD TORQUE SPECIFICATIONS FOR CAPSCREWS AND NUTS………………11-3
11.1.1 Metric Coarse Thread Standard Tightening Torque values. Make certain to tighten all
Capscrews & Nuts to proper torque values……………………………………………………..11-3
11.1.2 Metric Fine Thread Standard Tightening Torque values. Make certain to tighten all
Capscrews & Nuts to proper torque values……………………………………………………..11-4
11.2 SCREW AND TOOL SIZE …………………………………………………………………………………..11-5
11.2.1 CAPSCREW……………………………………………………………………………………………..11-5
11.2.2 CAPSCREW (SOCKET BOLT)…………………………………………………………………….11-5
11.2.3 SOCKET SET SCREW……………………………………………………………………………….11-5
11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES ……………………………………….11-5
11.3.1 JOINTS FOR PIPING (O-RING SEALING TYPE) …………………………………………..11-5
11.3.2 HYDRAULIC HOSE (30° FLARE TYPE) ……………………………………………………….11-5
11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS………………………..11-6
11.4.1 SLEEVE TYPE TUBE FITTING……………………………………………………………………11-6
11.4.2 PART NO. …………………………………………………………………………………………………11-6
11.5 PLUG ……………………………………………………………………………………………………………….11-7
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT ………………………………………………………….11-7
11.5.2 PLUG FOR HYDRAULIC EQUIPMENT ………………………………………………………..11-8
11.6 SPECIAL SPANNER FOR TUBE …………………………………………………………………11-9
11.7 SPECIAL TOOLS……………………………………………………………………………………………….11-9
11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND……11-9
11.9 COUNTER WEIGHT LIFTING JIG………………………………………………………………………..11-10
12-STANDARD MAINTENANCE TIMETABLE
12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR….12-4
13-MAINTENANCE STANDARD AND TEST PROCEDURE
13.1 HOW TO USE THE MAINTENANCE STANDARD………………………………………………….13-3
13.2 PERFORMANCE INSPECTION STANDARD TABLE……………………………………………..13-5
13.2.1 STANDARD VALUE TABLE………………………………………………………………………..13-5
13.3 MEASUREMENT ENGINE SPEED ………………………………………………………………………13-7
13.3.1 ENGINE SPEED MEASUREMENT………………………………………………………………13-7
13.4 MEASURING HYDRAULIC PRESSURE……………………………………………………………….13-9
13.4.1 STANDARD FOR HYDRAULIC PRESSURE MEASUREMENT ……………………….13-9
13.4.2 PRESSURE MEASUREMENT AND ADJUSTMENT ………………………………………13-9
13.5 MEASURING TRAVEL PERFORMANCES……………………………………………………………13-12
13.5.1 TRAVEL……………………………………………………………………………………………………13-12
13.5.2 TRAVEL DEVIATION………………………………………………………………………………….13-12
13.5.3 MOVEMENT DRIFT DUE TO GRAVITY ……………………………………………………….13-13
13.5.4 DRAIN RATE ON TRAVEL MOTOR …………………………………………………………….13-13
13.6 MEASURING SWING PERFORMANCES……………………………………………………………..13-14
13.6.1 SWING TIME …………………………………………………………………………………………….13-14
13.6.2 OVERRUN WHEN SWING STOPS………………………………………………………………13-14
13.6.3 SWING DRIFT DUE TO GRAVITY……………………………………………………………….13-14
13.6.4 DRAIN RATE OF SWING MOTOR……………………………………………………………….13-15
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES ………………………………13-16
13.7.1 CYLINDER SPEED…………………………………………………………………………………….13-16
13.7.2 GRAVITY DRIFT OF CYLINDERS……………………………………………………………….13-17
13.8 MEASURING SWING BEARING PERFORMANCES………………………………………………13-18
13.8.1 SWING BEARING BUCKET TIP PLAY …………………………………………………………13-18
13.8.2 SWING BEARING PLAY …………………………………………………………………………….13-18
13.9 MEASURING CRAWLER TENSION …………………………………………………………………….13-19
13.9.1 CRAWLER TENSION …………………………………………………………………………………13-19
–
SYSTEM SECTION
22-HYDRAULIC SYSTEM
22.1 SUMMARY………………………………………………………………………………………………………..22-3
22.2.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT ……………………………….22-3
22.2 HYDRAULIC CIRCUITS AND COMPONENT MODELS ………………………………………….22-4
22.3 HYDRAULIC CIRCUIT OPERATION…………………………………………………………………….22-5
22.3.1 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS………………………….22-5
22.3.2 NEUTRAL CIRCUIT……………………………………………………………………………………22-5
22.3.3 TRAVEL OPERATING CIRCUIT ………………………………………………………………….22-6
22.3.4 SWING OPERATING CIRCUIT ……………………………………………………………………22-7
22.3.5 BUCKET OPERATING CIRCUIT………………………………………………………………….22-7
22.3.6 BOOM OPERATING CIRCUIT …………………………………………………………………….22-8
22.3.7 ARM OPERATING CIRCUIT ……………………………………………………………………….22-8
22.3.8 SWING OPERATING CIRCUIT ……………………………………………………………………22-9
22.3.9 DOZER AND AJUUSTABLE CRAWLER FRAME WIDTH OPERATING CIRCUIT22-9
22.3.10 TRAVEL/DOZER COMBINED OPERATING CIRCUIT ……………………………………22-10
22.3.11 TRAVEL/BOOM COMBINED OPERATING CIRCUIT……………………………………..22-10
22.3.12 NIBBLER & BREAKER OPERATING CIRCUIT ……………………………………………..22-11
22.4 SCHEMATIC PIPING FOR HYDRAULIC SYSTEM…………………………………………………22-12
23-ELECTRICAL SYSTEM
23.1 HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION……………………..23-3
23.1.1 ELECTRICAL CIRCUIT DIAGRAM ………………………………………………………………23-3
23.1.2 HARNESS CONNECTION ………………………………………………………………………….23-3
23.2 ELECTRICAL EQUIPMENT & HARNESS……………………………………………………………..23-4
23.2.1 ELECTRICAL EQUIPMENT LIST…………………………………………………………………23-4
23.2.2 HARNESS & CABLE LIST…………………………………………………………………………..23-5
23.2.3 ARRANGEMENT DRAWING FOR COMPONENTS & HARNESS ……………………23-6
23.2.4 DETAIL OF HARNESS & CABLE…………………………………………………………………23-20
24-COMPONENTS SYSTEM
24.1 HYDRAULIC COMPONENTS………………………………………………………………………………24-3
24.1.1 HYDRAULIC PUMP……………………………………………………………………………………24-3
24.1.2 PILOT VALVE (ATT)…………………………………………………………………………………..24-6
24.1.3 PILOT VALVE (TRAVEL)…………………………………………………………………………….24-9
24.1.4 CONTROL VALVE……………………………………………………………………………………..24-14
24.1.5 SWING MOTOR ………………………………………………………………………………………..24-29
24.1.6 TRAVEL MOTOR……………………………………………………………………………………….24-36
24.1.7 SWIVEL JOINT ………………………………………………………………………………………….24-45
24.1.8 CYLINDER………………………………………………………………………………………………..24-49
24.2 ELECTRIC EQUIPMENT …………………………………………………………………………………….24-58
24.2.1 ELECTRIC EQUIPMENT LIST …………………………………………………………………….24-58
24.2.2 SPECIFICATION ELECTRIC EQUIPMENT …………………………………………………..24-60
DISASSEMBLING SECTION
31-DISASSEMBLY AND ASSEMBLING
31.1 GENERAL DISASSEMBLY & ASSEMBLY…………………………………………………………….31-3
31.1.1 CONTENTS OF GENERAL DISASSEMBLY & ASSEMBLY ……………………………31-3
31.1.2 SPECIFICATION OF TIGHTENING TORQUE……………………………………………….31-3
32-ATTACHMENT
32.1 REMOVING AND INSTALLING……………………………………………………………………………32-3
32.1.1 ATTACHMENT ASSEMBLY AND NAME………………………………………………………32-3
32.1.2 BUCKET …………………………………………………………………………………………………..32-4
32.1.3 ARM…………………………………………………………………………………………………………32-6
32.1.4 BOOM………………………………………………………………………………………………………32-9
32.1.5 SWING……………………………………………………………………………………………………..32-12
32.1.6 DOZER …………………………………………………………………………………………………….32-14
32.2 DISASSEMBLING AND ASSEMBLING…………………………………………………………………32-15
32.2.1 CYLINDER………………………………………………………………………………………………..32-15
33-UPPER STRUCTURE
33.1 REMOVING AND INSTALLING……………………………………………………………………………33-3
33.1.1 CANOPY…………………………………………………………………………………………………..33-3
33.1.2 GUARD (COVER)………………………………………………………………………………………33-4
33.1.3 COUNTERWEIGHT……………………………………………………………………………………33-6
33.1.4 BATTERY …………………………………………………………………………………………………33-7
33.1.5 FLOOR PLATE ASSEMBLY………………………………………………………………………..33-8
33.1.6 AIR CLEANER…………………………………………………………………………………………..33-10
33.1.7 HYDRAULIC OIL TANK………………………………………………………………………………33-11
33.1.8 FUEL TANK ………………………………………………………………………………………………33-13
33.1.9 PUMP……………………………………………………………………………………………………….33-14
33.1.10 CONTROL VALVE……………………………………………………………………………………..33-16
33.1.11 SOLENOID VALVE…………………………………………………………………………………….33-20
33.1.12 MULTI CONTROL VALVE…………………………………………………………………………..33-21
33.1.13 MUFFLER…………………………………………………………………………………………………33-22
33.1.14 ALTERNATOR…………………………………………………………………………………………..33-23
33.1.15 STARTOR…………………………………………………………………………………………………33-24
33.1.16 RADIATOR ……………………………………………………………………………………………….33-25
33.1.17 PILOT VALVE……………………………………………………………………………………………33-27
33.1.18 CONTROL STAND …………………………………………………………………………………….33-28
33.1.19 ENGINE ……………………………………………………………………………………………………33-33
33.1.20 SWING MOTOR ………………………………………………………………………………………..33-35
33.1.21 SWIVEL JOINT ………………………………………………………………………………………….33-37
33.1.22 UPPER FRAME…………………………………………………………………………………………33-40
33.2 DISASSEMBLING AND ASSEMBLING…………………………………………………………………33-43
33.2.1 HYDRAULIC PUMP……………………………………………………………………………………33-43
–
33.2.2 CONTROL VALVE……………………………………………………………………………………..33-57
33.2.3 PILOT VALVE (ATTACHMENT) …………………………………………………………………..33-77
33.2.4 PILOT VALVE (FOR TRAVEL) …………………………………………………………………….33-87
33.2.5 SWING MOTOR ……………………………………………………………………………………….33-92
33.2.6 SWIVEL JOINT ………………………………………………………………………………………….33-109
34-TRAVEL SYSTEM
34.1 REMOVING AND INSTALLING……………………………………………………………………………34-3
34.1.1 NAME OF TRAVEL SYSTEM PARTS………………………………………………………….34-3
34.1.2 CRAWLER………………………………………………………………………………………………..34-3
34.1.3 SIDE PLATE ……………………………………………………………………………………………..34-10
34.1.4 LOWER ROLLER ………………………………………………………………………………………34-11
34.1.5 FRONT IDLER…………………………………………………………………………………………..34-15
34.1.6 IDLER ADJUSTER …………………………………………………………………………………….34-19
34.1.7 SPROCKET ………………………………………………………………………………………………34-23
34.1.8 TRAVEL MOTOR………………………………………………………………………………………34-25
34.1.9 SWING BEARING………………………………………………………………………………………34-27
34.1.10 ADJUSTABLE CRAWLER FRAME WIDTH …………………………………………………..34-30
34.2 DISASSEMBLING AND ASSEMBLING…………………………………………………………………34-33
34.2.1 TRAVEL MOTOR……………………………………………………………………………………….34-33
TROUBLESHOOTING SECTION
42-TROUBLESHOOTING (HYDRAULIC SYSTEM)
42.1 GENERAL PRECAUTIONS…………………………………………………………………………………42-3
42.1.1 CONFIRM ACTUAL TROUBLED CONDITION AT SITE………………………………….42-3
42.2 TROUBLE DIAGNOSIS: HYDRAULIC ………………………………………………………………….42-4
42.3 TROUBLESHOOTING ……………………………………………………………………………………….42-5
42.3.1 ATTACHMENT ………………………………………………………………………………………….42-5
42.3.2 TRAVEL OPERATION………………………………………………………………………………..42-7
42.3.3 SWING OPERATION………………………………………………………………………………….42-9
42.3.4 PUMP……………………………………………………………………………………………………….42-10
43-TROUBLESHOOTING (ELECTRICAL SYSTEM)
43.1 TROUBLE DIAGNOSIS: ELECTRIC SYSTEM……………………………………………………….43-3
43.2 TROUBLESHOOTING………………………………………………………………………………………..43-4
43.2.1 GENERAL…………………………………………………………………………………………………43-4
43.2.2 ATTACHMENT OPERATION ………………………………………………………………………43-8
43.2.3 TRAVEL OPERATION………………………………………………………………………………..43-9
44-TROUBLESHOOTING (ENGINE)
44.1 TROUBLE DIAGNOSIS : ENGINE ……………………………………………………………………….44-3
44.2 TROUBLESHOOTING………………………………………………………………………………………..44-6
44.2.1 STARTING TROUBLE………………………………………………………………………………..44-6
44.2.2 E/G ROTATION TROUBLE …………………………………………………………………………44-8
44.2.3 OUTPUT DROUPS DOWN …………………………………………………………………………44-9
44.2.4 OTHER TROUBLE …………………………………………………………………………………….44-10
ENGINE SECTION
51-ENGINE
MITSUBISHI ENGINE SERVICE MANUAL 51-1
GENERAL ………………………………………………………………………………………………………………..1-1
SERVICE DATA………………………………………………………………………………………………………..2-1
BASIC AND SPECIAL TOOLS…………………………………………………………………………………….3-1
OVERHAUL DETERMINATION…………………………………………………………………………………..4-1
DISASSEMBLING ENGINE MAIN PARTS ……………………………………………………………………5-1
INSPECTION AND REPAIRING ENGINE MAIN PARTS ………………………………………………..6-1
REASSEMBLING ENGINE MAIN PARTS …………………………………………………………………….7-1
FUEL SYSTEM …………………………………………………………………………………………………………8-1
LUBRICATION SYSTEM ……………………………………………………………………………………………9-1
COOLING SYSTEM…………………………………………………………………………………………………10-1
INLET AND EXHAUST SYSTEM……………………………………………………………………………….11-1
ELECTRICAL SYSTEM ……………………………………………………………………………………………12-1
ENGINE ADJUSTMENT, BREAK IN OPERATION AND PERFORMANCE TESTS ………….13-1
TROUBLESHOOTING……………………………………………………………………………………………..14-1 71-SUPPORTING DATA
71.1 HYDRAULIC CIRCUIT DIAGRAM………………………………………………………………………..71-3
71.1.1 STANDARD SPECIFICATIONS …………………………………………………………………..71-3
71.1.2 HYDRAULIC CIRCUIT OPERATION ……………………………………………………………71-4
(1) NEUTRAL CIRCUIT……………………………………………………………………………………71-4
(2) TRAVEL CIRCUIT: TRAVEL FORWARDOPERATION AT 2ND SPEED……………71-5
(3) SWING CIRCUIT: SWING LEFT OPERATION ………………………………………………71-6
(4) BUCKET CIRCIT: BUCKET DIGGING OPERATION ………………………………………71-7
(5) BOOM CIRCUIT: BOOM UP OPERATION ……………………………………………………71-8
(6) ARM CIRCUIT: ARM IN OPERATION…………………………………………………………..71-9
(7) SWING CIRCUIT: BOOM SWING LEFT OPERATION……………………………………71-10
(8) DOZER CIRCUIT: DOZER DOWN OPERATION……………………………………………71-11
(9) COMBINED CIRCUIT: TRAVEL (FORWARD) 1ST SPEED/DOZER
DOWN OPERATION…………………………………………………………………………………..71-12
(10) COMBINED CIRCUIT: TRAVEL (FORWARD) 1ST SPEED/BOOM
UP OPERATION ………………………………………………………………………………………..71-13
(11) NIBBLER & BREAKER CIRCUIT: NIBBLER CLOSE OPERATION…………………..71-14
71.1.3 SCHEMATIC PIPING FOR HYDRAULIC SYSTEM ………………………………………..71-15
71.2 ELECTRIC CIRCUIT DIAGRAM…………………………………………………………………………..71-16
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